Assuming that this is a study for process improvement and not for spying on colleagues, my best answer would be to tell you how I would appproach this myself. I would certaintly not start with dealing with this question only from a statistical point of view. I would start with going to the workplace, just observe the area and the…[Read more]
To me, your problem sounds very similar to: “I should make a widget, and my customer says I should use a hammer at all costs”. 6Sigma is a tool, and you should select the tool that is best suited for the job you need to do. If indeed your solution is already clear, don’t start pretending as if it isn’t (so I disagree with Divda…[Read more]
Lets see if we can go a step further than disguising 6Sigma under a different name. You mention something very interesting, namely that you are in a pharmaceutical company that is quite heavily bound by dictated cGMP’s. This gives some things to think about. In most other industries we are much less limited in our wa…[Read more]
Maybe there are even more shortcomings than the two I mention here, butI can think of at least these ones:
A gage R&R is not about validating just the measurement tool, but validating a complete measurement system which is is more involving. In a good R&R study you should use parts that are within spec, just around spec and out…[Read more]
After giving it some thought, I think your situation is really not a problem but a unique opportunity. What you have on hand is a CEO who wants to implement a quality program, and has a very high identification level with it. Clearly he needs it to be a big succes. His key interest wouldn’t be to create a legacy that becomes a ho…[Read more]
Arend replied to the topic Product Report vs Process Report for Non-normal Data in the forum General 16 years, 10 months ago
I think the solution for how to do a baseline with non-normal data depends entirely on what sort of non-normality you are talking about. Is it a matter of many outliers ‘on top of’ a further normal distribution, or is the distribution essentially non-normal like for instance lognormal or exponential or even bimodal.
It could also de…[Read more]
3 (related) companies in Korea:
All three have a wide scale implementation that is an intergral part of their business.
Dear Eliseo,Both are ‘real’ values, and both can be important:
-the% Manufacturing Process Variation is a measure for the repeatability and reproducability, judged against the variation in the process.
-the% Tolerance Variation is a measure for the repeatability and reproducability, judged against the tolerance (USL-LSL).The first one is…[Read more]
Dear AberF,Actually Paul also discussed that between different process runs, the setters are taken out of the cart and put back in the same column, but not in the same row or depth as before. So only column is a constant, and the setters are changing positions every production run within their own column. Obvioulsy I would have taken it into…[Read more]
Dear Stathem,I would like to bring one (often overlooked) point forward regarding the discussion of process performance versus required gage R&R. This point is that it really depends on the purpose of the measurement:
-when a measurement is used to compare performance against specification limits (tolerance) the R&R performance needs to be judged…[Read more]
Dear Paul,It took a while before I really figured it out, using all the information you gave. Ill discuss in detail what I think the data are really saying.You have made an observation that there is a difference in the contact between setters and kiln car, so you distinguish two groups in the columns:
group A: kiln car columns 1, 3, 4, 6, 8, 9,…[Read more]
I am not sure that I completely understand your process description, the data you have and the question you are asking to these data.
There are 45000 setters in the process, as you mention, distributed evenly over the columns. That means each column has about 2812 setters? Do you have a more precise count of the total number of set…[Read more]
You already got a lot of good replies on your question, but from my own experience I would like to add one more: 6Sigma doesn’t work well if the rest of the ‘world’ doesn’t understand the approach you use. I think that especially management understanding and support for 6Sigma is essential. The last part of a project is usually the hardest to…[Read more]
This project is not taking place in my own working environment, but in an overseas factory in China where I am doing problem solving. There is progress in convincing the management members in question, by being polite and patient but sticking firmly on my standpoint. Also I use the persuasive powers of other managers who share my view…[Read more]
Gabriel,You’re right. That should teach me not to post late-night replies without reading twice ;-). Of course it is Control Limits. The real message, however, is that the fact that the operator is involved in the process doesn’t matter at all for the usability of the controll chart.Thanks for pointing out the blooper; let’s continue discussing…[Read more]
The fact that there is an operator doing the process doesn’t matter for the usability of the control chart. Your controll chart will show how well the result of the process is in control compared to the specs. The operator is an intrinsic part of the process that you are studying.
Obviously, the operator could be one of the fa…[Read more]
Dear Brij,I also have a problem with management buy-in about quick improvements, but interestingly it is just the other way around. I am dealing with a product robustness problem of which the root cause(s) are not yet known. This work takes place in an environment with a very low working discipline. I am trying to get rid of some obvious errors in…[Read more]
Dear Jackey,I guess from your description that there is one type of testing equipment that is used for in-line measuring, and the others are instruments for other purposes like laboratory measurements. Is that correct? In that case, the requirements for these testers probably are different:
-a tester that is used in comparing products against…[Read more]
Your first concern may not be about the ‘true value’, but which measurement is the better measurement. Calibrated equipment does not imply that the measurement result is reliable per se. Calibration is a property of the equipment but not of the measurement. The measurement also involves the operator (if it isn’t autometed), the parts, envi…[Read more]
Please also include:
In South Korea, 6Sigma is really big. Some brands profile themselves as 6Sigma companies even to the end user in retail shops. Apparently it is a widely recognized issue, otherwise it wouldn’t work as marketing strategy.