Fontanilla

Who said anything about calipers?  I use digital probes when measuring to that level.  The probes are good down to .0002mm.  Below that, you don’t get anything more.  And yes, I measured in a temperature controlled gage lab the first time I tried it.  First time, GRR came out to 147%!  Found an issue with flatness on the locating surface and corre…[Read more]

Paula, see the following link for a starting point.
http://www.mahrfederal.com/index.php?NodeID=8282

Chad darling, how can you say such a thing without any knowledge of the facts?  Opinion only?  That’s a shame.  Opinioneering is a poor substitute for actual data-driven knowledge of your subject matter.
Surely if you’ve built soooo many precisely machined components, you must have had good GR&Rs.  Are you saying that you in fact didn’t have goo…[Read more]

Exactly my point!  .01mm is child’s play for measurement with even a mechanical indicator.  My original post was to say that Paula could use this means to measure and that optical means, etc. weren’t required.  I merely used the tighter tolerance and more precise measurements to state that we can do better than .01mm.
.001mm is also achievable bu…[Read more]

Only if she listens to your (bad) advice.

I know perfectly well the difference between .001mm and .001inches.  All you really smart people who think it can’t be done have never done it.  My GR&R’s come out to around 10-12%.
What do you think the tolerance on most press-fit bearing bores is?  What do you think the tolerance on fuel injector nozzles is?  Power steering pump vanes?  If I ha…[Read more]

Laugh all you want.  We do it.

In fact, I’m at a machine run-off right now and am measuring to .001mm (1 micron).  We routinely hold tolerances in the sub-micron ranges.  Tolerancing gets tighter every year…

That’s funny!  I work in the automotive industry and we routinely measure (accurately and repeatably) down to .001mm using mechanical gages with electronic indicators.  Our gages are good down to .0001mm.  There are a great number of different probe configurations and electronic indicators from Federal Mahr and others.
Don’t waste your time wi…[Read more]

DPMO is rubbish.  Forget it.

Unless your simulation has noise built into it, you need to run it only once per experimental setup.  With no noise, a (computer) simulation will return the same result every run and thus, you will not get the confidence interval you are looking for.

Don’t you need to have the number of instruments to be fixed in the equation as well?  The level of complexity of the repair might also be necessary.  If it’s a routine service or major rebuild, it will impact productivity.  You might show a tech working a week on a single instrument (major rebuild) vs another knocking out a dozen in a couple of…[Read more]

Here’s the link.  It’s VA approved.  It’s an online or campus based university.
http://www.villanovau.com/Home/Content/VU/Military.aspx

Hi – This is not a Six Sigma project, this is a consulting project. I would start by benchmarking against other restaurants. Is everyone having the same problem?I would look at my cost structure, can some fixed costs be converted to variable costs?I would look at which menu items are more profitable. Can less profitable items and services be…[Read more]

The previous postings are spot-on with respect to management involvement and commitment.  You should be hearing “pick me” from the respective plant managers.  Those who are silent can be considered “passive resistors” to change.
You also want to ensure you don’t chose plants whose operations are in disarray.  While this “low-hanging fruit” may be…[Read more]

Give me $1500 and I’ll certify you with an “Industry Standard” lean certification.  It’ll be worth as much as the cert’s you get from the other sources mentioned and will come a whole lot quicker!

Shawn,
With exception of Tolerance Ellipse, ALL of the “Shainin” tools were and are “Six Sigma” first!  Shainin merely re-stated some of them and later, with the help of his sons, put clever packaging on the rest.  For example, the “trees” are nothing more than convergence or fault tree diagrams.  Isoplot is nothing more than a Scatter Plot.  B v…[Read more]

Back to the original question!  When a error isn’t detected, I assume that down the line, somewhere in the process, that error is detected.  If that is correct, you can gain an understand of the accuracy of your error-checker by comparing what that person has found vs what that person has missed.
You’d do well to heed Mr. Butler’s advice and s…[Read more]

It’s a mistake to try to apply correlation in this case.  ANOVA might be somewhat applicable but just barely.  You have ordinal data you’re trying to analyze with “normal” techniques.  The two shouldn’t be mixed in such a way.  If you feel you must put numbers to these, you would be better off using non-parametric analysis.  But the best way to a…[Read more]

I’m sure there are PLENTY of ideas.  In fact, I believe this question was answered within the last week or two.