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Comparing Processes: Lean Six Sigma Method

This article by Carol Dixon explores the process of comparing different options for improvement using Lean Six Sigma methodology. It discusses criteria evaluation, statistical hypothesis testing, and decision-making processes in manufacturing. An example of comparing semiconductor materials is provided to illustrate the process. The article concludes with considerations on cost-effectiveness.

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Comparing Processes: Lean Six Sigma Method

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  1. Which Process is Better? Carol Dixon, Freeflowe Technical Services Lean Six Sigma, Quality, Continuous Improvement 2/27/2014

  2. Introduction Carol Dixon, ASQ CQE, CSSGB Principal, Freeflowe Technical Servicescarol_dixon@freeflowe.com Phone: 541-602-5076 Lean Six Sigma, Quality, Continuous Improvement Consulting and Blended Training for small manufacturing businesses • Bachelor’s Engineering Physics • Graduate studies in Statistics • Member of ASQ since 2011 • Manufacturing and Quality Engineer in electronics, primarily Hewlett-Packard and medical devices

  3. Overview • Process Improvements in manufacturing frequently involve comparisons • What is a process? – Process Map • Which process is better? • Options • Criteria for evaluation • Comparison criteria for each option and between options • Statistical Hypothesis testing (t-test) • Complete evaluation • Results • Conclusions • Making decision

  4. Process Map New Supplier, material property, actual material change Raw materials Test/ inspect Process step 1 Tooling, Process or metrology, operator change Process step 2 Pass Final Product Process step n Process

  5. EXAMPLE – Which material is better? Two different semiconductor materials are being evaluated within a batch for impact to electrical resistance. (Typical batch size 25 wafers). Each wafer for this example will have 100 die. Specification (Target R) = 1250 Ω, LSL= 1200 Ω, USL1300 Ω • Wafers 1-6 – Old material • Wafers 7-25 – New material After processing all wafers are tested electrically and parameters are compared between the old and new.

  6. Hypothesis testing HO: µ1 = µ2 HA:µ1≠ µ2 HO :µ1= µ2 (α) Courtesy: http://www.cvgs.k12.va.us:81/DIGSTATS/main/inferant/d_tdist.htm

  7. Results • Go to JMP • Test for normality – R_mean • Hypothesis testing for R_mean and Yield • Process capability, CpK

  8. Conclusions • Is the new material better than the old material? Based on comparison criteria Y or N? • What if the new material costs 20% less? • What if the new material costs 20% more?

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