Six Sigma Foundations Continuous Improvement Training XY Matrix Six Sigma Foundations Continuous Improvement Training SEGWAY: Yesterday we did Brainstorming on Why you would be late for class. Some of you also Voted on which Reason(X) was important and chose your top 3 items. Today we are going to learn a different method that involves scoring of the X’s and their effect on the Y. This is just another way to prioritize items and which X’s have the largest impact on Y. Continuous Improvement - XY Matrix

Key Learning Points Tool to Quantify Opinions Tool for Prioritization Continuous Improvement - XY Matrix

What Do You Want to Know? What do you want to know? What are the inputs (Xs) and outputs (Ys) associated with this project? How do you want to see it? The graphical answer should be displayed via a process map. What type of tool produces this picture? Excel can provide this analysis via a special worksheet. What type of data does this tool require? A list of Xs and Ys is required. Where and how can you get this data? This information should come from the process map. All the Xs and Ys of this project should be identified on the map. Continuous Improvement - XY Matrix

XY Matrix Agenda Why do we need an XY matrix? Who should create an XY matrix? How to create a useful XY matrix? Example - Developing an XY Matrix In-class exercise Continuous Improvement - XY Matrix

Why Do We Need an XY Matrix? An XY matrix should allow everyone involved with a process to agree on outputs critical to the product and/or customer. Through numerical ranking, this matrix will allow your team to assign a level of importance to each output variable. Through association, the matrix will allow a team to numerically assess the effect of each X on each Y. This is the team’s first stab at determining Y = f(X). Finally, this document will lead the way to an area of focus on the process FMEA. Continuous Improvement - XY Matrix

CUSTOMER Input And Verification Is Strongly Suggested. Who Should Create an XY Matrix? The focused team working on a breakthrough project. ANYONE who had or has a role in defining, executing, or changing the process, including: Operators Maintenance technicians Engineers Supervisors Managers Design engineers CUSTOMER Input And Verification Is Strongly Suggested. Continuous Improvement - XY Matrix

How to Create a Useful XY Matrix Step 1: Use available information sources like process maps to aid you in your identification of inputs and outputs. Step 2: List the output variables (Ys) along the top section of the matrix. These are outputs that the team and/or customer deem important. These may be a subset of the list of Ys identified on the process map. Step 3: Rank each output numerically using an arbitrary scale (possibly 1 to 10). The most important output receives the highest number. Enter these rankings in the Output Ranking row of the matrix. Step 4: Identify all potential inputs or causes (Xs) that can impact the various Ys and list these along the left side of the matrix. Step 5: Numerically rate the effect of each X on each Y within the body of the matrix. Step 6: Use the results page to analyze and prioritize where to focus your effort when creating the preliminary FMEA. The XY matrix is a great team brainstorming tool. It can also facilitate future team activities. Continuous Improvement - XY Matrix

Example Step 1: Review the process map. Ys Xs VA Data VA VA Data NVA Op loads bracket #1 & housing into weld fixtureA Raw Bracket 1 Raw Housings Loading S.O.P. (1) Weld Schedules Air Pressure Voltage H20 Circulation Unloading/Transport S.O.P. (2) Raw Bracket 2 Subassembly Loading S.O.P. (3) Tip Dressing Unloading/Transport S.O.P. (4) Gauging/V.I. S.O.P. (5) Subassembly/Critical Dimensions Subassembly/Weld Location Subassembly/Weld Nugget Size Final Assembly/Critical Dimensions Initiates cycle start NVA Machine clamps VA Data Weld (10 welds) Unclamps subassembly Operator removes subassembly NVA Transports to weld fixture B or C Op loads subassembly and bracket #2 into Op loads subassembly and bracket #2 into fixtureB fixtureC Initiates cycle start. Initiates cycle start. NVA NVA Machine clamps VA Machine clamps Weld (20 welds) VA Weld (20 welds) Unclamps final assembly. Unclamps final assembly. Final Assembly/Weld Location Final Assembly/Weld Size Final Assembly/No Weld Flash All Welds Present? Operator removes final assembly Transports to gauge fixture. NVA Data Operator dimensionally gauges NVA Visually inspects final assembly. Continuous Improvement - XY Matrix

Example Step 2: List the important output variables along the top section of the matrix. Y here is a good part… These are the things that classify if the Housing Welding is a good part. Continuous Improvement - XY Matrix

Example Project: Housing Welding Date: 12/20/96 Output Variables Width Dimension Length Nugget Size Flash Free All Welds Present Rank 7 9 8 10 Inputs 1 2 3 4 5 6 11 12 13 14 15 View Results Delete Instructions DEMO Step 3: Rank each output numerically using an arbitrary scale. A scale of 1 to 10 is often used. Setting a scale form 1 to 10=best to give greater dispersion. Continuous Improvement - XY Matrix

Example Step 4: Identify potential causes (failed Xs) that can impact various outputs, and list each one along the left side of the matrix. X’s are All the things that effect the part being good. The Y’s are all the Things that go into making the part being good. Continuous Improvement - XY Matrix

Example Step 5: Numerically rate the effect of each X on each Y within the body of the matrix. Note: This captures what is known so far about the process. How important is the X to the overall effect on Y(10 is very important) Continuous Improvement - XY Matrix

Example Step 6: Use the resulting ranks to analyze and prioritize future team activities. If no FMEA exists, the highest-ranking inputs from the XY matrix should be addressed first. Continuous Improvement - XY Matrix

In-Class Exercise Break into your designated groups. Use an already created process map or the machining example on the following page. Use the six-step methodology explained to create an XY matrix (XYMatrix.xls) for the above process. Don’t forget to use the Xs and Ys identified on your process map as key information. Be prepared to report your results. You have 20 minutes for this exercise. Continuous Improvement - XY Matrix

In-Class Exercise (Alternate Map) VA (Xs) C Rotational Speed C Traverse Speed C Tool Type C Tool Sharpness C Shaft Material Characteristics C Shaft Length C Amount of Material Removed per Cut S Part Cleanliness C Coolant Flow N Operator Procedures N Material Variation N Ambient Temperature S Coolant Age Machining a shaft on a lathe. Cycle Time = 10 mins DPU = 0.056 NVA Re-work: Detailed cutting. Cycle Time = 40 mins DPU = 0.00 NVA Inspection. Cycle Time = 2 mins DPU = 0.00 (X,Y): Shafts needing detailed cutting (under-machined) (Ys) Diameter Taper Surface Finish Continuous Improvement - XY Matrix

Six Sigma Foundations Continuous Improvement Training XY Matrix Six Sigma Foundations Continuous Improvement Training Continuous Improvement - XY Matrix