Chapter - 3

Measure and Analyze

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 3.0 – Introduction to Tool

What is DOE ?
• 90% of the Engineering problems are analyzed using
“Atmospheric analysis”

• Root cause cannot be established just by “thinking”

• Solutions given based on judgment, engineering

guesses and Opinions will make the problem recur
again

• DOE tools helps to pinpoint the root causes using

simple Data collection and analysis techniques
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 3.0 – Introduction to Tool

Steps in DOE
• Collect data
• Analyze data
• Conclusion on the cause or sources of variation

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 3.0 – Introduction to Tool

Applications of DOE
• Problem solving
• Process and Product redesign/characterization
• Process optimization

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 3.0 – Introduction to Tool

Why Shainin DOE

• Collect data
• On-line without disturbing the regular production
• Analyze data
• Off-line – without fancy mathematics and statistics (To
analyze you need to know only how to count, add,
subtract, divide and multiply)
• Conclude
• Either the cause is creating problem or not creating
problem (without any ambiguity)
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 3.0 – Introduction to Tool

Why Shainin DOE

• Tools selected are to be:-
– Simple for everyone
– No complex mathematics, statistics and big jargons
– Line engineers should be able to analyze the data
– Should identify the sources of variation clearly
– Should not allow any ambiguity in the decision
making process (Application of Henley’s law)
– Team should get “addicted” to using these tools, day-
in, day-out
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 3.0 – Introduction to Tool

Why Shainin DOE

• Works on Elimination principle

• Analysis is easy & involves only the following operations

• Counting

• Addition

• Subtraction

• Division

• Multiplication

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 3.01 – Introduction to Tool

How Shainin DOE Works – Case 1

Process: Boring
• Problem:
• Bore unclean after the boring operation in flange yoke
• The suspected sources of variation are
• ‘Y’ axis with respect to 78 +/- 0.2
• Ovality in 45 Dia.
• Drill size Dia. 10.15/10.30
• Drill size Dia. 45 -0.25
• Align w.r.t 10.2 hole
• Shift in X Axis w.r.t Spigot Dia
• Face out
• Boring Operation
• Can we pinpoint the root cause(s) by thinking ??
• Shainin DOE gives very clear direction on which way we have to work and
8 helps to pinpoint the root cause(s)
 3.0 – Introduction to Tool

How Shainin DOE Works – Case 2

Process: Moulding
• Problem:
• Air entrapment in Rubber moulded part
• The suspected sources of variation are

• Temperature.
• Water content in blank.
• Positioning of rubber blank in the mould cavity.
• Optimum cure time (tc-90).
• Tensile strength of rubber compound
• ‘Can we pinpoint the root cause(s) by thinking ??
• Shainin DOE gives very clear direction on which way we have to work and helps to
pinpoint the root cause's)

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 3.0 – Introduction to Tool

How Shainin DOE Works – Case 3

Process: Forging
• Problem:
• Lap in forged part – Synchro rings
• The suspected sources of variation are
• Wall thickness variation in the raw material
• Input weight of ring before forging
• Temperature of ring before forging

• ‘Can we pinpoint the root cause(s) by thinking ??

• Shainin DOE gives very clear direction on which way we have to work and
helps to pinpoint the root cause's)

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 3.0 – Introduction to Tool

How Shainin DOE Works – Case 4

Process: Sand Casting
• Problem:
• Sand inclusions in castings – Sleeve cylinder
• The suspected sources of variation are
• Sand level during filling
• Pattern temperature
• Pouring temperature
• Shell weight
• Core position
• Core strength
• ‘Can we pinpoint the root cause(s) by thinking ??
• Shainin DOE gives very clear direction on which way we have to work and
helps to pinpoint the root cause's)

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 3.0 – Introduction to Tool

How Shainin DOE Works – Case 5

Process: Sheet metal Processing
• Problem:
• Wrinkles after drawing
• The suspected sources of variation are
• Cushion pressure
• Bead clearance
• Shut height
• Oil spray pattern
• Bead radius
• ‘Can we pinpoint the root cause(s) by thinking ??
• Shainin DOE gives very clear direction on which way we have to work and
helps to pinpoint the root cause(s)

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 3.0 – Introduction to Tool

How Shainin DOE Works – Example

• Principle of elimination

• No “Atmospheric analysis”

• Data based approach

• No conclusions are based on Judgements and Opinions

of various people

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 3.0 – Introduction to Tool

DOE tool used in 6s – A summary

Name of the tool Type of tool Origin

Paired Comparison Problem solving Shainin, Tukey

Product/Process Search Problem solving Shainin
Component Search Problem solving Shainin
Modified Component Search Problem solving WCMS
Multi-Vari analysis Problem solving Shainin
Concentration chart Problem solving Classical
Variable Search Problem solving/ Shainin
characterization/
optimization
Full Factorial Problem solving/ Classical (Ronald
characterization/ Fischer)
Optimzation
B Vs C Validation of root cause(s) Shainin
ANOVA (Analysis of Variance) Problem solving Classical
14 Response Surface Methodology Optimization Classical
 3.0 – Introduction to Tool

Quick overview of the application of the tools

• We will now see a quick overview of when each of the
tools are to be used

• This is done just as a starting point. In-depth application

will be discussed when we discuss the various tools

• The application of each tool is explained with an

example for easy understanding

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 3.0 – Introduction to Tool

Paired Comparison - Application

• When the SSV’s can be directly measured

/ verified / checked on Good and Bad
components selected based on the
response

Y = Bore Unclear SSV’s (X’s)

•‘Y’ axis with respect to 78 +/- 0.2
• Ovality in 45 Dia.
• Drill size Dia. 10.15/10.30
• Drill size Dia. 45 -0.25
• Shift in X Axis w.r.t Spigot Dia
• Resting face flatness
• Boring Operation

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 3.0 – Introduction to Tool

Product / Process Search - Application

• When the SSV’s cannot be directly

measured/verified/checked on Good and Bad
components selected based on the response
• SSV’s here could be Product or Process
parameters
Y = Bore Unclear SSV’s (X’s)
•‘Y’ axis with respect to 78 +/- 0.2
• Ovality in 45 Dia.
• Drill size Dia. 10.15/10.30
• Drill size Dia. 45 -0.25
• Shift in X Axis w.r.t Spigot Dia
• Resting face flatness
• Boring Operation

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 3.0 – Introduction to Tool

Component Search - Application

• When it is an functional problem

in an assembled product and
the assembly can be
disassembled and reassembled
without damaging the functional
components

Y = Solenoid not SSV’s (X’s)

•‘Components in the
passing in pull load test assembly
•Assembly Process
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 3.0 – Introduction to Tool

Modified Component Search - Application

• When it is an functional problem

in an assembled product and
some functional components will
get damaged during disassembly

SSV’s (X’s)
Y = Key rotation •‘Components in the
tight in Fuel lid assembly assembly (Outer cap will
get damaged)
•Assembly Process
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 3.0 – Introduction to Tool

Multi-Vari Analysis - Application

• When we know that the problem is created
only from one manufacturing process. After
we have zeroed in the manufacturing
process creating the problem. This tool is
used to study a particular process in depth

Y = Bore Unclear SSV’s (X’s)

•‘Y’ axis with respect to 78 +/- 0.2
• Ovality in 45 Dia.
• Drill size Dia. 10.15/10.30
• Drill size Dia. 45 -0.25
• Shift in X Axis w.r.t Spigot Dia
• Resting face flatness
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• Boring Operation
 3.0 – Introduction to Tool

Concentration Chart - Application

• If the nature of the defect is such

that it can come at any location on
the product and we want to study the
pattern of how the defect comes in
the product/process

Y = Pin holes SSV’s (X’s)

• Many, but first we want
to study where is the
occurrence of pinholes
in the component
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happening to get clues
 3.0 – Introduction to Tool

Variable Search - Application

• Product/Process characterization or redesign

• Number of design parameters are >3

SSV’s (X’s) – Design

Y = Variation in height
parameters
after hot riveting • Preheating time
•Holding time
•Current
•Recooling time
•Squeeze pressure
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•Squeeze time
 3.0 – Introduction to Tool

Full factorial - Application

• Product/Process characterization
or redesign
• Number of design parameters are
<=3

SSV’s (X’s) – Design

parameters
Y = Deposition • Current
• Pointage of the
solution
• Temperature of the
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solution
 3.0 – Introduction to Tool

RSM - Application

• Optimziation of the process for Multiple responses

Y1 = No excess solder SSV’s (X’s) – Design

deposition parameters
• Dipping time
Y2 = No excess flux • Temperature
Y3 = No flux on pins • Flux quantity

Y4 = Solder strength
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 3.0 – Introduction to Tool

Key Points

• Shainin DOE works on elimination principle

• Analysis of data is very easy

• Shainin DOE tools have no complex statistics and

mathematics. Is based on “Engineering” and “Common
sense”

• Tools pinpoint the root cause(s) through data and not

through atmospheric analysis of the people

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 End of Chapter 3.0

Clarifications if any

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