DMA I C

Analyze Overview

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 DMA I C

Analyze Phase
What is it?
The Analyze phase examines the data collected in
the Measure phase in order to generate a
prioritized list of the sources of variation (the Xs).

Why do we do it?
The Analyze phase focuses improvement efforts
by separating the potential vital few variables
(those most likely responsible for the variation)
from the trivial many (those least likely responsible
for the variation).
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 DMA I C

Analyze Phase
What are the key elements?

There are 3 key elements, or deliverables, in

the Analyze phase:

1. Prioritized list of all Xs

2. List of Vital Few Xs
3. Updated Charter and Financial Benefits

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 DMA I C

Analyze Phase
1. Generate potential Xs. The team
determines all possible sources of variation for
the Project Y;

2. Narrow the List of Xs. The team selects and

ranks those Xs they believe have the highest
degree of impact on the output (Project Y);

3. Vital Few Xs. The team statistically validates

with data these vital few Xs and begins to
quantify the relationship with Y.
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 DMA I C

Analyze - Generate Potential Xs

How do we capture all possible Xs?
The team will generally use a combination of:
- data analysis, and
- process analysis
to create a listing of all the possible causes of
variation.

Data Analysis
- use special statistical package i.e.
Minitab
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 DMA I C
Analyze Phase
1. Generate potential Xs. Brainstorming

Measurements Material Personnel

Flowmeters calibration
Boiler feed water quality

Hot water tk level faulty Start/Stop HP user

Chemical injection point

O2 Analyser calibration

Boiler Feed water temp.

Wash Water tk temp. faulty B oiler training

Demin plant pH & Conduct

Drum level controller
GJ of gas
per
Boiler load sharing Tonnes of
VSD for FDF flow control
LP pressure control
Steam
Frequent blowdown No tripping of boilers
Exit gas temperature
Air temp. fed to boiler CO in the exit gas Heat loss at burner assembly

Air/Gas ratio used Hot water heater HExchanger

Running 2 or 3 boilers
Steam leaks at flanges
Start/shoutdown procedure
Different mode of operations
Ambient temp. & weather Steam trap leaks
Plant operating instruction
LP relieve valve blow Fouling of boilers tube
Excess air used on boilers
Line insulation
Sudden steam demand

Environment Methods Machines

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 DMA I C
A “Good” Picture is Worth a Thousand Words!
ShotNo Length
1 59.50
2 58.75
3 58.25
63
4 60.25
5 58.00
62
6 60.50
61
> 7
8
61.25
60.50
Length

9 60.75
60
10 61.25
11 61.25
59
12 62.25
13 62.25
58
14 61.75
Index 5 10 15 20 15 61.25
16 61.25
17 62.50
• Make graphs from columns of data 18 62.00
• Display means, variation, trends, and relationships 19 62.00
• Communicate with team members and sponsors 20 62.00
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 DMA I C
Graphs of Process Output - Y
Discrete (Y) Continuous (Y)
Pie Chart of Zone D Shots Dot Plot Box and Whisker Plot
1 (13, 26.0%)

0 (37, 74.0%)

Histogram Normal Probability Plot

Bar Chart of Defects
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Number of Shots

20

10

0
0 1 2 3
Number of Defects
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 Graphs of Process Output DMA I C
Continuous or Discrete Y and Continuous Cont.
X
Y
Disc.
Disc. X Cont.

Time Series Plot Run Chart

Cont.
Y
Disc.
Disc. X Cont.

Scatter Plot Matrix Plot 9

 DMA I C

Analyze Phase Tools : Minitab

Dot Plot Time Series Plot
Histogram Run Chart
Box Plot Scatter Plot
Continuous Multi-Vari Chart 1-Sample t-Test Matrix Plot
2-Sample t-Test
ANOVA Simple Linear Regression
Test for Equal Variances Multiple Regression
General Linear Model (GLM)- ADV Tools General Linear Model (GLM)-ADV Tools
Y Pareto Chart Time Series Plot
Run Chart

Discrete

Chi-Square Test
Binary Logistic Regression Binary Logistic Regression-ADV Tools

Discrete Continuous
X
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 DMA I C

Analyze - Generate Potential Xs

Process Analysis

Detailed Subprocess Maps 11

 DMA I C

Analyze - Narrow the List of Xs

We need to separate
the “vital few” from the
“trivial many”.

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 DMA I C

Analyze - Narrow the List of Xs

How do we narrow the list of Xs?

Using team member’s Process Knowledge, the

team selects and ranks those Xs they believe
have the highest degree of impact on the output
(Project Y).

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 DMA I C

List of Vital Few X's

Preliminary Ranking of X's
• Control/Impact Analysis
• Relationship Matrix
• FMEA

Narrow to Root Causes

• Hypothesis Testing
• ANOVA
• T-test
• Chi-square
• Regression Analysis

Validated List of Root Causes 14


Control And Impact Analysis
• Estimate impact
– High
– Medium
– Low
• Can it be controlled?
– Can we “adjust” the X in
order to affect the output
of the Project Y?
DMA I C
A High impact means
large changes in X will
yield a large change in Y.
Things that are beyond
our control include
naturally occurring
events and inputs that
are not easily adjusted.
(e.g. Skill or Experience
of Staff)
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 DMA I C
Analyze Phase
2. Narrow the List of Xs. Control & Impact Matrix
IMPACT
High Medium Low
Mode of operation Boiler Feed Water Temp. Line insulation
 Running 1 HP Boiler at a time  FEM heat recovery system must be Flow meter calibration
C  Improve Concentrator running rate online Fouling of boiler tubes
 Improve HP pressure controller Plant Operating Instruction
O  Improve steam demand/supply to avoid  Standardize way of operating
Relieve valve blow
 normally happen during low
N In Our
sudden demand
 Blowdown parameters demand of steam
O2 Analyser Calibration
Control Boiler Feed Water Quality
 Boiler training

T  Anion Cation pH & Conductivity control

Steam leakages
 Through steam trap
R  Demin Stock tank pH & Conductivity
 Boiler feed tank pH & Conductivity
 Through leaking lines

O  Chemical dosing control

Air/Gas ratio used

L 

Consistent control used
Excess air control
Blowdown Frequency

Out Of Air temperature fed to boiler Ambient temperature and

weather
Our Control
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 DMA I C
Failure Mode & Effects Analysis - FMEA
A process for systematically identifying potential problems before they occur.
FMEA is used to:
• Identify What Can Fail
• Identify How It Can Fail
• Estimate Risk of Failure
• Determine Effect of Failure
• Evaluate Control Plans
• Prioritize Actions

FMEA can be used for:

• Complex Processes
• New Products
• Safety, Environmental and Financial Concerns
• Customer Requirement Planning

FMEA is a simple, but powerful tool 17

 DMA I C

FMEA can be used any time, for processes or

products, to answer the question,
“What can go wrong, how and why?”
• In the Measure phase to identify CTQs and Ys
DMAIC

• In the Analyze phase to link causes to the effects, thereby

identifying potential X's
• In the Improve phase to determine the appropriate improvement
actions to be taken
• In the Control phase to help develop and document long-range
process control plans

FMEA can be used in all worlds…Engineering,

Manufacturing, and Transactional!
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 DMA I C
FMEA Basic Definitions
Failure Mode:
• The manner in which a specific part/process fails
• If not detected and either corrected or removed, will cause one of the
“effects” to occur (can sometimes be identical to effect)
• Can be associated with a defect - an event that goes outside of specification.
How could this process fail to complete its intended function?

Cause:
• A condition that produces a Failure Mode or a process deficiency that results
in a Failure Mode

Failure Effect:
• Impact on customer requirements if failure mode is not prevented or
detected (often cost, schedule, and/or performance related). Effect is the
result of the Failure Mode occurring?
• Effect should be expressed in terms of the product/process function
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 DMA I C
More FMEA Definitions

Current Controls:
• The mechanisms that prevent or detect the Failure Mode before it
reaches your customer. Current Controls include SPC, Inspections,
Monitoring, Training, Preventive Maintenance
Recommended Actions:
• Corrective actions to reduce severity, occurrence and/or detection
rankings. Directed at the highest RISK and critical severity items

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 DMA I C
Examples
Failure modes Causes Effects
Lost paperwork No standard process Unsatisfied Customers

Computer interface Mismatch between User unable to access

not accurate systems information

Tool Broken Excessive feed Damaged part

rate

Late Shipment Product re-worked Unsatisfied Customers

Broken Container Incorrect Packaging Missing or Damaged

Products

Whether an event is a Failure Mode, Cause or an

Effect is determined by where you are in the process. 21
 DMA I C
Ratings to Risk Factors
1 Scoring 10
• Severity (SEV): How significant is the Least Most
impact of the Effect to the customer
Significant Significant
(internal or external)?

• Occurrence (OCC): How likely is the

Cause of the Failure Mode to occur? Not Likely Likely to
• Detection (DET): How likely are the to Occur Occur
current controls to detect the Cause or
Failure Mode if it occurs before the risk
is passed to the customer? Likely to Not Likely
Detect to Detect

FMEA includes detection in the risk equation

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 DMA I C
Quantifying Overall Risk
Risk Priority Number (RPN)
• A numerical calculation of the relative risk of a particular
Failure Mode
• RPN = Severity x Occurrence x Detection
SEV x OCC x DET
• This number is then used to place priority on which items
need additional quality planning or to have an abatement
plan developed
The RPN provides an action point for our FMEA

When RPN> 120 some abatement action should be

taken to reduce the level of risk. 23
 DMA I C

Analyze - Validate the Vital Few Xs

What is Hypothesis Testing?

Hypothesis Testing helps determine whether

observed differences or changes are statistically
different or simply due to random variation
(chance).

When performing this test, we begin by assuming

that there is no difference and then let the analysis
“prove” with some level of confidence (usually 95%)
that there is a difference.
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Minitab DMA I C

De-Watering Steam Matrix Plot

= Shows some
effect.

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 Minitab DMA I C

Regression Analysis: Dewatering Steam

The regression equation is
Dewatering Steam = - 63.7 + 0.0241 Total Effect Reflux + 0.209 Water to Reactor
- 0.497 EO Charge + 0.922 EO Feed Concentration
- 0.165 G-5 3rd Eff Pressure + 0.947 G-6 4th Eff % GLYCOL
Predictor Coef SE Coef T P
Constant -63.704 9.116 -6.99 0.000
Total Ef 0.024126 0.001690 14.28 0.000 Major X’s:
Water to 0.209430 0.006560 31.92 0.000 • Total Effect Reflux
EO Charg -0.49737 0.03772 -13.19 0.000
EO Feed 0.92226 0.07833 11.77 0.000 • Water To Reactor
G-5 3rd -0.16518 0.02437 -6.78 0.000
G-6 4th 0.94707 0.09661 9.80 0.000
• G-5 3rd Eff Press
• G-6 4th Eff Btms Glycol%
S = 6.096 R-Sq = 92.2% R-Sq(adj) = 92.1%

Analysis of Variance
Source DF SS MS F P
Regression 6 132255 22042 593.14 0.000
Residual Error 300 11149 37
Total 306 143403

Source DF Seq SS %SS

Total Effect Reflux 1 10500 7.3%
Water to Reactor 1 108288 75.5% These Four Have The Largest
EO Charge 1 674 0.5%
EO Feed Concentration 1 1047 0.7%
Effect on De-Watering Steam
G-5 3rd Effect Press 1 8175 5.7%
G-6 4th Eff % Glycol 1 3571 2.5%
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 DMA I C

Analyze Phase Summary

There are 3 key elements, or deliverables, in

the Analyze phase:

1. Prioritized list of all Xs

2. List of Vital Few Xs
3. Updated Charter and Financial Benefits

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 DMA I C
Analyse Phase
Team Member Duty
Input from Team Member at Analyse phase:
1. Process Mapping
- Help in doing detail Process Mapping
2. Gather Potential X’s
- Team brainstorm on potential caused of the
problem
3. Narrow X’s
- Identify X’s within control & impact to the
process
4. Vital few X’s
- Agree on statistical analysis i.e. major factor 28