1. Short Form Tool 13 ITTTM Tool #13 Short Form “Statistical Foundations For Data-based Improvement, Lean, Six Sigma Solutions” Topics 1. Focus and benefits of data 2. Foundational definitions of quality 3. Attributes, defects, defectives 4. Inspection, data gathering systems 5. Tool applications………

2. Short Form Tool 13 ITTTM Focus And Benefits Of Data Monitors process for team problem solving Prevention rather than detection Knowledge based to modify, adjust, correct Disciplined approach, ongoing improvement Uniformity decreases nonconformance Core communication device Fewer samples, inspection costs reduced Provides enhanced measure of capability Enables data based decisions to be made Less scrap, rework and other waste

3. Short Form Tool 13 ITTTM Documentation Tools, Lean Data Tools, Six Sigma Service, Tools Manufacturing, Non- Manufacturing Synchronous Tools, New Product Development Project Team Cultural Change And Continuous Improvement Information Analysis, Communication Systems Applied Research, Project Structure Enhanced Problem Solving, Decision Making Internal, External, E- commerce Relationships Quality Management Systems (QMS) International Standards Organization (ISO) Professional Outcomes, Growth, Knowledge Technological Infrastructure Industrial Technologists’ Toolkit For Technical Management Focus And Benefits Of Data

4. Short Form Tool 13 ITTTM Characteristics And Standards Identification, Evaluation Standard Deviation, SPC Data Collected Documentation, Process Control By Operators Using SOP Brainstorming For Corrective Action Ongoing Improvement In Teams Basic Relationships In Data, SPC, Teams, Documentation, Improvement Focus And Benefits Of Data

5. Short Form Tool 13 ITTTM Tracking, Collecting Data, Short/Long Runs Sampling Conformance To Standards Attribute Data Variable Data In-process Control By Operators Via Forms, SOP’s Capability Studies And Gage R & R SOP’s, Ongoing Process Control Plan (OPCP) Brainstorming For Corrective Action Bar And Pie Charts, Paretos, Graphs Cause/Effect, Failure Mode And Effects Analysis (FMEA) Disciplined Problem Solving Ongoing Improvement Teams Cost Reduction, Enhanced Communication, Competitiveness Expanded Relationships In Data, SPC, Teams, Documentation, Improvement. Characteristics And Standards Identification, Evaluation Standard Deviation, SPC Data Collected Focus And Benefits Of Data

6. Short Form Tool 13 ITTTM Range = 20 - 4 R = 16 Range Foundational Definitions Of Quality 10 46 = 4.6 X = 3, 3, 4, 4, 5, 5, 5, 5, 6, 6 Mean

7. Short Form Tool 13 ITTTM Normal Curve, Standard Deviation 1 s 2 s 3 s -3 s -2 s -1 s 68.26% 95.46% 99.73% Lower Spec Limit Upper Spec Limit Nominal Foundational Definitions Of Quality +/- 1 standard deviation, 68% of population +/- 2 standard deviation, 95% of population +/- 3 standard deviation, 99.7% of population

8. Short Form Tool 13 ITTTM Variation: range; variance; standard deviation Variance is square of standard deviation Broader look, range, behavior around mean Standard deviation is total variation at mean Normal Curve, Standard Deviation 1 s 2 s 3 s -3 s -2 s -1 s 68.26% 95.46% 99.73% Lower Spec Limit Upper Spec Limit Nominal Foundational Definitions Of Quality

9. Short Form Tool 13 ITTTM Example calculation of standard deviation: Data 5, 6, 7, 6, 8 n = 5 X = 6.4 List the Xi List Xi - X List (Xi - X) 2 5 - 1.4 1.96 6 - 0.4 0.16 7 0.6 0.36 6 - 0.4 0.16 8 1.6 2.56 Sum (  ) 5.20 Normal Curve, Standard Deviation Foundational Definitions Of Quality

10. Short Form Tool 13 ITTTM The formula for sample standard deviation is: = ∑ (Xi - X) 2 n -1 Normal Curve, Standard Deviation  = “the sum of” Xi = individual measures X = average n = sample size s,  standard deviation 2 n -1 s,  = ∑(Xi - X) s,  = 5.20 4 s,  = 1.30 s,  = 1.14 s,  Foundational Definitions Of Quality

11. Short Form Tool 13 ITTTM Foundational Definitions Of Quality Central Tendancy Mean or average Mode or most Median or position Inferential Statistics Inferences in data Probabilities Descriptive Statistics Distribution Range, highs to lows Tolerance, acceptance range Defects Non-functional Non-conforming Varies from specification Defect may not spoil product Defect, unacceptable product Judged as unfit for use Defective Multiple defects Unacceptable or acceptable Depends on severity Customer demands

12. Short Form Tool 13 ITTTM Attributes, Defects, Defectives Attributes Defined Not measurable Good or bad Judgement calls May not be gaged Obvious characteristics Go, no-go gages Attribute Examples Appearance Texture, touch Color coordinates General fit Variable Defined Measurable, such as diameter Discreet differences Variation defined precisely Instrumentation Defined, detailed characteristics Objectivity is goal Variable Examples Diameter Length Cloth density Surface finish

13. Short Form Tool 13 ITTTM Shifting Attribute To Variable Data Attributes, Defects, Defectives

14. Short Form Tool 13 ITTTM Characteristics, Charting, Data, Foundations Analyze, Assess Process Compare Characteristics Documentation, Improvement Provide, Pursue Benchmark Data Vendor Certification, Communication Baseline For Adjustments Determine Consistency, Capability Evaluate For Standard Procedures Attributes As Broad Foundational Characteristics’ Relationships. Attributes, Defects, Defectives

15. Short Form Tool 13 ITTTM Quality characteristics are important features Defined by customer Refined by engineering and design groups Variable or attribute data Explained in context of print, notes Characteristics may be ranked by importance Goal is to further define a characteristic Use characteristic as a measure for quality Continuously evaluating characteristics Shift from attribute to variable data over time Attributes Identified, Inspection, Start For Charting Inspection, Data Gathering Systems

16. Short Form Tool 13 ITTTM Freq- uency Of Occur -rence 20 42 % Of Total Occur- rence % General Shape Of Chart Is Constant, But Frequency And % Values Shift To Present Relationships Inherent In Facts Being Shown. Pareto Is Often Done Early In Analyses, Piggy- Backed On Histograms. It Is Used To Show Areas Needing Attention Versus Those We Can Postpone. Thus It Is A Good Decision Tool. 1838 1634 1430 1226 1021 8 17 613 49 25 01 Shade Columns To Show Differences Among Findings Rank Findings From Highest To Lowest And Left To Right High RPM Squea l Noise Level FinishBlemi shes Too Heavy Availa bility % Of Occurrences Is For Each Attribute Relative To Total Of All Occurrences. Chart Can Be Expanded To Show Unlimited Numbers Of Attributes Histograms, Bar, Pie, Pareto Charts, Checklists Inspection, Data Gathering Systems

17. Short Form Tool 13 ITTTM Histograms, Bar, Pie, Pareto Charts, Checklists Work function: Date of Observation TalkingIdle, Not At Work Area WalkingIdle, Work Station Other Non- Productive General Observations Part:Reviewed By:General Inspection Description: Supplier:Gage/Device: Operation:Characteristic: No.DateOperatorRun Quantity Sample Size Number Rejected Number Accepted Corrective Actions 1 2 ……Forms The Base For The Inspection System Inspection, Data Gathering Systems

18. Short Form Tool 13 ITTTM Attributes Identified, Inspection, Start For Charting Inspection, Data Gathering Systems Operation: ExamplePart: ExampleCharacteristic/Attributes: Shape, Color, Buldge, Rip Operator: Example ShapeColorBuldgeRip General Corrective Actions/Other: Location: Example #Sample Size (n) Number Def.(np) Explanations/Reasons For Rejects: 160105131 2607412 3 6222 4 5311 5 9531 6 82222 7 8341 8 11542 960125331 1060743

19. Short Form Tool 13 ITTTM Tool Applications……. Tool 13 applications are: VSPC, introduced, continuously built, not just at start PASPC also introduced, built gradually, evolved Documentation System Design, Communication, DSDC ISOQSAOPP, designed to help set a plan for team GOTA, vacabulary, glossary of terms All follow through, do and post, independently Toolkit applications are a key part of the courseware Located in separate folder of the CD Provides the template for team portfolio Each application s part of team project, portfolio Designed to be done by all, each team member First read long form, then short review, applications Total contribution in application form is compiled Portfolio is gradually evolved around applications

20. Short Form Tool 13 ITTTM Tool Applications……. P-Attribute Statistical Process Control (PASPC) First logical step for SPC, based on attributes Interactive with GSIC, integrated systems Inspect, track attributes as key characteristics Do key statistical analysis, charting around on this Analysis tool for improvement, leads to variable data Partial table below is start for collection, calculation Supplier:Customer:Product or process: Inspection/data gathering description: Operation:Part:Part characteristic being analyzed: Date Time Sample n # def (np) P = np/n Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

21. Short Form Tool 13 ITTTM Tool Applications……. Variable Statistical Process Control (VSPC) Interactive with, base for, most other statistical systems Inspect, track key characteristics, document process Do key statistical analysis, charting around on this Analysis tool for improvement, leads to variable data Partial table starts continuous development in project Part:Operator:Inspection, Data Gathering Description (Attach Pertinent Information): Characteristic:Operation: Date Time Measure Value 1 2 3 4 5 Sum Average Range Calculate Grand Mean or X Double Bar = All Averages Summed/n Calculate UCL = X Double Bar + (A2) (R Bar); Calculate LCL = X Double Bar – (A2) (R Bar) Where A2 =.58 Constant Calculate R Bar = All Ranges Summed/n Calculate UCL R = (D4) (R Bar); And LCL R = (D3) (R Bar) Where D3 = 0 And D4 = 2.11 Constants Configure Graphs To Accommodate Values Calculated, And To Fit Within Work Areas, Illustrating Process Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

22. Short Form Tool 13 ITTTM Tool Applications……. Glossary Of Terms, Applications (GOTA) Continuously added to over entire course, by all Helps enhance vocabulary, get all on same page Terms are in toolkit, various parts, not just this course A sampling of the form (partial) is shown…….. Provide A Definition For Each Term Identified, Explain How Your Team Will Apply The Concepts, Principles To Your Project: Ongoing Process Control Plan: Corrective Action System: QFD: Pareto Analysis: Statistical Process Control: Variable Measurement, Charting: Attribute Measurement, Charting: Capability: Mean, Range: Gage Repeatability & Reproducibility: Normal Curve:

23. Short Form Tool 13 ITTTM Tool Applications……. ISO/QS Audit, Objective Prioritization Plan (ISOQSAOPP) Preliminary plan, setup of assessments, work for team Familiarize with ISO, auditing, all on same page, terms Strategic planning, team level, change and improvement Project 50% done when “problem” nailed down “hot spots” focus, project objectives, gradually PPDPOA Gantt from SDA form or template, for time, sequence Partial form is shown…….. Organization Under Discussion:Current Operation:Location: General Description Of Operations/Production Functions/Systems Being Assessed As An Internal Audit: ISO/QS Element (TS 16949 2002—Others)Technical Function DescriptionAudit Preliminary InformationActions, Recommendations For Change (list each element separately for analysis/audit)(describe technical function being audited)(How does function compare to standard)(explain anticipated necessary actions, changes) Planning Statement Or Issue, Particularly As Associated With The Service Environment:Criticality Level: HML (H = 5; M = 3; L = 1) Fac = Facility issues; Cost = Cost issues; Time = Time issues; Pers = Personnel issues Objectives Prioritized, 5 Being Highest:Criticality HML FacCostTimePers 5, 4, 3, 2, 1 Problem Background:Resources? (Budget/Other Concerns)? Task/Deliverable/Objective:Who Will Do?How Measured?

24. Short Form Tool 13 ITTTM Tool Applications……. Documentation System Design, Communication (DSDC) Initial design, plan for how the team will work Given that all work is about communications……. Documentation is blackboard is critical Must consider initially how this will happen, DSDC DSDC provides opportunity to reflect on, discuss ResearcherCommunication Method, Internal And External Customers: Toolkit/Blackboard Design Element, How Does It Work? How To Improve Professional Relationships, Communication? 1. Identify How The Systems’ Design You Are Advocating Can Assist IN Tieing Together PPDPOA, TPMSS, FACR, TRIRPA And Other Elements Of Team Problem Solving And Improvement: Explain ISO/QS Characteristics And Other Necessary Entities To Be Possessed By Documentation And Communication Systems, Categorically, Particularly Focused On Service Functions: Using The Template At The End Of The Applications Complete A Cause And Effect Diagram Indicating Issues And Opportunities For Systemic Documentation Relationships/Improvements, Particularly Focused On Service Functions: Identify And Explain Why Your Organization Is Well Suited To The Documentation And Communication System Being Developed, Particularly Focused On Service Functions: