The Scientific Method and Quality Improvement

1. The Scientific Method and Quality Improvement OCMA 2006 tom.sutton@mohawkcollege.ca

2. Continuous Improvement

3. Ideas

4. Seven Statistical Tools • Check sheet • Pareto chart • Cause and effect diagram • Histogram • Scatter plot • Stratification • Graphs (control charts)

5. Problem • 75 defective springs in a week’s production • Check sheet with defect type • Display on a Pareto chart • Identify the important problem • Focus on the “vital few” not the “trivial many”

6. Pareto Chart

8. Histogram of Crack Size

11. DESIGN Ideas

12. Experiment for three factors

13. RUN DESIGN Ideas

14. RUN DESIGN ANALYZE Ideas

16. RUN DESIGN ANALYZE Ideas

17. RUN DESIGN ANALYZE Ideas More Ideas KNOWLEDGE

18. What is Six Sigma?

19. Process Capability

20. 99% Quality Level • 20,000 lost mail articles per hour • Unsafe drinking water 15 minutes /day • 5000 incorrect surgical operations per week • 2 short or long landings at major airports/day • 200,000 wrong drug prescriptions per year • No electricity for 7 hours per month

22. Six Sigma Capability

23. Six Sigma • Define • Measure • Analyze • Improve • Control

24. Six Sigma Black Belt • Define • Project scope • Metrics • Problem statement

25. Six Sigma Black Belt • Measure • Process analysis • Probability and statistics • Collecting and summarizing data • Properties and applications of prob. Distributions • Measurement systems • Analyzing process capability

26. Six Sigma Black Belt • Analyze • Exploratory data analysis • Sources of variation • Regression, analyze residuals • Hypothesis testing • Interval estimates • Tests for means, variances and proportions • Paired comparisons • ANOVA • Contingency tables

27. Six Sigma Black Belt • Improve • Design of experiments • Design principles • One factor experiments • Full factorial experiments • Fractional factorial experiments • Robustness concepts • Mixture experiments • Response surface methodology • Steepest ascent • Higher order experiments • Evolutionary Operation (EVOP)

28. Six Sigma Black Belt • Control • Statistical Process Control • Application of control charts • Analysis of control charts • Advanced SPC • Short run SPC • EWMA, CUSUM • Lean tools for control • Measurement system analysis • Design for Six Sigma • Quality Function Deployment • Robust design • Failure mode and effects analysis

29. Six Sigma Black Belt • Improve • Design of experiments • Design principles • One factor experiments • Full factorial experiments • Fractional factorial experiments • Robustness concepts • Mixture experiments • Response surface methodology • Steepest ascent • Higher order experiments • Evolutionary Operation (EVOP)

30. Design of Experiments

31. Popcorn Experiment

32. Analysis

34. The Helicopter Experiment • Design an experiment to study the factors that may affect flight time. • Measure distance from target as well

35. Helicopter Factors

36. References • Paper by George Box • www.statease.com • www.minitab.com • www.asq.org • www.isixsigma.com