PDF Demo - GlobalQualityVillage
Contents
1. x FrajectID POOOO1 Stage Analyse Close Tablet Weight Control Mic No 2 Period 16 17 August 201 1 Characteristic Tablet Weight Grams Normal Probability Plot Cum Probability 1 000000 ti zvalue 0 990099 3 0 977444 t 0 541315 1 0 499725 0 150454 0 022702 0 001346 0 000032 0 966 0 971 0 977 0 922 0 957 0 992 0 997 1 003 1 009 Sorted Data 18 Aug 2011 10 03 SYS COMPANY TEG NDRUN INDIA 0505 Example Project Manufacturing Industry Normal Probability Plot NPP is a very important visual aid for checking the normality of data i e to examine whether the data comes from a population with Normal Distribution If the data follows Normal Distribution the plotted points would form a straight line Frojectio POOOO1 Stage Analyse Tablet Weight Control Mic No 2 Period 16 17 August 2011 Characteristic Tablet Vveight Grams Run Chart 11 13 Sample Number 18 Aug 2011 10 05 XYZ COMPANY TRVANDRUM INDIA 555005 Example Project Manufacturing Industry Run chart is a simple plot of sample averages which gives a visual understanding of patterns and trends in control chart data O Auto Correlation Chart S od 11 Se Frojeci Do POOOO1 Stage Analyse Close Tablet Weight Control Mic No 2 Period 16 17 August 2011 Characteristic Tablet Weight Grams Auto Correlation Chart Rhojkj2. 8 JD o hean Jese 31 8 G G G 3 TIRAR 84 0 0 C qp 0 p D G p 4 jrug 0 A JD 92 i 5 pegen 786 0 0 0 0 E po 8 JgAug20I 87 E 0o po JaMug2U E D 8 18 p sugeoni 1482 0 0 0 0 9 Auge 920 pn 0 0 00 jg eure 54 0 0 2 0 0 D 3 je eA s Je Jep ja RR 37 93 gamgzU BB NS EUER E 31 Aug 2011 765 TELE a save Update Insert Row Above J Delete Row Column Operations Refresh Close 4 Record 1 Please do not edit row numbers Software manages it by itself saj Paj LA rol on ca c c Example Project Service Industry Then he created a new data file by going to the menu item File gt New Data File After that he entered the data collected in August 2011 and saved the file 9 Data Analysis Work Book Pareto Analysis cix sigma Project ID Putin Project Phase Main Title Accounts Data Error Analysis cub Title Period 1 31 August 2011 Data File Mame Prj2_data tts Browse View Datatfile Legend Name Clerical Error Data Unit Nos Legend Row No D W Draw Colourfilled Bars Data Columns From ja To 7 weightage Row Mo Data Rows From l To 25 Appl
3. Fact Based Management Tools Module SPC EPC Six Sigma Version 7 2 for Windows XP and later editions Computer Software for Statistical Process Control SPC Engineering Process Control EPC and Six Sigma Process Improvement In this simple demo our software is presented in the form of a series of screen shots It would give you the feel of how the actual software works and looks like Narrative is on the bottom panel of each slide Concepts and features are explained through two enlightening six sigma projects one from service industry and one from manufacturing industry Please press Enter or Arrow keys on the keyboard to browse the slides at your own pace Process Improvement using SPC EPC Six Sigma Tools What is SPC Statistical Process control SPC is a scientific and inexpensive way to prevent defects It is an effective check against assignable causes of process variation You would require SPC tools for every Six Sigma project When to use EPC Once a process is brought to stable condition using SPC charts Engineering Process Control EPC helps in predicting the process performance and pro active adjustments thereby reducing process variability It adds extra power to your process control schemes Both SPC and EPC are very essential for achieving the PPM parts per million defect levels expected of your Six Sigma initiatives In this context it is very important
4. 695005 Data Server Mick Mame Program Folder I C p T Hr Example Project Manufacturing Industry Then he created a data file and entered the data that was collected with the help of team member Data Analysi 3l L Charts and histogram aix sigma Project ID PUOOO Project Phase Analysis Tithe Tablet eight Control Sub Title M c Na 2 Period 16 1 August 2011 Characteristic Y Tablet vveight Measurement Unit Grams Basic SPC Chart ETC MEN Chart Type Conventional O OOOO ZOB Homogenisation Rule Stop when 25 samples are dropped ES W Draw control charts with colour bands Datalnput Specifications SPCParameters EPCParameters Process Info Data File tabletweighttts Browse View Datafile Data Columns From i Tn Data Rows From To Sample Size Column tor p np and u charts only Nominal salue Column lt for short run chart type only Decimal places required in numeric output 4 lt between 0 and 3 only Option for Control Chart Limits START AMALYSIS HOW Add Mew Record Goto Workbook ID gt 8 Data Analysis Work Book SPC Charts and Histogram a Sigma Project ID POOOJI Project Phase Analysis Tithe Tablet vifeight Control SubTitle Myc Ma 2 Period 16 1 August 2011 Characteristic Y Tablet Weight Measurement Unit Grams Basic SFC Chart xas JE Chart Type Conventional JE Homogenisation Rule Stop when 25 samples are dropped E iv Draw contr
5. Flaminal value Column For short run chart type only Decimal places required in numeric output 4 lt between 0 and 9 only Add New Record Loto Workbook ID gt Delete KIKI Workbook ID 1 Total 2 records Example Project Service Industry Also the project leader wanted to get an estimate of the current levels of Six Sigma Metrics of the data entry process For this he has decided to open a control chart workbook and use the u chart To setup u chart the project leader has gone to the menu item File gt Manage My Workbooks Start Data Analysis gt Control Chart and Histogram and created a workbook record FBMTools SPC EPC Six Sigma Module L Data file read in successfully You may now open the control chart related reports and graphics From the menu bar i 1 Project ID POQOQA Stage Analyse Control Chart C PIR Close i i Accounts Data Error Monitoring Period 1 31 August 2011 Characteristic Clerical Errors Nosi Record u Chart 0 0159 0 0052 0 0005 1 j 5 Ti Jg 11 13 15 Sample Number 05 Sep 2011 13 58 XYZ COMPANY TRIVANDRUM INDIA GE Example Project Service Industry The following control chart u chart was displayed As the sample sizes were varying the chart was drawn with varying control limits not as straight lines Areas within control limits shown in green colour and areas outside limits in red colour 24 Uuery Kepor
6. Sigma Quality Level Yield Engineering Process Control EPC e Supports Integral Proportional Integral and Proportional Integral Derivative PID control models e Draws EPC prediction chart e Performs process adjustment calculations Optional Control Chart Features e Can draw control charts with lines or colour zones e Can also draw charts with user defined limits process monitoring mode e Homogenizes data with user selected cut off General Features e Can import data from Access Excel Text files e Can export data to Access Excel Text files e Supports workgroups amp project management e Includes a detailed user manual in pdf e Includes sample data files for every tool e Provision for FREE paid user training on software operations at our training facility in Kerala e Provision for SPC EPC Six Sigma training in Kerala amp e Consultancy at extra cost OS amp Recommended Minimum Hardware e Operating System Windows XP or later editions e Computer PC Laptop e CPU speed 1 GHz e RAM 1 GB e Hard Disk 2 GB free disk space e Screen Color monitor with 1024 x 768 resolution or higher e Printer Color Inkjet Laser printer Edition wise Comparison This software comes in two forms namely LITE Edition multi user and STANDARD Edition multi user to suit the varying requirements of prospective buyers We highly recommend STANDARD edition for corporate users and LITE
7. 19 20 Sample Number Lamda 0 1500 Gain qij 0 1092 Target 1 0000 Next Point Prediction 1 0005 Control Action Leave Feed Rate X at its present level XxYZCOMPANY TRIZAHDREURM INDIA 625005 Example Project Manufacturing Industry Then hit the START ANALYSIS NOW button and checked the EPC chart Graphics menu 18 Aug 2011 18 04 The thin graph in black colour is the sample mean Ihe thick graph in blue colour is the EWMA predictor for process average The next point prediction predicted value for process average at 8 00 PM was 1 0005 and the advice was to leave the Feed Rate X at its present level i e 2 13 What are you thinking now 2 Never thought that such things could be done in your organisation also As they say It is better late than never IRI STILE L Welcome To Login As tt User t Admin LA 4 d FOM lools SPC 7 EPC Six Sigma Module www GlobalQualityVillage com j Reports Graphics About Build Data Server List Setup Data Source Manage My Project Records Setup Global Options 4dmin only New Data File Setup Font and Colour Scheme Set deis Add Control User Accounts Upgrade an Old FTS Data File Print Data Import Data From Cause and Effect Diagram Export Data To Change Project Leader Pareto Analysis Change My Login Passwor Scatter Plot and Regression Manage My Workbooks Start Data Analysis Revive Admin Exit LICENSEE XYZ COMPANY TRI
8. Average Honogenised Population Sigma Homogenised Statistical Process Control Limits Computed from data har Chart Upper Control Limit UCL Central Line CL Lower Control Limit LCL standard Deviation Chart Upper Control Limit UCL Central Line CL Lower Control Limit LCL stop when 25 samples are dropped 0 JU 01 0098 v Pages M 4 fi b IM 4 Pj 0 0641 2468 Ratio Cr Performance Index Cpk Taguchi s Index Con Pearn s 365 Capability Index Cpkmi Luceno s Mon Mormal Capability Index Cpc Six Sigma Metrics Defects Per Million DPM 2542 1366 Sigma Quality Level 4 1066 Yield 3 99 5455 General Information Project ID POOOOL Project star Analys Tablet Making Stanley John Manager SPC Chart Selected xbar 3 Chart Type Conventional No of Samples Analysed z4 Detection of Runs of Cyclic Patterns A run above o ength 4 sti run below o run above run below of length 3 Mo significant cyclic variations Pages M 14 f K N NOTK K Scatter Plot and Linear Repression Six Sigma Project ID Poood vi Project Phase Analyse E Main Tithe Tablet Weight Control Sub Tithe Mic Mo 2 Period 16 17 August 2011 Data File tablet_weight tts Browse View Datafile Independent arable s Feed Rate Data Column 8 Dependent arable Y Avg Tablet Weight Grams Data Column E Data Rows From am To 24 i Show Regression Line M Show Equation Decim
9. EWA Target MUG 1 00 lw Use homogenised proces FIR Steiner s fJ 0 50 050 Control Limit sidth L in Sigmas J r Data File read in successfully You may now open Ehe control chart related reports and graphics from the menu bar Example Project Manufacturing Industry HHL l FrojectID POOOO Stage Analyse Close Tablet Weight Control T able Mic No 2 Period 16 17 August 2011 Characteristic Tablet Weight Grams Histogram Frequenay 0 9551 0 9695 0 9515 0 9932 1 0049 1 0166 1 0223 1 0400 Tablet Weight Based on un homoagenized data Mean amp SD computed by Frequency Table method LSL 0 9600 TGT lt 1 0000 USL lt 1 0400 N 96 Hean 0 9615 SD 0 0099 18 Aug 2011 10 01 XYz COMPANY TRIVANDRUM INDIA 25005 Example Project Manufacturing Industry Histogram depicting the data distribution Spread viz a viz tolerance band technical specifications CO Frequency Table FrojectID POOOO1 Stage Analyse Close Tablet Weight Control Mic No 2 Period 16 17 August 2011 Characteristic Tablet Weight Grams Frequency Table 3 G 10 ZH 22 20 4 1 2 3 4 5 G T 8 Mean 0 9875 Standard Deviation 0 0098 N 96 18 Aug 2011 10 02 KTZ COMPANY TEGANDRUN INDIA acere Example Project Manufacturing Industry Frequency Table optional add on to Histogram showing data distribution in tabular form
10. Operations Refresh Close Please do not edit row numbers Software manages it by itself LICENSEE XYZ COMPANY TRIVANDRUM INDIA 695005 Data Server Mick Mame Program Folder I Example Project Manufacturing Industry After process re set fresh data were taken from 2 00 PM onwards and entered in the same data file as above SPL Charts and histogram Analysis Tithe Tablet Weight Control Sub Tithe Mic Ma 2 Period From 18 Aug 2011 Characteristic Y Tablet vveight Measurement Unit Grams Basic SPC Chart Chart Type Hama genis sation Rule M Draw control charts with colour bands Data Input I apecifications SPCParameters EPCParameters Frocess Info Data File jtablet_weighttts Browse View Datatfile Data Columns From J Tn From To sample size Column for p np and u charts only Nominal Value Column amp for short run chart type only Decimal places required in numeric output 4 lt between D and 2 only Option for Control Chart Limits START ANALYSIS HOW Add New Record Goto Workbook ID gt Workbook ID 2 Total 2 records Fraject ID POOOO1 Stage Control Tablet VVeight Control Mic No 2 Period From 18 Aug 2011 Characteristic Y Tablet Weight Grams Engineering Process Control Chart Contro Model Integral 1 0043 UB 1 0041 Target 1 0000 LB lt 0 9959 0 9950 1 2 3 1 5 6 7 6 g 10 11 12 13 14 15 16 17 12
11. edition for small businesses and academic users professors teaching SPC Six Sigma executives preparing for oix Sigma Green Belt Black belt examination etc Both editions are economically priced making them very affordable to corporate bodies as well as individuals Particulars Lite Edition Standard Edition Target user segment SMEs Teachers Students Large Companies Max records rows analysis 100 10000 Max No of data columns 50 200 Max No of Users 1 Site License 5 Unlimited Product warranty amp support 3 months 6 months User training in Kerala India For nominal fee FREE for 1 person No of FREE upgrades 2 9 Migration to Standard Edition Allowed Not required Thank you for the patience Please see the CD pricing STANDARD Edition 7 NJ Ns Note One site license of Standard edition allows unlimited number of users at buyer s one site premises This offer includes product support for six 6 months 8 hours of hands on training for one user at our training facility in Kerala India and THREE major upgrades i e version 7 xx to version 10 xx NO site aM E Lite 4 TAA AN 5 users B Y es a d pue Note One site license of Lite edition allows a maximum of five 5 users at b uye rs one premises 1 offer includes arre support for three 3 months and TWO major T i e e Version 7 XX o version 19 99 Lite is mener suitable for academic purposes an
12. k Ehoik 01 0 02443 1 00 02 0 1722 03 0 0815 0 50 04 0 1395 05 0 4282 0 60 06 0 2190 07 0 0178 08 0 1095 xus 09 0 0381 10 0 0208 0 20 11 0 3137 12 0 0284 0 00 13 0 1507 14 0 1824 420 15 0 1408 16 0 0899 440 17 0 1063 18 0 0886 60 19 0 1333 20 0 0716 21 0 0124 baa 22 0 0529 23 0 0440 Lag k XYZ COMPANY TRIVANDRUM INDIA 625005 18 Au a 2011 10 06 Example Project Manufacturing Industry Traditional SPC charts are not effective when the data is highly auto correlated i e when consecutive data points are correlated If the bars on the Auto Correlation Chart are shorter it indicates less amount of auto correlation In case the data is highly auto correlated use Un weighted Batch Mean UBM chart Froject ID POOOO1 Stage Analyse Tablet Weight Control Mic No 2 Period 16 17 August 2011 Characteristic Tablet Weight Grams Xbar Chart 1 0039 UCL 0 9379 CL 0 9715 LEL standard Deviation Chart 0 0223 UCL 0 0099 CL 0 0000 LEL 1 3 5 i 9 11 13 15 1i 19 11 21 Sample Number 18 Aug 2011 10 07 yz COMPANY TRIVANDRUM IN DIA 65005 Example Project Manufacturing Industry Control chart shows that the process is under statistical control That means there is no sporadic assignable cause present The process is stable Normal Curve Prin ProjectID POOOO1 Stage Analyse Close Tablet Weight Control Mic No 2 Period 16 17 August 20
13. to provide a statistical software to your personnel for error free data analysis and charting on regular basis Our FBM Tools SPC EPC Six Sigma module is a Windows based computer program designed specifically for improvement projects by seasoned Engineer Statistician experts alumni of the Indian Statistical Institute Before getting into the details of the software let us look at one example project from service industry and one from manufacturing industry to learn how to put SPC EPC Six Sigma tools to use Please see the software screens and read the narrative at the bottom panel ALLLLLLWULULLLALLAAAEP2 b M Aooooo o oOeoo L L LEOEAAL1A1ABtECEEZEaAXLAN ALLLLLZBAZdEEZEEZTZ ZPECGK amp Six Sigma Project Information Database Project ID POUDU eter unique ID Project Status Reason for Project Emomina crecords VV Project Title Accounts DataQualit lmprovement aaa Froject Objective To reduce errors in accounts dat VV Froject Description Froject Leader Stanley John Job Title Manager View Edit the List of Team Members View Edit the List of Key Input and Output Yarnables Ks and KOW s Tablet Weight Control To reduce weight varnat Rejection due to weight This is for on going SPC stanley Accounts Data Quality To reduce errors in acc Errors in ac records PT stanley Stanley Add New Record save Lp dete Delete Record Retresh Close Hd 4202 LLI Example Project Service
14. 11 Characteristic Tablet Weight Grams Normal Curve 0 9232 0 9421 0 9604 0 9757 0 9970 1 0153 1 0336 1 0519 Based on homogenised data Tablet Weight Grams LSL 0 9600 TGT 1 0000 USL lt 1 0400 Hean 0 9879 SD 20 0107 Cpz1 25 Cpkz 27 Cpm 0 52 Cpkm s 057 Cpe 0 22 DPH 4542 0366 Sigma Quality Level 4 1066 Yield i 99 5458 KTZ COMPANY TRIVANDRUM INDIA 625005 Example Project Manufacturing Industry 18 Aug 2011 10 08 oix Sigma Metrics amp Probability Distribution Normal gives an idea about expected rejections Though none of the data analysed were beyond specifications the small red zone below the lower specification limit LSL indicates possibility of manufacturing out of spec products Also the process is barely capable Cp 1 33 and not centered Cpk 1 General Information Project ID Project Staq Process Analyst asic SPC Chart Selected woe er Specification Limit USL Target Value ITGTI Lower Specification Limit iLSL Basic Statistics From riginal Data Number of Records Analysed Sample Size ini Grand Average Population Sigma Maximum value Hinimum Value Data Above Upper Specification Limit Data Below Lower Specification Limit FooooL Analys Tablet Making Stanley John Manager bar s Conventional 1 0400 1 0000 0 0107 0120 0 2610 Data Homogenisation Homogenisation Rule No of records dropped Result of Homogenization Grand
15. Industry In a certain company there were chronic data entry problems in the Accounts Department As part of its Six Sigma initiatives the company s management has decided to study the data entry errors by collecting the data for one month and analysing it The company has designated its Manager Mr Stanley John as the Project Leader Mr John has created a project record by going to the menu item File gt Manage My Projects A Data Editor C ia G CADocuments and Settings Desktop See v Demo DatetPre datats _ Cal 001 Cal 002 Cal 003 Cal 004 Cal 005 Cal 006 Cal 007 Cal 008 E Total Ma of Records rong Posting Incorrect Figures Cheque Details Missing Forex Conversion Error Spelling Mistakes TOTAL ERRORS rA 6 0 0 2 0 0 E 0 pg d m7 2 QUeAwg U 869 0 0 D Jo 0 0 Dd 2 39 gjW gzW Bi 0 0 Jg JJ 00 DP p 4 jUMewg 0 1307 a 4 62 J p E 5 ugen eno 5 pg 0 pg D 0 A D 4 B6 9 Jj jp OB Aur 2011 83 0 00 0 0g 9 D g2 ae 532 L 0 0g 9g qp jg pragen e E go 8 9 Re pl 0 JU m3 gq2 J 4 20B 40 8 NE E SS E Do gageo E 0
16. Period 12 30 September 2011 Characteristic Clerical Errors Mos Record u Chart 0 0032 0 0007 0 0000 1 2 3 4 5 b f Q 9 10 11 12 13 14 15 16 1i 19 10 20 Sample Number 01 Oct 2011 14 32 XYZ COMPANY TRIVANDRUM INDIA 52505 Example Project Service Industry See the u chart for September 2011 8 Control Chart Data Summary Zoom 100 Control Chart Data Summary Pages MI4 General Information Project ID Project Stage Process Nane analyst Name Basic SPC Chart Selected Chart Type Basic Statistics From Original Data Number of Records Analysed sample Size n Grand Average Maximum Value Minimum value Six Sigma Metrics Defects Per Million DPM Sigma Quality Level Yield amp T bM Example Project Service Industry oee the improved Six Sigma Metrics for September 2011 Prior to Six Sigma initiatives these were Defects per Million DPM 8186 15 oigma Quality Level Yield 96 3 90 99 18 P n z Control Accounts Data Entry Stanley John Defects Unit in Conventional 2 017 Varying sample size 0 0007 0 0025 0 0000 gt 679 2555 d 7050 5 99 9321 Hope that you liked the sample project from service industry Example Project Manufacturing Industry Ol Six Sigma Project Info rmation Database Project ID PODOO lt Enter auniguelD Project Status Reason for Project Rejection due to vvei
17. VANGRUM INDIA 695005 Data Server Nick Mame Program Folder FBM Tools SPC EPC Six Sigma Module www GlobalQualityVill HEG onm Graphics About List of Software Users List of My Projects List of My Workbooks Control Chart Data Summary Control Chart Run Analysis LICENSEE XYZ COMPANY TRIVANDRUM INDIA 695005 bata Server Mick Mame Program Folder T EPC SIK Sigma Module www Globalluality illage com File Reports About Cause and Effect Diagram Pareto Diagram Scatter Plot and Regression Histogram and Frequency Table Normal Probability Plot NPP Run Chart Auto Correlation Chart Control Chart For Variable Data Normal Distribution Engineering Process Control EPC Chart For Attribute Data Poisson Distribution LICENSEE XYZ COMPANY TRIVANDRUM INDIA 695005 Gata Server Nick Mame Program Folder d FBM lools SPC 7 EPC six Sigma Module www D LATIS TTE T File Reports Graphics About FEM Tools SPC EPC Six Sigma module LICENSEE XYZ COMPANY TRIVANGRUM INDIA 695005 Gata Server Nick Mame Program Folder Basic SPC Charts Supported Advanced SPC Charts Supported Other Tools Supported Statistical Analysis and Computations e Summary statistics e Run analysis detection of cyclic variations e Process capability indices Cp Cpk Com Cpkm Cpc for non normal data e Six Sigma metrics Defects Per Million
18. acteristic Y Tablet Weight Measurement Unit Grams Ww Perform Engineering Process Control EPC computations Name of Input Variable ai Feedback Control Model Overall Gain tg Proportional Gain Kp Integral Gain Ki Derivative Gain Kd Process Target TI 1 EPC Smoothing Constant Lamda Find best fit Lamda from pr i Adjustment Boundary salue LI 0 0041 Option for Control Chart Limits ati START ANALYSIS NOW forkbook ID gt Save Jpdate FEM Tools SPC EPC Six Sigma Module www GlobalQualityVillage com Data Editor O File Reports Graphics About A X tablet_weightfts BowNo Coon Cota ooo ot Co sot Raa HDD reve Qoses Tost T H E Cf VAwm Hs Qs 9 Qsy RR HR 2m E Aui SSRs Qs 4 96 E O9 3864 200 B Amen He mz pwe Qss oe DR 207 fe WAwamW T e TTT T TTT T 158 Ee 1 H H O H H e epes O e E E o y LEE ERN RN ERN RN H H RN js Aum Tans Uus F US 1 Uz 1s TE n e hemem BOO dps 95 O7 n y TL Q R pean TRR Nr HIN E pss 213 i hemem Ts m e 087 H Q e hemm peme fpo pe T 2 5 hemem pawo pa 895 lH ss asi ET Ke JO jj E T S O S jes LL A a S H H S Le e e e S H H 1 Eg ees oe GG H 1 oo Le TT Eg e e e e e e 1 S H H H H H H H ha TTT C H H H H H H 1 S H H H H H H 1 a save Update Insert Row Above Delete Row Column
19. aht varistions 00 Project Title TabletWeightContral 00 Fraject Objective Toreduceweightvariations 00 Project Description is for on going SPC implementation on the Tablet Making machine Project Leader John Job Title Manager View Edit the List of Rey Input and Output Variables KY and KO s My Projects 3 Analyse 5 Conia Y Frajectlb Project Title FrajectObjectie ProjectDescription ProjectLeaderUserlD Tablet Weight Control To reduce weight variat Rejection due to weight This t for on going SPO stanley Accounts Data Quality To reduce errors in acci Errore in ac records stanley Add New Record save Update Delete Record Retresh Close Kg Record 1 of 2 LLI Example Project Manufacturing Industry As the first step the project leader has created a project record by going to the menu item File gt Manage My Project Records 24 List of Project leam Members Pra ect IL Poon User lb ratna Select one from list Name Ratna Raj Job Title Lab Technician Existing List of Team Members UserlD Userdame Usertob The LA FOOUOT ratna Ratna Raj Lab Technician Agg Mew pr d B m P i gt uc gH Hg H Ee A Rong AA 295 wr I A E g m g mi 1 N ek E E E SI List of Key Variables Input and Output Project ID poo Mame of variable Feed Rate Type Impact ibi list af KI s and EC pp Feed Fate Key Input variable Critical To Qua
20. al places in output ja N General Motes Hame of Process Name of Analyst START ANALYSIS Add New Record Goto Workbook ID gt Workbook ID 1 Total 1 records O Scatter Diagram and Regression Line FrojectID POOOOT Stage Analyse Tablet VVeight Control Mic No 2 Period 16 17 August 2011 Avd Tablet Weight Y Vs Feed Rate LX Avg Tablet Weight Grams Y scatter Plot 0 9951 0 9934 0 9916 0 9399 0 9881 0 9864 0 9847 0 9829 0 9812 0 9794 0 9777 t 1 9200 1 9360 1 9520 1 9680 1 9840 2 0000 2 0160 2 0320 2 0480 2 0640 2 0800 Feed Rate Kq s X Y 0 7583 0 1082 X R Square 0 9951 N 24 18 Aug 2011 10 17 YZ COMPANY TRIVANDRUM INDIA 625005 Example Project Manufacturing Industry By clicking on the START ANALYSIS NOW button he could se the scatter plot amp regression line As a rule of thumb R square value must be at least 0 70 for the regression line to be considered as meaningful Mr John looked at the R square value It was 0 9951 very close to the perfect value So he decided to use the equation Example Project Manufacturing Industry nd Histogram aix sigma Project IC IP Project Phase Analysis Tithe Tablets Weight Control oub Title Mic No 2 Period 16 1 August 2011 Basic SPC Chart xes E Chart Type Conventional E Homogenisation Rule Iv Draw control charts with colour bands Data Input specifications T Process Into Char
21. and Materials He went to the menu item File gt Manage My Workbooks Start Data Analysis gt Cause and Effect Diagram and created a workbook record O Cause and Effect Diagram ProjectID POOOO Stage Analyse Close Accounts Data Error Analysis Period 1 31 August 2011 Cause and Effect Diagram People 56 85 95 Method 43 15 95 Equipment 0 00 9 Incorrect Figures 10 96 96 Spelling Mistakes 23 28 95 Forex Conversion 8 80 95 EFFECT Accounts Data Wrong Posting 22 50 96 Cheque Details 34 25 Errors Materials 0 00 Vo Measurements 0 00 Vo Resources 0 00 Vo STZ COMPANY TRIVANDRUM IN DIA 625005 05 Sep 2011 16 27 Example Project Service Industry When he clicked on the START ANALYSIS NOW button the software has displayed the Cause amp Effect Diagram SI Data Analysis Work Book SPC Charts and Histogram She sigma Project ID Poo002 9 Project Phase Analysis Tithe Accounts Data Error Monitoring sub Title Period 1 31 August 2011 Characteristic Pr Clerical Errars Measurement Unit Nos Record Basic SPC Chart Defects Unit ul Chart Type Conventional Homogenisation Rule in SS TERS se b Draw control charts with colour bands Data Input SPC Parameters EPC Parameters Data File Prj2 data fte Browse lew Datatile Data Columns From 0 To 7 Data Rows From To sample Size Column Z for p np and u charts only
22. d or small organizations SIRWILL SOFTWARE PRIVATE LIMITED 29 Bhanu Lane TC 5 674 1 Vattiyoorkavu Road Peroorkada Thiruvananthapuram Kerala India 695005 24x Phone 91 9846110273 Email gqv_consultant yahoo com Website eShop https www GlobalQualityVillage com
23. emi Qu QB 8 HS P S sem ma p B p a asn 8S6 B B 8 p L s BWeSeewi E p B B8 f 4h hd le TUE ERE Row save Update Insert Row Above L Delete Row Column Operations Refresh Close 4 Record 1 Please do not edit row numbers Software manages it by itself LICENSEE XYZ COMPANY TRIVANDRUM INDIA 695005 Data Server Mick Mame Program Folder Example Project Service Industry oee the freshly collected data for September 2011 44 Data Analysis Work Book SPC Charts and Histogram Six Sigma Projectio P ULOZ 7 Project Phase Analysis Tithe Accounts Data Error Monitoring sub Tithe Period 12 30 September 2011 Characteristic Y Clerical Errors Measurement Unit Mas Fecord Basic SFC Chart Defects Unittuy B Chart Type Conventional O O O O E Homogenisation Rule M Drew control charts with colour bands Fracess Info speciicatians SPCParameters EPCParameters Data Input Data File Frj data fts Browse View Datafile Data Columns From Data Rows From sample Size Column for p np and u charts only for short run chart type only Njominal value Column Decimal places required in numeric output 4 lt between D and 3 only Option for Control Chart Limits 2 vej Update ok ID 1 Total 2 records Project ID POOOO Stage Control Accounts Data Error Monitoring
24. ing Mistakes Wrong Posting Incorrect Figures Forex Conversion Error GRAND TOTALS 146 00 146 00 100 00 05 Sep 2011 16 08 VE COMPANY TRVANDRUM IN DIS 225005 Example Project Service Industry And when he clicked on the View Table button the Pareto Table was shown as above He has decided to present this Pareto output along with a Cause amp Effect Diagram to the concerned data entry operators for further brainstorming and improvement MI Data Analysis Work Book Cause and Effect Diagram Six Sigma ProjectID P00002 Project Phase Display Name of Tool Cause and Effect Diagram Main Title Accounts Data Error Analysis Sub Title Pernod 1 31 August 2011 Cause s Cause Main Cause 1 People Contribution 75 56 65 Sub Cause Legends Contribution 1 Wrong Posting 22 EB 2 Spelling Mistakes 23 29 3 Incorrect Figures 10 96 d U B U Effect Accounts Data Errors le Report contribution for Main Causes Motes le Report contribution Z for Sub Causes also Decimal places in output 2 lt Otod Process Accounts Data Entry Analyst stanley John START ANALYSIS HOW Add Mew Record Goto Workbook ID gt Save f Update B JE EE SITE sl Kg Workbook ID 1 Total 1 records Example Project Service Industry He has also decided to group the errors under six categories variation of Six M s such as People Method Equipment Resources Measurements
25. lity poo Tablet Weight Key Output Variable Critical To Quality R f d AA ka E EU Pet rin xd ia p L i WE B s ed S MS E FEM Tools SPC EPC Six Sigma Module www GlobalQualityVillage com Data Editor O Fie Reports Graphics About A x CADocuments and Setingsiwsi Desktop SPC v Demo DateMablet weight nz RewNo coom eom foao cot4 CoUs eoe couy feo O e De Time Meg i Wewe Wema WelhHM AweregeWeigN reed atekais ANH 0 Qs sp 958 1s us B5 4 Aui Hs 595 10e 093 03 e i TET 4 H Aw Rmn SCOTS teAugeor Re SSCS j azn aem em HRS HRERL IIT Us e e TTI Ce fean AD Hs i0 TRT RRs E IH Ra Rs edit e eag TDD Des i3 E oa 4 Tara Iann 93 RER i5 Raa ns 098 999 0996 038 e ibus 0 amp Awe i Hs foarte i8 Aum n He 095 06 080 038 OO e Eua Aui Hs HR o e o o oOo Pit aa ns 8 3E 099 HR e prae B maem ans pae 193 95 e s 1g o Ya Taan a HR RRR e E S SL S i m B Row save Update Insert Row Above J Delete Row Column Operations Refresh Close 4 Record 2h Please do not edit row numbers Software manages it by itself LICENSEE XYZ COMPANY TRIVANDRUM INDIA
26. ol charts with colour bands Data Input f SPCParameters EPCParameters Process Info Technical Specifications v USL 104 P UCL M UCL R S MR MS RTT 1 00 EAM TRIS CL R S MR MS LSL E mt M LCL R S MR MS Important Mate When vou apt for user defined control limits this software would draw the control charts using those limits only This ts usually done for real time operator leyvel process monitoring after the pr is brought under statistical control Normally a senior person say the Quality Control In charge computes these limits penodically from old recent data using this software and updates the entres manually The control limits must be revised as frequently as possible Please read the user manual for more information Option for Control Chart Limits ave Update x SPC Charts and Mis DRI s LET Six Sigma FrajectiD POUDIT Project Phase Analysis Title Tablet Weight Control Sub Tithe M c Mo 2 Period 15 17 August 2011 Basic SPC Chart Chart Type ig Characteristic Y Tablet vyveight Measurement Unit Grams Data Input specications I Process Info Chart Type Required Parameters Figures in brackets are the recommended values Moving Average Avg Period wi Z between 2 and 200 only Cu Sum Head Start 2 50 2 50 ieference Value K in Sigmas O 50 0 50 in Sigmas KA l Decision Interval H fin Sigmas 3 00 6 00 Cu Sum or
27. rs on accounting concepts correct posting to enable automatic spell check facility of the accounting software and also to keep dictionary CDs at data entry work stations to re write the integrated management system IMS work instructions in such a way that cheque details would never be lost in the communication process and to continue with the u chart for monitoring the day to day error levels Let s see what was the result of implementing the corrective actions amp FEM Tools SPC EPC Six Sigma Module www GlobalQualityVillage com Data Editor O File Reports Graphics About A x Prje data fts BowNo Celo Cote Co od os TSI Pfs GH eee j90 uU 54 B E Bo A E G ea 108 434 jj je euge B B B E b Jg o jg ART TRER A 0 B3 p JJ Jp I P2428 Aug 2071 45 o 00 B D jo gg g65 0 0 2 qa E 0 0 p P Ep C O jg Aterinprovemaris p S S S Ep e LLLCLCLLCCCRGLCCCC jes eset B Q Aq B LH jo Semi 4 Q qp Q8 p B Ls TSS ms I J CSCC SSCS S y Seni j s o B p 8 d Lp pessem E p qp p S ha Sen ma TTT TTT TTT S 88 ja E NEM NNNM NEM RENE MEME MEE MEME e S T erBepta0r wp H H A Ls geseemn es o js Semi E p 8 p f La Se mo n D n p n jgeseemi me B p 8 S grSe
28. t Control Chart Data Analysis summary sections to be included h Basic Statistics Data Homogenisation I Control Limits Process Capability Indices Ca Cpky w om Sigma Metrics Remarks Optional 8 Control Chart Data Summary e Zoom 1002 Control Chart Data Summary General Information Project ID Project Stage Process Name analyst Name Basic SPC Chart Selected Chart Type Basic Statistics From Original Data Number of Records Analysed sample size n Grand Average Maximum Value Minimum Value Six Sigma Metrics Defects Per Million DPM Sigma Quality Level Yield amp POOOD a Analyse Accounts Data Entry Stanley John Deftects Unit fu Conventional 5 25 Varying Sample Size O 0082 0 0156 0 0000 Bl85 15 08 3 9020 923 1847 Pages M4 PIH Example Project Service Industry Having done the preliminary data analysis it is now time for brainstorming and improvement Example Project Service Industry Brain Storming amp Improvement Looking at the Pareto Analysis Cause amp Effect Diagram and the Control Chart the data entry operators as well as the project leader agreed that the root causes of the problem were 1 People Human errors spelling mistakes and wrong postings and 2 Method Procedural flaws in communicating cheque details It was decided to impart training to all data entry operato
29. y weightage Decimal places in output 2 5 M General Mates Mame of Process Accounts Data Entry Name of Analyst stanley John START ANALYSIS HOW Add New Record Goto Workbook ID gt i Delete Refresh L Ose ta Workbook ID 2 Total 1 records Dri Example Project Service Industry Looking at the data he decided to first carry out a Pareto Analysis For this he went to the menu item File gt Manage My Workbooks Start Data Analysis Pareto Analysis and created a workbook record el Pareto Diagram ProjectiID POOUO Stage Analyse L PHL oe Accounts Data Error Analysis Table Period 1 31 August 2011 Legend Clerical Error Nos Pareto Diagram t Contribution Rank Legend 100 O1 Cheque Details Missing Q Spelling Mistakes a0 Q Wrong Posting 04 Incorrect Figures on UG Forex Conversion Error 70 60 50 40 30 20 10 0 03 UE 05 Rank Total Weighted 146 00 Nos 06 Sep 2011 16 06 XYZCOMPANY TREIZAMDEUM INDIA GGG Example Project Service Industry When he clicked on the START ANALYSIS NOW button the software has displayed the Pareto Diagram s Pareto Table Ed Project ID POOOO Stage Analyse Accounts Data Error Analysis Period 1 31 August 2011 Legend Clerical Error Nos Pareto Analysis Table Legend Total Weightage Wid Total Contribution 5 Cumulative 5 Cheque Details Missing spell
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