PB

James,Certification is ISO predominantly indicates that they have procedures in place to address the various elements of the ISO Standard. I am not sure how the ISO auditor looks at their CAPA process in that whether they have closeout process for open CARs and whether there are CARs open on the book for a specific length of time.As a customer…[Read more]

Hi Andy U.,Thanks for the response. The original poster needs to be given some feedback based on what you have said and I need your take on that (my response in capitol below):
I have question about establish first phase QFD.First we collect customer requirements,then we give design requirements – THAT WOULD BE CORRECT.The question is when give…[Read more]

Andy U,Yes I am still doing the Taguchi methods and I am fine as well.Regarding QFD, when a totally new concept is thought of for introduction into a market place (iPOD for example), I wonder how these concepts can be carried in to a QFD approach? I could see a lot of ‘focus groups’ to provide feedback but eventually you (the company) would decide…[Read more]

Keep in mind that if you are modifying / improving current product you may already have some design parameters in place and VOC may affect manufacturing process as opposed to never having made that product and you are working with a brand new slate and brand new manufacturing process.Scoring the QFD will be vital and be sure to have many internal…[Read more]

There has been a LOT discussed on 1.5 shift. You should have done a search before posting question.PB

Hello,When you say “applique” do you mean component or something applied onto a molded component? If it is a molded compoent – how did you derive on the 3 factors? What about mold cooling, injection pressure, back pressure, etc?What I typically do is to do a Taguchi DOE with most of the relevant molding factors and with limited experimentation…[Read more]

Bill,I agree with Shooter. However, as the question you have asked is regarding optimization of the inspection (which I take it are attribute type inspections), I would do the following:- Identify areas of inspection on a print and provide training to operators so that they are aware of what to look for in that area of the product. Even having…[Read more]

Steve,
I have not posted in this forum for a while but this article was an awesome read.
‘Please tell us about your problems so we can all work on that together’. What power this statement has!
Keep up this kind of good work.
PB

Gabriel, welcome back.
Beginner,
You are really caught between the rock and hard place. There are times when you have a generic product (McDonald hamburger, or a ballpen, etc.) the customer may not bother to complain if the product did not meet specification or can get immediate resolution of their complaints. (Even they may have customers who…[Read more]

Andy,
Good to be in touch again. Last time I got into Taguchi (from exchange with you) DOE and have started using the Taguchi DOE in the Minitab*. As I am currently having a lot of DOE experimentation for multi-cavity molds, the dynamic DOE idea sounds interesting.
Can you please highlight how I could incorporate this in a multi-cavity mold…[Read more]

Andy,
Interesting information.
PB

Wish you and everyone at isixsigma the same as well. You have not missed much on the isixsigma.
PB

Stan is absolutely correct. Use the Taguchi DOE in your Minitab* 14 and use Hi/Low on your 11 factors. You can chose # of runs (please pay particular heed to Stan’s recommendation to use the first variable as the one which is hardest to change, second variable will be next hardest to change, etc.)
Once you are done, you can analyze using…[Read more]

Stan,
You are absolutely correct on this.
PB

Billybob,
I would like to know what that ‘Work Function’ guy ‘V’ has to say about this. I would love to see his charts and graphs.
PB

MR,
Please make sure (as Great Girth points out that it is a Lean project [actually a VSM project]) that the packaging process is documented and efficiencies, kanbans, cycle times, value added and non-value added activities, etc. are all dcoumented. Once the VSM process is mapped out, you can do current and future state maps and document improv…[Read more]

Yanet,
What is your population size? What is your AQL level? What is the acceptable ‘alpha’ and ‘beta’ risks? What are your accept/reject levels?
With that info, you can look up the ANSI tables for sample size.
PB

Maharajan,
What does a window manufacturing process look like? Where is the start and where is the end? How many stations do the same work? Do these stations feed station only in front of it or do these feed any station in front?
Do you work by a set schedule? (50 windows per day) OR Do you have a floating schedule? Do you make custom windows?…[Read more]

SSS,
I am not aware of assessment tools to select GBs. However, I can not understand how it would be ‘discriminatory’? If you do not find your best people, you may lose out from the starting gate. This is like any job where you have specific requirements for the position and the best candidate gets the job.
PB

Mike,
I am not sure whether Pika understands what FMEA means. Before he can do anything, he needs to get a good (solid) understanding of what this tool is all about. Once he has that, he will understand that this tool requires a thorough Process Map, maybe even a completed Cause & Effect sheets, before he can begin the FMEA chart. He needs to…[Read more]