1. The Scientific Method and Quality Improvement OCMA 2006 tom.sutton@mohawkcollege.ca

2. Continuous Improvement

3. Ideas

4. Seven Statistical Tools Check sheet Pareto chart Cause and effect diagram Histogram Scatter plot Stratification Graphs (control charts)

5. Problem 75 defective springs in a week’s production Check sheet with defect type Display on a Pareto chart Identify the important problem Focus on the “vital few” not the “trivial many”

6. Pareto Chart

8. Histogram of Crack Size

11. Ideas DESIGN

12. Experiment for three factors Steel TempCarbonOil Temp Low HighLow HighLow High Low High LowHigh LowHigh

13. Ideas DESIGN RUN

14. Ideas DESIGN RUN ANALYZE

16. Ideas DESIGN RUN ANALYZE

17. Ideas DESIGN RUN ANALYZE More Ideas KNOWLEDGE

18. What is Six Sigma?

19. Process Capability

20. 99% Quality Level 20,000 lost mail articles per hour Unsafe drinking water 15 minutes /day 5000 incorrect surgical operations per week 2 short or long landings at major airports/day 200,000 wrong drug prescriptions per year No electricity for 7 hours per month

22. Six Sigma Capability

23. Six Sigma D efine M easure A nalyze I mprove C ontrol

24. Six Sigma Black Belt D efine Project scope Metrics Problem statement

25. Six Sigma Black Belt M easure Process analysis Probability and statistics Collecting and summarizing data Properties and applications of prob. Distributions Measurement systems Analyzing process capability

26. Six Sigma Black Belt A nalyze Exploratory data analysis A. Sources of variation B. Regression, analyze residuals Hypothesis testing A. Interval estimates B. Tests for means, variances and proportions C. Paired comparisons D. ANOVA E. Contingency tables

27. Six Sigma Black Belt I mprove Design of experiments A. Design principles B. One factor experiments C. Full factorial experiments D. Fractional factorial experiments E. Robustness concepts F. Mixture experiments Response surface methodology A. Steepest ascent B. Higher order experiments Evolutionary Operation (EVOP)

28. Six Sigma Black Belt C ontrol Statistical Process Control A. Application of control charts B. Analysis of control charts Advanced SPC A. Short run SPC B. EWMA, CUSUM Lean tools for control Measurement system analysis Design for Six Sigma A. Quality Function Deployment B. Robust design C. Failure mode and effects analysis

29. Six Sigma Black Belt I mprove Design of experiments A. Design principles B. One factor experiments C. Full factorial experiments D. Fractional factorial experiments E. Robustness concepts F. Mixture experiments Response surface methodology A. Steepest ascent B. Higher order experiments Evolutionary Operation (EVOP)

30. Design of Experiments

31. Popcorn Experiment BrandTimePowerTasteBullets Low 7432 HighLow 7535 LowHighLow7116 High Low8013 Low High817 HighLowHigh778 LowHigh 426 High 323

32. Analysis

34. The Helicopter Experiment Design an experiment to study the factors that may affect flight time. Measure distance from target as well

35. Helicopter Factors Factor-+ Paper typeRegularBond Wing length3.00”4.75” Body length3.00”4.75” Body width2.00”1.25” Paper clipNoYes

36. References Paper by George Box www.statease.com www.minitab.com www.asq.org www.isixsigma.com