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2.2. Process Variability Problem Solving

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18 views

2.2. Process Variability Problem Solving

Uploaded by

soumilidas91221
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Process Variability & Problem

Solving
Process Quality: Conformance to specifications

• Specification  the bull’s eye


• Is it possible to consistently hit the bull’s eye
in practice?
• There will be variation, even when the
shooter, the gun, and the target remains
the same  the natural variation of the
process
Natural Vs. Systematic Process Variation

• Process goal => conform to specification


=> hit the bull’s eye
• Natural variation: the spread of the points
(closeness to each other)
• Process A and B have less natural variation than
process C and D
• Systematic variation: on an average, how far
are the points from the bull’s eye
• Process B and D have systematic variation
• To achieve the process goal, both the
variations must be controlled
Process improvement and control

• How do we improve a process?


• By reducing the spread/dispersion of the
outcome values
=> by reducing the natural variation of the
process
• How do we control a process?
• By ensuring that systematic variation is
minimized or eliminated
• How do we detect systematic variation?
• There is systematic variation if
a. The process starts deviating away from the centre
b. The spread of the process starts increasing
Sources of systematic variation

MAN MATERIAL MACHINE METHOD MEASUREMENT ENVIRONMENT


• Person-job • Faulty • Faulty • Faulty • Faulty • Temperature
fit • Recent equipment method instrument • Dust,
• Training substitution • Changed followed • Faulty contamination
• Regular • Change in settings • Change in calibration • Humidity
worker Vs. supplier • Faulty method not • Incorrect use
substitute • Change in tooling, jigs, incorporated of instrument
• Health, well- supplier’s fixtures • Faulty
being process controls
Cause and Effect Diagram
Problem Solving and the PDCA Cycle

PLAN DO
• Identify problem • Implement action plan
• Collect and analyse data • Monitor
• Plan corrective action • Train people

ACT CHECK
• Standardize changed • Collect new data
configuration • Analyse data
• Repeat improvement • Verify improvement
cycle
Six-Sigma; DMAIC

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