EXPERIMENT (it is the systematic procedure carried out under controlled THE 4 POTENTIAL TRAPS THAT CAN CREATE
CREATE EXPERIMENT DIFFICULTIES (1) The concepts of Statistical Process Control (SPC) were initially developed by Dr.
conditions in order to discover an unknown effect, to test or to establish a
hypothesis or to illustrate a known effect)
Experiment design can be used at the point of greatest leverage to reduce
DESIGN cost by speeding up the design PROCESS, reducing late
ENGINEERING design changes and reducing product MATERIAL and labor
COMPLEXITY.
FACTOR (it is a component of experimental design which is the inputs to
the process.)
LEVEL (it is a component of experimental design which is the setting of
each actor of the study)
RESPONSE (it is a component of experimental design which is the output of
the experiment)
error (it refers to all unexplained variation that is either within an
experiment run or between experiment runs and associated settings
changing)
Designed experiments are also power tools to achieve manufacturing cost
SAVINGS by minimizing PROCESS VARIATION and reducing REWORK,
SCRAP and the need for inspection.
Noise factor(these are uncontrollable factors that induce variation under
normal operating conditions)
An alternative to the control chart approach is to use the F-TEST to
compare the MEANS of alternate treatments.
SPC CHART (it is a chart that includes historical data from the baseline
process used to evaluate a new process method by plotting the results)
ANOVA (it is a statistical tool used to determine hither the difference in
treatment means is due to random chance or significant different process)
20.F-TEST ANALYSIS (it is the basis for model evaluation of both single
factor and multi-factor experiments.)
THE EXPERIMENTAL DESIGN PROCESS (1) define the problem (2) determine
objectives (3) brainstorm (4) Design of experiment (5) conduct experiment
and collect data (6) analyze data (7) interpret results (8) verify predicted
results
THE COMPONENTS OF EXPERIMENTAL DESIGN (1) factor (2) level (3)
response
THE PURPOSE OF EXPERIMENTATION (1) comparing alternatives (2)
identify the significant input (factor) affecting an ouput (response) (3)
reducing variability (4) achieving an optimal process output (response) (5)
minimizing, maximizing or targeting an output (response) (6) Improving
process or product (robustness) fitness for use under varying condition (7)
reducing variability
unexplained variation (2) noise factor (3) correlation (4) combined effects or
interaction
THE THREE ASPECTS TO BE STIPULATED OR TO BE CONSIDERED IN DESIGN OF
EXPERIMENTS (1) factor (2) level (3) response
GIVE FIVE EXAMPLES OF INPUTS OF A NEW CELLPHONE DESIGN (touchscreen, li-
ion battery, sony lenses for camera)
ILLUSTRATE A.) your own example of design of experiment using the three
components of an experimental design (factors, levels, response). (B.) the
flowchart of the experimental design process
BENEFITS OF SPC
1. reduce defects and non conformities. 2. It matches process compatibility to
product requirements. 3. It increase process instabilityand consistency. 4. Shows
ability to meet costumer requirements. 5. It raise employee involvement and
ownership.
CHARACTERISTICS OF SPC
1. prevention focus. 2. Data driven. 3. Graphic centered. 4. Operator run system.
5. Implementing timely corrective action.
Where can variation occurs?
1. machine 2. Materials 3. Operators 4. Maintenance 5. Environment 6.
Measurement systems.
Histogram- are groups of distribution of data designed to show centering,
dispersion(spread)shape (relative frequency of data.
-it can provide a visual display of large amounts of data that are difficult to
understand in a tabular or spread sheet form.
- it is used to understand how the output of a process relates to costumers
expectations (targets and specifications and help the question “is the process
capable of meeting customer requirements?
HOW TO START
The 1st step in constructing a histogram is to decide how the process should be
measured what data should be collected. The which is measured on a continues
scale such as volume, size, weight, time, temperature.
Next step is to gather the data as a rule of thumb over 50 data points should be
collected in order to see meaningful patterns. Use historical information to
establish a baseline ( if the measurement method was exactly the same).
Put the gathered data in a tabular form or in a spread sheet. Once the histogram
is developed the data can be analyzed with regard to costumer
expectation(specifications). If the histogram of a process sample falls within the
specifications there is no action to be taken. But if the histogram has too much
dispersion or variability to meet costumer expectation action should be taken to
make the output more consistent or some number of defects has been produced.
Walter Shewhart of Bell Laboratories in the 1920's, and were expanded upon by Dr.
W. Edwards Deming, who introduced SPC to Japanese industry after WWII. After
early successful adoption by Japanese firms, Statistical Process Control has now
been incorporated by organizations around the world as a primary tool to improve
product quality by reducing process variation.
2 sources of process variation
1. Chance variation that is inherent in process, and stable over time,
2. Assignable, or Uncontrolled variation, which is unstable over time.
Process Variability
that control charts do not require normally distributed data in order to work -
they will work with any process distribution
Why Is Dispersion So Important?
Often we focus on average values, but understanding dispersion is critical to the
management of industrial processes
Control Limits
Statistical tables have been developed for various types of distributions that
quantify the area under the curve for a given number of standard deviations from
the mean (the normal distribution is shown in this example). These can be used as
probability tables to calculate the odds that a given value (measurement) is part of
the same group of data used to construct the histogram.
Shewhart found that control limits placed at three standard deviations from the
mean in either direction provide an economical tradeoff between the risk of
reacting to a false signal and the risk of not reacting to a true signal - regardless the
shape of the underlying process distribution.
If the process has a normal distribution, 99.7% of the population is captured by the
curve at three standard deviations from the mean. Stated another way, there is
only a 1-99.7%, or 0.3% chance of finding a value beyond 3 standard deviations.
Therefore, a measurement value beyond 3 standard deviations indicates that the
process has either shifted or become unstable (more variability).
Implementing Statistical Process Control
1. Determine Measurement Method
2. Qualify the Measurement System
3. Initiate Data Collection and SPC Charting
4. Develop and Document Reaction Plan
5. Add Chart to Control Plan
6. Calculate Control Limits After 20-25 Subgroups.
7. Assess Control
8. Analyze Data to Identify Root Cause and Correct
9. Design and Implement Actions to Improve Process Capability
10. Calculate Cp and Cpk and Compare to Benchmark
11. Monitor and Focus Efforts on Next Highest Priority
TAGUCHI METHODS
Dr. Genichi Taguchi is a Japanese statistician and deming prize winner
who pioneered techniques to improve quality through robust design of
products and production processes. Dr. taguchi developed fractional
factorial experimental designs that use very limited number of
experimental runs. The specific of taguchi experimental design is to
understand the taguchi loss function which is the foundation of his quality
improvement philosophy.
2 approaches of taguchi 1. Noise- considered as the variation from
environmental to manufacturing and component failure. 2. Cost-
considered as the rate of deterioration in the area.
5 primary tools used in robust design approach.
1. p- diagram – used to categorize variables into noise, signal or the input,
response or the output, and control factors related with a product. 2. Ideal
function- utilize to statistically or mathematically identify the ideal or
ultimate outline of the signal response association as represented by the
design idea for developing the higher level system work fault free. 3.
Quadratic loss function- also termed the quality loss function and is used
to measure the loss earned or acquired by the costumer or user from the
intended performance due to a deviation from it. 4. Signal to noise ratio-
used to predict the quality of the field by going through systematic
laboratory test or experiments. 5. Orthogonal arrays- used to collect and
gather reliable information about controls factors which are considered
the design parameters with minimal number of test and experiments.
4 main steps in robust design parameter methods
1. problem formulation- this step would incorporate the identification of
the main function, development of the p- diagram, classifying the best
function, signal to noise ratio and planning or strategizing the experiments.
2. Gathering of data- this is the stage where experiments or test are
performed in either simulation or hardware. 3. Factor effects analysis -this
is the stage where results or outcome of the control factors are estimated
and such results are evaluated. 4. Prediction/ confirmation – this is the
stage where in predicting the performance or operation of the product
model under the most favorable arrangement.
3 steps in scientific study
1. deciding the objective 2. Consider the method 3. Evaluate the method in
relation to objective.