W2-4 Intended Function - Final Candidate

Determine Measure
of Intended Function
THE PROCESS Y
Instructor File
Week Two – Module Four
Continuous Improvement
Black Belt/ Green Belt Training at Superior Essex
Week One Week Two
5 Self-taught Modules Measure Phase
 1. Six Sigma Overview  Introduction
 2. Recognizing Improvement Opportunities  Clarify the Process/Product & Customer CTs
 3. Defining Opportunities in Sigma TRAC  Characterize the Defect
 4. Meet Minitab® 4. Determine Measure of Intended Function
 5. Data Collection and Analysis 5. Validate the Measurement System
6. Evaluate Process Behavior
7. Evaluate Process Capability PROJECT
8. Identify Potential Xs MANAGEMENT
Week Three Week Four

Analyze Phase Improve & Control Phases
1. Introduction 1. Introduction
2. Estimation & CI 2. Determining Counteractions
3. Hypothesis Testing 3. Fractional Factorial Designs
4. Correlation & SLR 4. Robust Design (Nominal-the-Best)
5. ANOVA 5. Polynomial & Multiple Regression
6. Basic DOE 6. Control Phase
LEADERSHIP VSM
7. Full Factorial Designs 7. Error-proofing
8. Verifying Xs 8. Summary Project Presentations
Project Presentations
Week Five: Review Projects through Improve Phase

Superior Essex, Feb2014 2 W2-4 Measure of Intended Function_Inst.ppt
Define
Define
1 Identify what’s important to the customer. Define project scope.
Measure
Measure
2 Determine what to measure (Y) and validate the measurement system.
3 Quantify current performance and estimate improvement target.
Analyze
Analyze
4 Identify causes (Xs) of variation and defects.
5 Provide statistical evidence that causes are real.
Improve
Improve
6 Determine solutions (ways to counteract causes) including operating
levels and tolerances.
7 Install solutions and provide statistical evidence that the solutions work.
Control
Control
8 Put controls in place to maintain improvement over time.
9 Provide statistical evidence that the improvement is sustained.

About This Module
Measure
Measure
2 Determine what to measure (Y) and validate the measurement system.
3 Quantify current performance and estimate improvement target.
 Measure phase steps are applied in two ways:
PREVIOUS MODULE:
1. Measure the defect (negative outcome).
THIS MODULE:
2. Measure the process’s intended function (positive
outcome).
GRASP
GRASP THE
THE SITUATION:
SITUATION:
Why
Why does
does the
the process
process exist?
exist?
How
How does
does the
the process
process work?
work?
How
How well
well does
does the
the process
process accomplish
accomplish it’s
it’s intended
intended function?
function?

Learning Objectives
After completing this module, you will be able to…
1. Create a statement of intended function for the process

(or product) your team is working to improve.
2. Create a How-How diagram to gain detailed understanding
of how the process (or product) works.
3. Develop a variable measure of intended function
(Process Y).
4. Identify sources of variation in the Process Y.

Determine Measure of Intended Function:
Contents
Part One: Stating the Intended Function
Part Two: How the Process Works (How-How

diagram)
Part Three: Measure of Intended Function (Process Y)
Part Four: Sources of Variation (Multi-vari chart)

Part One
Stating the Intended Function

Battery Manufacturing Sub-process:
“Heat Seal Cover to Container”
Step 1: Heat Platen
Step 2: Melt plastic of container & cover
Cover
Platen
Container
Step 3: Step 4: Press container

Retract Platen and cover together.
What is the intended function of this process?

Why does the process exist?
Battery Manufacturing Sub-process:
“Heat Seal Cover to Container”
Step 1: Heat Platen
Step 2: Melt plastic of container & cover
Cover
Platen
Container
Step 3: Step 4: Press container

Retract Platen and cover together.
The intended function of this process is to seal the

battery container with the cover. The seal must be
good enough to assure the battery retains acid.
Intended Function Defined
 The “Intended Function” is a statement of what a process is

supposed to do.
 The intended function is stated in positive terms - not as the
absence of problems.
 A process may have more than one intended function.
Process Intended Function Statements Problems or Defects

Heat seal cover to To create a seal. Leaks
container
We
We initiate
initiate Six
Six
Why
Why do
do we
we care
care Sigma
Sigma projects for
projects for
about this?
about this? these reasons!
these reasons!

Why Focus on Intended Function?
 Why do defects occur?

 Defects occur when the process’ intended function is not
provided consistently, within and between cycles (units) of
production.
Consider the battery heat seal example:
The intended function of

this process is to create a
seal between the cover
and the container.
When a strong seal is not provided at every

location around the sealed area (within unit), and
for every battery (between units), leaks occur.
Driving variability out of a process’ intended function

minimizes the chances for defects to occur.
Workbook: Exercise 4.1
Intended Function Statements

Exercise 4.1:
Intended Function Statements
Allotted Time
7 MINUTES
ASSIGNMENT:
ASSIGNMENT:
1.
1. Review
Review the
the statements
statements provided
provided inin your
your workbook
workbook
describing
describing “What
“What we
we want
want from
from the
the process.”
process.”
2.
2. Identify
Identify which
which statements
statements are
are “intended
“intended function
function
statements”
statements” andand which
which statements
statements areare written
written as
as an
an
“absence
“absence of of problems”.
problems”.
3.
3. Use
Use the
the space
space provided
provided toto write
write the
the statement
statement of
of
intended
intended function
function for
for your
your project.
project.

4.1: Intended Function Statements
Intended Function or
Process What we want from the process
Problem?
Spot Welding Create strong bond
No splatter
Battery Pasting Spread paste uniformly onto grid
No voids
Sewing Seat Covers No hanging threads
No wavy seams
Straight seams
For your project:

Problem / defects:_______________________
Statement of intended function:________________________

Measuring the Intended Function
 The elimination of defects may best be achieved by

NOT measuring the defects themselves.
 A good variable measure of intended function (Process Y)
allows us to minimize functional variation.
 In many Six Sigma projects, the creative development of a
function-based measurement system has been the key
enabler to variability reduction and defect elimination.
To aid in the search for a good Process

Y, the team must understand the
physics of how the process works.

Part Two
How the Process Works

Goal: Grasp How the Process
Accomplishes Function
 After stating the intended
function of a process, the team Know the Learn how
Intended the process
works to understand how the
Function works
process accomplishes that
function. Identify
Identify a Validate
 This understanding will help good the
the team: Critical
Process Y Process Y
X’s
– Identify a good Process Y
(a measure of the intended
function) and eventually,
– Identify critical Xs (factors related to energy, machine settings,
materials, etc. that could contribute to variation in the Process Y).
TO LEARN HOW A PROCESS WORKS

1. Observe the process as it is operating.
2. Ask the subject matter experts.
3. Create a How-How diagram.

1. Observe the Process
 Use the high-level process map as a guide.

 Take notes throughout the process, from start to end.
 For each major process step, identify:
– Input energy source that is being used, and how it is being used.
– Other inputs such as materials and/or components.
– Outputs (intended and unintended).
– Specific actions that take place, such as …
• Movement of materials and equipment.
• The combining (or changing of physical state) of materials.
The goal of the investigation is to clarify how

the process does what it is intended to do.
Question everything!

2. Ask the Experts
 Ask the subject-matter experts to explain the specifics behind

what you observe.
 Ask: How?
 What physical changes are taking place with the equipment or
product, in the time order that they occur?
 Be sure to have the expert explain how energy is being used
throughout the process.
Who are
the
Make a list of specific “How” experts?
questions to ask the experts.
Question everything!

A Schematic Assists in Formulating
Questions
 Use or create a schematic of the process to help visualize
how the process works.
 For example, could the schematic below help the “Stamping”
team see how the stamping process works?
 Might it help the team generate specific questions to ask
experts, so they can better understand how the process works?
STAMP PROCESS
What questions
would this
schematic prompt
the team to ask?

4. Create a How-How Diagram
 A cousin to the “Five Whys” process, in a How-How diagram, each

process step is questioned with “how?”, and each response is
questioned with “how?” until a complete understanding of the
process’s functionality is documented.
 Unlike the Process HOW-HOW DIAGRAM
How? How?
Map, the How-How
diagram deals only
with the physics of
how the process
works.
TIME
 The tree may have Intended

as many branches Function
as needed to
describe the
complete physics.
The physics becomes more
detailed, moving left to right.
How-How Diagram Example:
Heat Seal Cover to Container
INTENDED
FUNCTION:
To create a
seal between
cover and
container.
State the
intended
intended
function

HOW?
INTENDED Ask: How?

FUNCTION: How is the seal created?
To create a What
What physical
physical changes
changes areare
seal between taking
taking place
place with
with the
cover and equipment or product, in the
Time
container. time order that

that they
they occur?
occur?

HOW?
Heat Platens
INTENDED Melt plastic on

FUNCTION:
cover and
To create a container
seal between
cover and
Time
Press cover to
container.
container
Seal is formed

HOW? HOW?
Heat Platens
How
How are
are the
the
INTENDED
platens heated?
FUNCTION:
Melt plastic on
cover and
seal between
cover and
Time
Press cover to
container.
container
Seal is formed

HOW? HOW?
Electrical current is
Heat Platens converted to heat
FUNCTION:
cover and
seal between
cover and
Time
Press cover to
container.
container
Seal is formed

HOW? HOW?
Electrical current is
Heat Platens converted to heat
FUNCTION:
cover and How is plastic
To create a container melted?
seal between
cover and
Time
container Press cover to

container
Seal is formed

How-How Diagram Example: Heat Seal Cover to Container
HOW? HOW?
Heat Platens Electrical current is

converted to heat
FUNCTION: Press cover and container
cover and against the heated platen
seal between
cover and
Time

container
Seal is formed

HOW? HOW?

converted to heat
seal between
cover and How
How is
is cover
cover
Time
container Press cover to pressed

container pressed to
to
container?
container?
Seal is formed

HOW? HOW?

converted to heat
seal between
cover and Hydraulic press
Time

container
Seal is formed

HOW? HOW?

converted to heat
seal between
Time

container
How is seal formed

Seal is formed after cover and
container are pressed
together?
together?

HOW? HOW?

converted to heat
seal between
Time

container
Melted plastic that is
joined together (from
Seal is formed cover and container) is
solidified through cooling

HOW? HOW?

converted to heat
seal between
Time

container
Melted plastic that is
joined together (from
Seal is formed cover and container) is
solidified through cooling
What are some potential sources of

variability in the resultant seal? Be specific.
Create a How-How Diagram

Exercise 4.2:
Create a How-How Diagram
Allotted Time
20 MINUTES
ASSIGNMENT:
ASSIGNMENT:
1.
1. Select
Select one
one of
of the
the Six
Six Sigma
Sigma projects
projects from
from your
your group.
group.
2.
2. Create
Create aa How-How
How-How diagram
diagram ofof the
the process,
process, filling
filling in
in
answers
answers to to the
the extent
extent known.
known.
3.
3. Create
Create aa list
list of
of “How”
“How” questions
questions toto ask
ask subject
subject matter
matter
experts.
experts.
4.
4. Be
Be prepared
prepared to to share
share the
the diagram
diagram andand questions
questions with
with
the
the larger
larger group.
group.

Part Three
Measure of Intended Function

(Process Y)
Measure of Intended Function:
Process Y Examples
 We will now review two scenarios that will introduce some ideas
about measuring Intended Function.
 The examples are not fully discussed or evaluated at this time.
You will have an opportunity to explore them more fully later in
the training.
– Team A: Stamping Parts Inputs Process Outputs
• Sheet metal • Formed part
– Team B: Foaming Panels blank
STAMPING
PARTS
• Press break
Draw
• Die
Punch
Form
Inputs Process Outputs

• Sheet metal Foam Panels • Panels filled
• Foam with foam
chemicals (solid)
(liquid)
• Hardware

The Situation – Team A: Stamping Parts
Project Name: Stamp Parts –

Eliminate Defects
Y % defective (fractures)
Problem 6% of parts produced FRACTURE
Statement: are defective
(fractures) Inputs Process Outputs
• Sheet metal STAMPING • Formed part
blank PARTS
Project Eliminate defects due • Press break
Draw
Objective to fractures • Die
Punch
Form
Brainstorm:
How might the team proceed?
The Situation – Team B: Foaming Panels
Project Name: Foaming Panels – Inputs Process Outputs

Eliminate Excess Foam • Sheet metal Foam Panels • Panels filled
• Foam with foam
Y % of foam that is wasted chemicals (solid)
(liquid)
Problem 14% of foam is wasted • Hardware
Statement:
Project Eliminate excess

Objective (wasted) foam, while
assuring panels fill
completely
 Liquid foam is sprayed into panels that are used in Air Handling
Units. The foam provides the needed insulation.
 The foam expands (and solidifies) to “hopefully” fill the panel.
 The problem is that, to be sure the panels fill, operators use a
“fudge factor” … spraying more foam than is needed in most
How might
cases. the team
 Consequently, foam pours out the ventilation holes. proceed?
The Importance of Process Y
 The elimination of defects may best be achieved by

NOT measuring the defects themselves.
 A good variable measure of intended function (Process Y)
allows us to minimize functional variation.
 In many Six Sigma projects, the creative development of
a function-based measurement system has been the key
enabler to variability reduction and defect elimination
TEAM NEXT STEPS Know the Learn how

Intended the process
Brainstorm possible measures of Function works
intended function for the process.
Use the How-How diagram, the IPO Identify
Identify a Validate
diagram, the Process Map, and the good the
creativity of the team. Critical
Process Y Process Y
X’s

Brainstorm Possible Process Ys
 Consider the battery welding example:
 To get a good seal, the melting of plastic at all locations
around the sealed area should be consistent.
 What “measures” could reflect that?

Testing the Selected Metric
Intended Function: To create seal

between cover and container.
 The Battery Team evaluated options and selected “Height of

Battery” (after welding container to cover) as a Process Y.
 After considering the physics, they think that attaining the same
height (right height) at all locations along the perimeter of the
battery leads to a good seal.
 They will work to drive out variation in the “Height of Battery”
(after welding) as a strategy to consistently achieve good seals.
Before using this Process Y to minimize

variation, how might the team “try it out”?
 What needs to be considered?

Testing the Selected Metric
Process Y: Height of Battery
 What needs to
be considered?
mm
CONSIDERATIONS Caution:
A tall container combined with a tall
Variation in press travel cover, or short container combined
with short cover will produce
Variation in battery container height different battery heights. Yet, both
could have good seals.
Variation in the cover height Or, two batteries could have same
overall height, yet one with good
seal, and the other not.

Testing the Y: Considering Options
Possible
Measures Consideration Conclusions
(Process Y)
May work if component variations are
1. Height of negligible compared to variation in
Battery overall change in height due to melt
and squeeze.
2. Change in May be difficult to measure

overall
height due
to melt and
squeeze
Burst strength is (a) destructive,

3. Burst (b) may be misleading: Inadequate
Strength strength could be the result of various
failure modes and c) may just show
material strength.
 The team ran physical tests on the first two options, and
selected “Change in Height” as their Process Y. (Component
variation was too great to use “Height of Battery”).
Measuring the Selected Process Y:
Be Creative!
 In many Six Sigma projects, the team may need to create an
innovative way to efficiently and effectively measure the
selected Process Y.
 The team should:
– Be creative!
– Consider options!
Innovative measuring is often a key enabler

to breakthrough process improvements!

Examples of Creative Measuring
 Many successful Six Sigma teams have developed creative

measurement systems that enabled them to measure
intended function in a timely and low-cost manner.
 Two specific examples are presented:

 Example A: Battery Pasting Process
 Example B: Door Arm-Rest Opening

Example A:
Battery Pasting Process (PowerFrame)
CTQ : Paste should be applied to the grid A B
so that the grid is centered in the plate
(to prevent warp)
Process Y : Ratio of paste above
grid to paste below the the grid,
(A/B)
The measurement challenge: How to quickly and

easily measure paste centering within the plant.
Initial Measurement System : New Measurement System :

• Samples sent to Lab • Team members take
Assessment : measurements in plant
• 3 to 6 Week Turn Around Assessment :
• No Gage R&R • 10 Minute Turn Around
• Labor Intensive • Passed Gage R&R

Battery Pasting Process (PowerFrame),
cont.
1. Remove paper and dry raw plates in the
sample preparation oven as for AOM test.
2. Working on a ventilated table, position dry plate
2. Position lug
on the fixture locating the lug in the identified slot. between pins.
3. Lay erasing template 3. Clamp template
on plate positioning lug and plate in place.
marks to lug locating
pins. Clamp plate &
Template in place.
4. Brush paste at
template windows.
(Use a brass brush,
comparable to
erasing) Wires should
Template is on
be exposed, but paste top of sample.
should not be
fractured. 4. Brush paste at
template windows.

Battery Pasting Process (PowerFrame),
cont.
Plate will have windows on top and bottom where
the paste is removed to a level below the wire.
Paste Brushed
out to below
level of wire.
Position tip of depth

micrometer on wire
intersection and measure.

Example B: Door Arm Rest Opening
This gap distance is

critical to customers.
If it’s too small, the
armrest does not install.
If it’s too large,
there is a gap.
The measurement
challenge: the critical
area is contoured.
Y= Gap distance (mm)
Before: CMM in metrology, 3-4 After: Calipers with fixture.

day turnaround and large costs for Can be measured at any time for
shipping and measuring. a cost of $3.00

The Team’s Clever Measurement Device:
Calipers with Fixture
Clay is molded to fit snap
feature on part and base This measurement
of the caliper. system was highly
repeatable and
reproducible (good
Gage R&R).
Clay piece snaps onto

calipers.
The clay keeps the calipers at the

correct angle and allows the user
to measure the same contour
Clay piece snaps onto a End of
surface.
snap feature on door. Example B
Important Points About Process Ys
 A good Process Y is needed for optimizing the process, but is

often not suitable for on-going monitoring of the process.
 An entirely different metric or test may be used during on-going
production.
“Y”:
“Y”: Process
Process
Output
Output
As
As aa function
function of
of “x”:
“x”:
•• Causes
Causes
Y = f(x) •• Process
Process Factors
•• Process
Factors
Process Inputs
Inputs
A good Process Y enables us to evaluate effects of

factors (Xs), and thereby reduce variation.

Measure of Intended Function:

Stamping Parts and Foaming Panels
Exercise 4.3:
Measure of Intended Function
Allotted Time
30 MINUTES
ASSIGNMENT:
ASSIGNMENT: Two
Two Examples
Examples
 Process
Process Example
Example A:
A: Stamping
Stamping Parts
Parts
 Process
Process Example
Example B:
B: Foaming
Foaming Panels
Panels
For
For the
the example
example to to which
which your
your team
team is
is assigned:
assigned:
1.
1. Write
Write aa statement
statement ofof intended
intended function
function for
for each
each process.
process.
2.
2. ToTo the
the extent
extent possible,
possible, describe
describe the
the physics
physics ofof how
how the
the process
process
works.
works.
3.
3. Propose
Propose oneone or
or more
more Process
Process Ys
Ys that
that the
the team
team might
might consider.
consider.
4.
4. Evaluate
Evaluate the
the effectiveness
effectiveness and
and ease
ease of
of using
using each
each metric.
metric.
5.
5. Prepare
Prepare toto present
present your
your findings
findings to
to the
the larger
larger group.
group.

4.3: Measure of Intended Function
Example A: Stamp Parts Process
Inputs Process Outputs

STAMP PROCESS
• Sheet metal STAMPING • Formed part
blank PARTS
• Press break
Draw
• Die
Punch
Form
HOW DEFECTS OCCUR

4.3: Measure of Intended Function
Example B: Foaming Panels Process
 Panels, used within air handling Inputs Process Outputs

units, are filled with a liquid • Sheet metal Foam Panels • Panels filled
“foam”. The foam expands • Foam with foam
inside the panel, resulting in a chemicals (solid)
solid foam that should fill the (liquid)
entire panel. • Hardware
 The problem is that the panels The

The panels
panels are
are
do not always fill completely. To closed
closed onon all
all
compensate, operators typically four sides, but
four sides, but
are
are shown
shown
use a “fudge factor” and shoot opened
opened here
here to
to
in considerably more foam than illustrate how
illustrate how
is needed. Wasted foam pours foam
foam grows.
grows.
out the ventilation holes, into
the plant.
 In an effort to drive out variation
(so less material can be used,
while completely filling the
How Foam Grows
panels), the team searches for
a good Process Y.

Part Four
Sources of Variation
(Multi-vari chart)
Discovering Sources of Variation
 The battery team selected “Change in Battery Height” (before

and after welding container to cover) as their Process Y.
 Driving out variation in the Process Y is a key strategy for
improving the seal.
 The team now works to discover where variation happens:
– Within a Part
– Part to Part
– Over Time
To discover the biggest

source(s) of variation, the team
conducts Multi-vari Analysis.

What is Multi-vari Analysis?
 Multi-vari analysis is a graphical analysis technique used to

identify and quantify dominant sources of variation in a process.
 The tool graphically depicts multiple sources of variation
allowing the examination of families of variation.
FAMILIES OF VARIATION
Within
Within Unit
Unit Unit-to-unit
Unit-to-unit Time-to-time
Time-to-time
(or
(or part)
part) (or
(or part-to-part)
part-to-part)
The objective is to determine which

family exhibits the largest variation.

Potential Sources of Variation: Examples
Output (Y) to Potential Sources of Variation

Team
Improve (Within, Between, Time)
Battery Team: Change in  Within battery
“Welding Battery height (left side vs. right side; front vs. back)
container to (before and  Battery to Battery
cover” after welding)
 Day to Day
Seat Track Team Track efforts  Within a seat track (different locations
along the track)
 Seat Track to Seat Track
 Hour to Hour
Visor Clip Team Clip diameter  Within clip

(right end vs. left end; minimum vs.
maximum diameter on same end)
 Clip to clip
 Lot to Lot
Note: Of the three families of variation, “within unit” is the least intuitive.

When Should Multi-vari Analysis Be Used?
 Many processes exhibit multiple potential sources of variation.

 Often, clear evidence indicating the source of the most
significant variation does not exist.
 Multi-vari analysis is an effective tool used to identify and
quantify dominant sources of variation in a process.
 Multi-vari analysis Multi-Vari Chart for Effort by Position - Time
narrows the search for

1 2 3 4 5
1 2 3 Position
13 Left
critical Xs. 12
Right
 It allows subsequent 11
Effort
10
designed experiments 9
and “cause & effect”

8
analysis to be more 6
1 2 3 4 5 1 2 3 4 5
focused and efficient. Panel variable: Time

Part

The Multi-vari Analysis Approach
1. Identify potential sources (families) of variation.

2. Create a data sampling plan that will capture all potential
sources of variation.
3. Validate the Measurement System (MSA).
4. Collect the data. Avoid adjusting the process; record any
observations or adjustments that must be made.
5. Construct and interpret the Multi-vari chart.
Identify Construct
Create data
Potential Perform Collect the and interpret
sampling
Sources of MSA data the Multi-vari
plan
Variation chart

Multi-vari Analysis:
Seat Track Effort Example
The Seat Track team conducts Multi-vari analysis:
Identify Construct
Create data
Potential Perform Collect the and interpret
sampling
Sources of MSA data the Multi-vari
plan
Variation chart
Team Output (Y) to Improve
Seat Track Team Track efforts

1 Identify potential sources of variation.
WITHIN UNIT UNIT-TO-UNIT TIME-TO-TIME
WITHIN SEAT TRACK-TO- HOUR-TO-

TRACK TRACK HOUR
Are the efforts the Compare variation How much is the

same throughout in a sample of 3 to process changing
the entire seat 5 tracks taken at a from one hour to
track? snapshot in time. the next during
the day?

2 Create data sampling plan.
 Measure effort in at least two locations of the same seat track.

 Measure 5 consecutively produced tracks, each track being
measured in the same two (or more) locations.
 Collect another subgroup of 5 consecutive pieces at a different time
during the day.
 Continue to sample until you have enough data to represent the full
range of variation that your experience (or experts) suggests exists.
– Note any process changes, such as when the process went
down, a tool change, etc.

2 Create data sampling plan (continued).
SAMPLING TIPS:
 Sample size should be at least
WITHIN PART:
three, preferably five. Sample
The Seat Track team measured effort
at least three times per shift,
in two locations on each seat track.
more often if it is a high
FIRST DAY SECOND DAY production operation with
frequent tool changes.
Right at Starting Middle of Morning
Time  Do the study over two days
Just Before Lunch Right After Lunch (minimum).
Middle of Afternoon Just Before Quitting  When choosing the time of day to
Time sample, maximize time-to-time
variation by choosing those
hours where the most change
is likely to occur.
3 Perform MSA 4 Collect the data.
 Perform MSA (Measurement System Analysis): The team

conducts Gage R&R to assure adequacy of the measurement
system for this application (see MSA module).
 Collect the data: The team creates a data collection sheet that
matches their sampling plan, and then collects the data using
the verified measurement system.
Seat Track Rail Dimension

DATE TIME LOCATION 1 LOCATION 2
55 tracks
tracks were
were
1 March 7:00 a.m. measured
measured at at
11:00 a.m. each
each date/time,
date/time,
2:00 p.m. at
at two
two
locations.
locations.
2 March 9:30 a.m.
12:30 p.m.
3:15 p.m.

5 Construct and interpret Multi-vari Chart
 The Multi-vari Chart: The effort data is plotted in a way that visually
conveys the amount of variation coming from each potential source.
 Minitab can be used to create the chart.
The
The horizontal
horizontal
line
line
The
The length
length ofof (connecting
(connecting
the
the vertical
vertical line
line averages)
averages)
shows
shows within
within shows
shows track
track to
to
track
track variation.
variation. track
track variation.
variation.
(variation
(variation
between
between
locations
locations 11 and
and
22 on
on same
same track)
track)

Multi-vari Chart Interpretation
Data from one day:

SEAT TRACK EFFORTS Location
Location 1
Location 2
13
12 What is the
biggest
11
source of
variation?
Effort
10
r
9
Within Seat
8 Track
7
variation is
dominant.
6
(as shown by
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
the red lines)
7:00 a.m. 11:00 a.m. 2:00 p.m.

Multi-vari Chart Interpretation (continued)
 Suppose the graph looked like this:

Location 1
SEAT TRACK EFFORTS Location 2
12
11
What is the
biggest
10 source of
variation?
Green Y
9
Effort
8
Time-to-
7 Time
variation is
6
dominant.
5
1 2 3 4 5 16 17 18 19 20 31 32 33 34 35
Time to Time Variation is Dominant
7:00 a.m. 11:00 a.m. 2:00 p.m.

Multi-vari Chart Interpretation (continued)
 Suppose the graph looked like this:

Location 1
SEAT TRACK EFFORTS Location 2
10.5
What is the
biggest
source of
9.5
variation?
Green Y
Effort
8.5 Track-to-Track
variation is
dominant. (as
7.5 shown by the
blue lines)
1 2 3 4 5 16 17 18 19 20 31 32 33 34 35
Unit to Unit 11:00
7:00 a.m. Variation
a.m.
is Dominant
2:00 p.m.

Creating Multi-vari Charts Using Minitab®
 Open Minitab® data file: “Track Effort”.

 Select Stat > Quality Tools > Multi-vari Chart.
Within
Within Panel
Panel
Variable
Variable
Panel
Panel
Variable
Variable
 The choice of factors dictates the graph’s appearance.

 Listing “time” as the last factor enables the graph to
display time from left to right.

Multi-vari Chart Interpretation
In
In Minitab
Minitab
terms,
terms, this
this is
is
“Panel 1”.
“Panel 1”. SEAT TRACK EFFORTS Location 1
Location Location 2
13
12
11
Effort
10
r
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
7:00 a.m. 11:00 a.m. 2:00 p.m.

Creating Multi-vari Charts Using Minitab®
 The data as displayed in this chart indicates that the major

source of variation is location (within track variation).
11stst entry
entry into
into Minitab:
Minitab:
33 entry
rd
rd
entry Within
into Within partpart variability
variability
into
Minitab:
Minitab: Multi-Vari Chart for Effort by Position - Time
Panel
Panel 1 2 3 4 5
variable
variable
(Time)
(Time)
1 2 3 Position
Left
: Part Mean
13
Right
12
: Time Mean
11
Effort
10
9
22nd
nd entry into
entry into
Minitab:
Minitab: 8
Part
Part to
to part
part 7
1 2 3 4 5 1 2 3 4 5
Part
Panel variable: Time

Multi-vari Analysis:
Molding Foam Blocks and Laser Welding
Exercise 4.4: Multi-vari Analysis:
Molding Foam Blocks and Laser Welding
Allotted Time
20 MINUTES
ASSIGNMENT:
ASSIGNMENT:
1.
1. Read
Read the
the description
description of
of the
the processes
processes provided
provided in
in your
your
workbook:
workbook:
 Process
Process Example
Example A:A: Molding
Molding Foam
Foam Blocks
Blocks
 Process
Process Example
Example B:B: Laser
Laser Welding
Welding
2.
2. Using
Using Minitab
Minitab®® and
and the
the data
data inin the
the file
file “4.4
“4.4 Multivar.MTB”,
Multivar.MTB”,
create
create aa Multi-vari
Multi-vari chart
chart for
for each
each process.
process.
(In
(In Minitab
Minitab® :: Select
®
Select Stat
Stat >> Quality
Quality Tools
Tools >> Multi-vari
Multi-vari Chart.).
Chart.).
3.
3. Determine
Determine the the source
source ofof greatest
greatest variability
variability for
for each
each of
of the
the
processes.
processes.

4.4: Multi-vari Analysis:
Example A: Molding Foam Blocks
 Large Foam Blocks are molded, THREE MOLDED FOAM BLOCKS
then sliced into sheets for use in
making headliners. Uniform
density of the foam is desired.
 Three blocks are measured.
From each block, three sheets
(slices) are sampled: from near
the bottom, the middle, and near
the top.
 From each sheet, density
measurements were obtained
FROM EACH FOAM BLOCK:
from seven locations per sheet.
Bottom Sheet
Create a Multi-vari chart.
Determine the largest source Middle Sheet
of variability in density: 1 2 3
– Block to Block Top Sheet
– Between Sheets 4
– Between Locations. 5 6 7
 The data is in the Minitab file:
Foam Block
4.4: Multi-vari Analysis:
Example B: Laser Welding
Fusion Width
 Weld integrity was evaluated by
measuring “fusion width”.
 The goal is to obtain consistent width
welds while staying above 1mm.
 We have data from the beginning
and the end of a four-hour run.
 The data comes from three different
fixtures and from four weld
locations on each frame.
Create a Multi-vari chart. Evaluate the
sources of variability in fusion width:
– Over time (beginning and end of
run) 1 2
– Between fixtures
– Within part: different weld
locations
 The data is in the Minitab file “Laser
Welding-Fusion.” 3 4

Determine Measure of Intended Function –
Summary
 An effective strategy to eliminate defects is to NOT measure
the defects themselves. Instead, measure the process’
intended function (Process Y).
 Minimizing variation in the process’ intended function minimizes
the chances for defects to occur.
 To determine a good Process Y, it is important that the team
gain a solid understanding of how the process works.
 The creative development of measurement systems to
measure the intended function enable breakthrough
improvements to be made.
 Conduct Multi-vari analysis on the Process Y to determine
where variation occurs (Within Part, Part to Part, Time to Time).

W2-4 Intended Function - Final Candidate

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Determine Measure

Week Three Week Four

Week Five: Review Projects through Improve Phase

3 Quantify current performance and estimate improvement target.

5 Provide statistical evidence that causes are real.

9 Provide statistical evidence that the improvement is sustained.

3 Quantify current performance and estimate improvement target.

 Measure phase steps are applied in two ways:

Superior Essex, Feb2014 4 W2-4 Measure of Intended Function_Inst.ppt

After completing this module, you will be able to…

1. Create a statement of intended function for the process

Superior Essex, Feb2014 5 W2-4 Measure of Intended Function_Inst.ppt

Part One: Stating the Intended Function

Part Two: How the Process Works (How-How

Part Three: Measure of Intended Function (Process Y)

Part Four: Sources of Variation (Multi-vari chart)

Superior Essex, Feb2014 6 W2-4 Measure of Intended Function_Inst.ppt

Stating the Intended Function

Step 3: Step 4: Press container

What is the intended function of this process?

Step 3: Step 4: Press container

The intended function of this process is to seal the

 The “Intended Function” is a statement of what a process is

Process Intended Function Statements Problems or Defects

Superior Essex, Feb2014 10 W2-4 Measure of Intended Function_Inst.ppt

 Why do defects occur?

The intended function of

When a strong seal is not provided at every

Driving variability out of a process’ intended function

Intended Function Statements

Superior Essex, Feb2014 13 W2-4 Measure of Intended Function_Inst.ppt

For your project:

Superior Essex, Feb2014 14 W2-4 Measure of Intended Function_Inst.ppt

 The elimination of defects may best be achieved by

To aid in the search for a good Process

Superior Essex, Feb2014 15 W2-4 Measure of Intended Function_Inst.ppt

How the Process Works

TO LEARN HOW A PROCESS WORKS

Superior Essex, Feb2014 17 W2-4 Measure of Intended Function_Inst.ppt

 Use the high-level process map as a guide.

The goal of the investigation is to clarify how

Superior Essex, Feb2014 18 W2-4 Measure of Intended Function_Inst.ppt

 Ask the subject-matter experts to explain the specifics behind

Superior Essex, Feb2014 19 W2-4 Measure of Intended Function_Inst.ppt

Superior Essex, Feb2014 20 W2-4 Measure of Intended Function_Inst.ppt

 A cousin to the “Five Whys” process, in a How-How diagram, each

 The tree may have Intended

Superior Essex, Feb2014 22 W2-4 Measure of Intended Function_Inst.ppt

INTENDED Ask: How?

container. time order that

Superior Essex, Feb2014 23 W2-4 Measure of Intended Function_Inst.ppt

INTENDED Melt plastic on

Superior Essex, Feb2014 24 W2-4 Measure of Intended Function_Inst.ppt

Superior Essex, Feb2014 25 W2-4 Measure of Intended Function_Inst.ppt

Superior Essex, Feb2014 26 W2-4 Measure of Intended Function_Inst.ppt

container Press cover to

Superior Essex, Feb2014 27 W2-4 Measure of Intended Function_Inst.ppt

Heat Platens Electrical current is

container Press cover to

Superior Essex, Feb2014 28 W2-4 Measure of Intended Function_Inst.ppt

Heat Platens Electrical current is

container Press cover to pressed

Superior Essex, Feb2014 29 W2-4 Measure of Intended Function_Inst.ppt