Select Measures

The Define
Select Measures

Quality Process

Improvement Select
Select
Measures

Model
Measures

Collect &
Interpret
Data

Select Measures Is
No Investigate &
Process
Stable Fix Special
Causes
Purpose: ?

• Develop understanding of Yes

customer needs.
Is
• Determine ‘possible’ process Improve
Process
No
Process
Capable
response control points. Capability
?

Yes
Use SPC to
Maintain
Current
Process

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 Select Measures
Select Measures

Importance of Measures

Outputs
Process Customers
Products or Services

Need Measures of Process Performance

 To learn about the process.
 To identify improvement
opportunities.
 To monitor performance of
the process.

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 Select Measures
Select Measures

Use of Measures

Products or Services

Process Customers

Measurement
Process
Dealing with Dealing with
the Future the Past
Process Control Product Control
and Improvement and Disposition

What Does This Information Make The Decision

Tell Us About The Process? And Move On

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 Select Measures
Select Measures

Effective Measures

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 Select Measures
Select Measures

Example Measures

Typical Measures of Process Performance

Manufacturing Product characteristics (weight, dimensions,

color, chemical composition, appearance, etc.),
% not meeting customer specifications, etc.

Administrative Number of errors, time to complete activity,

percent not meeting requirements, etc.

Service Service time, delivery time, number of

complaints, etc.

Management Number of injuries, difference between amount

budgeted & actual expenditures, etc.

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 Select Measures
Select Measures

Types of Measures
 Counting Measures
Can
Cancount
count
 Count the number of items that do not the
thegood
good
conform to some standard. and
andbad.
bad.
 Count the number of nonconformities Can
Cancount
count
in a given area, volume, or time the
thebad
bad
period. only!
only!

 Instrument Measures
 Quality characteristic is measured by
some type of measuring instrument
(weight, time, size, chemical analysis,
dollars, ...)

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 Select Measures
Select Measures

Developing Measures

 Understand the customer's needs, expectations, and

wants.
 Use process map to identify key points for measures.
 Develop & document the measurement process.
 Develop a process for collecting, recording, and
analyzing data.
 Try the measure.

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 Select Measures
Select Measures

Selecting Measures

Outputs
Process Customers
Products or Services

? Gauge

In-Process
Gauge

Final Product
Gauge

Customer Satisfaction

 Where can we measure the process?

 What are pros and cons of the above locations?
 Where should we start?

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 Select Measures
Select Measures
Process Variables
Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)
Input Properties Uncontrolled / Response / Output Product
Controlled Variables Variables Properties
Process Variables

Process Variables -- All physical or analytical measurements related to a process.

Measurements can be electronic, manual observations, or laboratory results.
Measurements can be in-process or final product oriented.

Process variables can be broken down in to several different types:

•Input Properties - Inputs
•Uncontrolled / Controlled Variables - Inputs
•Response Variables – Outputs (Secondary)
•Product Properties – Outputs (Primary – See on Big Block/SIPOC)

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 Select Measures
Select Measures
Input Properties
Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)
Input Properties Uncontrolled / Response / Output Product
Controlled Variables Variables Properties
Process Variables

Input Properties (Inputs)-- Properties of inputs to the process that can be controlled
through contact with supplier.

Examples:

•Manufacturing - Purity of raw materials, composition of mixes, dope solids,

dope viscosity
•Lab - Purity of reagents, brand/model of instrument
•Maintenance - Condition of tools, size/composition of gaskets used in repair
•Administrative - Number of mistakes in data

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 Select Measures
Select Measures
Controlled/Uncontrolled Variables
Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)
Input Properties Uncontrolled / Response / Output Product
Controlled Variables Variables Properties
Process Variables
Controlled Variables (Inputs)-- Variables held at a set point or within a range
(standard operating conditions), either manually or by an automatic algorithm (EPC).
Set Point -- The desired level of a controlled variable.
Uncontrolled Variables (Inputs)– Variables that do not have a control system. Can
only be monitored.
Examples:
•Manufacturing - Feed rate of mix, reactor temperature settings (C), outside
temperature (U), pump shaft speed (C), metering pump speed (C)
•Lab - Hot plate temperature setting, time to cook a sample (C)
•Maintenance - Alignment gauge settings, lathe settings (C)
•Administrative - Procedures followed (U)
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 Select Measures
Select Measures
Response/Output Variables
Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)
Input Properties Uncontrolled / Response / Output Product
Controlled Variables Variables Properties
Process Variables
Response Variable (Outputs) – an analytical or measured variable that is used to control or
monitor the process but is not a measurement on the final product.

Time Lag -- A delay between expected effects of variables.

Example: 20 minutes after increasing a temperature (controlled input variable), the reactivity
(output variable) begins to increase.

Examples:
•Manufacturing - Composition before distillation, early stage viscosity
•Lab - Visual check for dissolution during heating, final temperature of heated solution
•Maintenance - Vibration of pump during operation, micrometer readings of machined part
•Administrative - Budget variance during the project

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 Select Measures
Select Measures
Product Properties / Output Variables
Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)
Input Properties Uncontrolled / Response / Output Product
Controlled Variables Variables Properties
Process Variables

Product Properties (Outputs) -- Measurements made on the final product that indicate its
performance. Important to "Value". Probably will be on Big Block/SIPOC.

Target -- The desired state of a response variable or product property.

Examples:
•Manufacturing - Lab test result on final product (IV, L*, a*, b*, lubricant level, denier,
entanglement)
•Lab - Lab test result on “known” reference material
•Maintenance - Equipment performance in the field, length of time until failure
•Administrative - Number of errors in Certificates of Analysis or purchase orders
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 Select Measures
Select Measures
External/Input Variables
External Variables

Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)

Input Properties Uncontrolled / Response / Output Product

Controlled Variables Variables Properties
Process Variables

External Variables (Inputs) -- Variables that are not controlled but may have
an effect on the process. Typically uncontrolled.

Examples:
•Manufacturing - Ambient temperature
•Lab - Humidity
•Maintenance - Vacation scheduling during deer hunting season
•Administrative - Employee morale

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Customer Requirements / Output Variables Select Measures
Select Measures

External Variables

Inputs
Outputs
Suppliers (Raw Process Customers
(Product)
Materials)
Input Properties Uncontrolled / Response / Output Product Customer
Controlled Variables Variables Properties Requirements
Process Variables
Customer Requirements (Outputs) -- Fitness-for-use specifications given by the
customer. Will be on Big Block/SIPOC or directly influenced by product property outputs.

Specifications -- the range of measurements of a product characteristic within which the

product is judged acceptable to meet customers’ requirements.

Examples:
•Manufacturing - Purity above 99.7%
•Lab - Sample Value reported within 2 hours
•Maintenance - Repairs completed within 4 hours
•Administrative - Errors below 0.5%
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 Select Measures
Select Measures

Three Ways to Control Key Variables in a Process

Control to a
Standard

Statistical Engineering
Process Process
Control Control

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 Select Measures
Select Measures

Statistical Process Control (SPC)

•Involves use of control charts, special cause action

plans and control strategies to identify and take action
on special causes.

•Primarily used on response variables and product

properties (outputs).

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 Select Measures
Select Measures

Engineering Process Control (EPC)

•EPC moves variation from where it bothers you to

where it doesn’t bother you. (Ex. cruise control)

•Automatically makes compensating adjustments

at a specified frequency.

•Must have reliable measurement, autocorrelated

data, and process adjustments with clear cause &
effect.

•Applied to inputs and outputs

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 Select Measures
Select Measures

Control To A Standard
•A standard way to perform a task (S.O.P.).

•A standard range that a key process variable should

be within.

•S.O.P.'s should be audited.

•Primarily used in inputs.

•Fundamental backbone of S.P.C.

•MUST be done first!

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