Brooklyn Academy

Lean Six Sigma Yellow Belt

Presented by:
Khaled Aboul-ata

6 Lectures

Every Monday

From 6 to 10 PM

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Workshops

Group Project

Final exam at last lecture

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Optimum Total Quality Cost

Defect level
Quality
Cost
Minimum Total
Quality Cost
Failure Cost
Conformance
Cost

Low Defect High

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Special Causes Vs. Common Causes

5

• Special Cause: Variation is caused by known factors that

result in a non-random distribution of output. Also referred to
as “Assignable Cause”.

• Common Cause: Variation caused by unknown factors

resulting in a steady but random distribution of output around
the average of the data. It is the variation left over after Special
Cause variation has been removed and typically (not always)
follows a Normal Distribution.
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During 2019, the defective percentage of product

X was 2% .

This represents a gap of 1.5% from the industry

standard of 0.5% that amounts to US 200,000 of
annual cost impact.

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Create your own business case

1. Current Performance
2. Datum
3. Gap
4. Financial Impact

* Search for frequent problems with unknown reason

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1. Nominate 5 improvement projects

2. Select project based on evaluation criteria
3. Create business case
4. Develop project charter
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Worksheet Format and Structure

Menu Bar
Session Window
Tool Bar

Worksheet Data Window

Data Window Column Conventions

Text Column C1-T Date Column C2-D

(Designated by -T) (Designated by -D)

Numeric Column C3
(No Additional Designation)
-
Other Data Window Conventions

Data Entry Arrow

Column Names
(Type, Date, Count & Amount

Rows
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Hot Key Available

(Ctrl-S)

Submenu Available (…
at the end of selection)

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Minitab Interoperability

Minitab

Excel
PowerPoint

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Boxplot....

•Let’s look at the same data

using a Boxplot….

Boxplot....

•Go to:
•Stat…
•Basic Statistics…
•Display Descriptive
Statistics...

1
Boxplot....

Fill out the screen as

follows:
•Select Variable….
•Select Graphs…..

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Boxplot....

•Select Boxplot of
data….
•Select OK…..
•Select OK again
on the next
screen...

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Boxplot....

We now have our

Boxplot of the data...

10

Boxplot....

•There is another way we

can use Boxplots to view
the data...
•Go to:
•Graph…
•Boxplot...

11
Boxplot....

Fill out the screen as

follows:
•Select Y Variable….
•Select X Variable….
•Select OK…..

13

Boxplot....

Note that now we

now have a box plot
broken out by each
variable
Note that number 6
again seems to be the
source of the high
readings…..

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220 100

80
165
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Cumulative Ratio
60
Defects

110
40

55 40
33 31 20
26 21 18 17 15 12 7
0 0
1 2 3 4 5 6 7 8 9 10
Process

Pareto Chart....

•Let’s generate a Pareto Chart

from a set of data….
•Go to File… Open
Project…. Load the file ….
•Now let’s generate the Pareto
Chart...

3
Pareto Chart....

•Go to:
•Stat…
•Quality Tools…
•Pareto Chart….

Pareto Chart....

Fill out the screen as

follows:
•Use the Chart Defects
table...
•Labels in “Category”…
•Frequencies in
“Quantity”….
•Add title and hit OK..

3
 Pareto Chart....

Minitab now completes

our pareto for us ready to
be copied and pasted into
your PowerPoint
presentation….

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Scatter plot....

•Go to:
•Graph…
•Plot...

30

Scatter Plot....

Fill out the screen as

follows:
•Select Y Variable….
•Select X Variables…..
•Select OK when
done...

31
Scatter plot....

We now have two

Scatter plots of the
data stacked on top of
each other…
We can display this
better by tiling the
graphs….

33

Scatter plot....

To do this:
•Go to Window…
•Tile...

55
Scatter plot....

Now we can see

both Scatter plots
of the data…

Scatter plot....

•There is another way we

can generate these scatter
plots….
•Go to:
•Graph…
•Matrix Plot...

5
Scatter Plot....

Fill out the screen as

follows:
•Click in the “Graph
variables” block
•Highlight all three
available data sets…
•Click on the “Select”
button...
•Select OK when
done...

Scatter plot....

We now have a series

of Scatter plots, each
one corresponding to a
combination of the
data sets available…
Note correlation
between variables

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Month Discount Quantities

1 2 15.2
2 4.5 16.1
3 5 16.6
4 7 15.7
5 8.5 23.1
6 12 22.9
7 15 23.6
8 10 18.3
9 11 22
10 25 42.8
11 40 84.2
12 32.5 64.2
13 35 76.9
14 30 52.2
15 27.5 53.2
16 22.5 39.7

5-

Day Temperature Defect

1 34 22
2 26 6
3 24 10
4 15 18
5 36 31
6 14 22
7 30 19
8 32 26
9 23 12
10 28 11
11 21 15
12 35 29
13 17 14
14 38 36
15 11 29
16 40 35
17 31 21
18 13 27
19 18 16
20 41 38
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Process Capability

51
 Capability Formulas;

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LSL – Lower specification limit

USL – Upper specification limit

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• Home • Automobile

– Circuit breakers in any electric – Seat belts

circuits – Air bags
– Hot water button in water – Car engine warning lights
dispenser • Office
– Child proof caps on medications – Spell check in word processing
– Safety button in lighters software
• Computers – Questioning “Do you want to
– Mouse insertion delete”
– USB cable connection • Factory

– Battery insertion – Dual palm buttons

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Control Target Who How When Where Action

Subject

Defective
Quality Notify
Defective Quality units / Every
0.5% inspection Production
percentage Engineer Sample Hour
store Engineer
inspected

Measure
Temperatu Production Every Production Adjust
60 temperature
re Engineer Hour line temperature
of heater

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ATTRIBUTE type CONTINUOUS

of data

type of
subgroup
attribute
size
data
DEFECTS DEFECTIVES

Sample size 1 2-5 10+

type
type of
of defect
subgroups
I – MR X–R X–S
Chart Chart Chart
CONSTANT VARIABLE CONSTANT VARIABLE
Individuals Mean & Mean &
& Moving Range Std. Dev.
Range

NP
C Chart U Chart P Chart
Chart

Number of Incidences Number of Proportion

Incidences per Unit Defectives Defectives
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Khaled Aboulata Biography

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