1. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Multi-State Advanced Manufacturing Consortium US DOL SPONSORED TAACCCT GRANT: TC23767 RELEASE DATE12/7/2015 VERSIONv 001 PAGE1 of 15 PRIMARY DEVELOPER – Janaina Gasparelo, Henry Ford College I NTEGRATED Q UALITY S ESSION 9 P ROFESSOR J ANAINA G ASPARELO H ENRY F ORD C OLLEGE J ANUARY, 2015 US D EPARTMENT OF L ABOR M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM

2. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Statistical Process Control The Nature of Variation SPC as Way to do Business Basic Statistics for Control Chart Standard Deviation Diagram Basic X-bar, R Control Charts AGENDA

3. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Quantitative measures of Quality – On target (accuracy) – average value – Variation (precision) – standard deviation How to reduce Variation? – Variation cannot be inspected, analyzed or control-charted out of processes and products. – Analysis is a post-mortem evaluation. – Relying on inspection, analysis or QC (cherry picking) to control quality is ineffective, inefficient, and expensive. STATISTICAL PROCESS CONTROL (SPC)

4. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Common Causes – “natural”, random variations due to design of hardware and software (including operation procedure) systems. – Stable pattern of variation. Process is in a state of statistical control. – “In control” does not necessary mean good quality, it can also mean consistently bad quality. If an “in control” process is producing bad quality, then the hardware and/or software systems need to be improved. THE NATURE OF VARIATION

5. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Special cause (assignable cause) – Variation that is not due to random variations but specific non-random reason. Results in process that is out of statistical control. – Changes in process variables due to hardware/software problems, operator error. Changes in raw material, etc. When investigating variations, need to know (or find out) what are the causes (input) and what are the effects (outputs). This knowledge leads to what variables to measure and chart. THE NATURE OF VARIATION

6. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License 1.Find out exactly what the customer wants. - product properties needed - price customer is willing to pay - specs that makes sense test items that reflects performance range of acceptable properties/tests - dialogue with customer (outside-in approach) SPC: A WAY TO DO BUSINESS

7. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License 2.Make the product the customer wants it - package size - packaging details tamper proof package bar codes special needs (barrier or humidity, etc.) SPC: A WAY TO DO BUSINESS

8. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License 3.Continue to make and sell the customer this same product time after time. - capacity considerations (grow with customer) - process capability changes with scale change - Inventory control – JIT delivery SPC: A WAY TO DO BUSINESS

9. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License 4.Continuous Improvement - reduce common causes and eliminate special causes variations. - keep abreast of customer requirements - beware of cultural issues SPC: A WAY TO DO BUSINESS

10. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Frequency distribution The Normal Distribution “Bell Curve” - distribution of data according to # of Standard Deviation from Mean Central Limit Theorem – The averages of random subgroups from a non-normal distribution will have normal distributions. BASIC STATISTICS FOR CONTROL CHART

11. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License STANDARD DEVIATION DIAGRAM

12. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC X-BAR, R CONRTROL CHARTS Control chart is simply a modified Normal Frequency Distribution plot (turned 90 degrees). It helps to determine if we had a “special cause variation”. Decide on the information you want: What are we trying to control (not a post-mortem)? What do you need to know to improve process? What are the causes (inputs) and the effects (outputs) in a process? you want to control (improve) the inputs, then the outputs will follow Can you measure the needed input? Integrate into documentation/decision

13. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC X-BAR, R CONRTROL CHARTS 2.Gather Data -Decide on data frequency that corresponds to the processes -Comments on unusual observation -Measurement accuracy and reproducibility -Calibration -Reliability studies (interlab uniformity) -Real time Data -Historical data (Data Mining)

14. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC X-BAR, R CONRTROL CHARTS 3.Choose rational subgroup size -MIL spec (suggesting subgroup size to use) -Subgroup size normally 3-6. Could be as high as 30. -Averages of subgroups tend to form a normal distribution (central limit theorem).

15. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151207_v001_msamc_courseware_quality_ppt920151207_v001_msamc_courseware_quality_ppt9 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Multi-State Advanced Manufacturing Consortium US DOL SPONSORED TAACCCT GRANT: TC23767 RELEASE DATE12/7/2015 VERSIONv 001 PAGE15 of 15 PRIMARY DEVELOPER – Janaina Gasparelo, Henry Ford College SAFETY DISCLAIMER: M-SAMC educational resources are in no way meant to be a substitute for occupational safety and health standards. No guarantee is made to resource thoroughness, statutory or regulatory compliance, and related media may depict situations that are not in compliance with OSHA and other safety requirements. It is the responsibility of educators/employers and their students/employees, or anybody using our resources, to comply fully with all pertinent OSHA, and any other, rules and regulations in any jurisdiction in which they learn/work. M-SAMC will not be liable for any damages or other claims and demands arising out of the use of these educational resources. By using these resources, the user releases the Multi-State Advanced Manufacturing Consortium and participating educational institutions and their respective Boards, individual trustees, employees, contractors, and sub-contractors from any liability for injuries resulting from the use of the educational resources. DOL DISCLAIMER: This product was funded by a grant awarded by the U.S. Department of Labor’s Employment and Training Administration. The product was created by the grantee and does not necessarily reflect the official position of the U.S. Department of Labor. The Department of Labor makes no guarantees, warranties, or assurances of any kind, express or implied, with respect to such information, including any information on linked sites and including, but not limited to, accuracy of the information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership. RELEVANCY REMINDER: M-SAMC resources reflect a shared understanding of grant partners at the time of development. In keeping with our industry and college partner requirements, our products are continuously improved. Updated versions of our work can be found here: http://www.msamc.org/resources.html.http://www.msamc.org/resources.html