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Fred Spiring The University of Manitoba & Pollard Banknote Ltd. Some Applications of Process Capability: Within a Six Sigma Philosophy
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Overview Background Assessing Process Capability Monitoring the Process Customer Satisfaction Short Run/Low Volume processes Research Ideas
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Background Producing Lottery Tickets Multistage process, involving up to five printing presses Multiplant organization, similar process with different equipment Requirements and regulations result in interplant production
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Background Customer Spec Production Spec
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Background
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Trim Edge red-to-base across red-to-base along Stock Edge Crosshairs gray-to-base across gray-to-base along and L marks
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Background Initial Study Red Station-across X bar = 0.1004 S = 0.00364 n = 66 T = 0.1000
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Background Based on the initial study results, the various internal stakeholders created production specifications The production specifications now reflect the ability of the process
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Background = Cpm = Parameter Estimator 1.001
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Assessing Process Capability Process Capability is dynamic “One-shot” assessments of capability can be misleading Estimates of the PCIs are stochastic Graphic assessments are critical
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Assessing Process Capability Process Capability assessment performed on a quarterly basis (20 quarters-(1997-2001)) Process Capability chart is used to monitor
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Assessing Process Capability Mar-97Apr-98Mar-99Mar-00Mar-01 0.1010.1010.0960.0960.095 0.1050.0980.1040.0970.096 0.0990.0950.0960.0990.100 0.0980.0990.0980.0980.097 0.0970.1030.0970.0970.097 Jun-97Jun-98May-99Jul-00Jun-01 0.1030.1000.1040.1010.096 0.0960.1030.1030.1040.104 0.0960.0990.0990.0970.096 0.1020.0950.1050.0960.103 0.0970.0960.1020.0980.103 Sep-97Sep-98Sep-99Sep-00Sep-01 0.1000.1010.1040.1010.099 0.1040.0970.0990.0980.101 0.0960.0990.0960.1030.099 0.0960.1030.1040.1040.100 0.1000.0950.0960.1050.099 Dec-97Nov-98Dec-99Dec-00Dec-01 0.0980.0970.1050.0970.099 0.0970.0960.1010.0980.099 0.1040.0990.0960.1060.100 0.1020.0980.0980.1000.101 0.0980.0970.0970.1030.101 Red Station Quarterly data
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Assessing Process Capability UCL=0.10364 Average=0.09939 LCL=0.09514 UCL=0.00622 Average=0.00298 LCL=0.00000 X-bar s X-bar & S chart (1997-2001)
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Assessing Process Capability Capability Chart (1997-2001)
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Assessing Process Capability Pr = (1- ) Limits of the form (L 1, U 1 ) can be found Pr = (0.9927)
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Assessing Process Capability
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Monitoring the Process UCL=0.10364 Average=0.09939 LCL=0.09514 UCL=0.00622 Average=0.00298 LCL=0.00000 X-bar s U=4.6285 Average=1.1201 L=0.5021
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Monitoring the Process Process changes adopted & implemented (2001) Capability assessment continued on a quarterly basis (2001-2003) Sample size increased to n=10
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Monitoring the Process
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UCL=0.10364 Average=0.09939 LCL=0.09514 UCL=0.00622 Average=0.00298 LCL=0.00000 X-bar s U=4.6285 Average=1.1201 L=0.5021
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Customer Satisfaction Incorporate the customer requirements directly into the process Already had sign-off on production, but we asked them to quantify the critical characteristic(s) Provided cost/pricing models based on the quality characteristics
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silver-to-base along Customer Satisfaction grey-to-base along purple-to-base along
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Customer Satisfaction On TargetTwo point shift Four point shift
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Customer Satisfaction On Target Two point shift
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Short Run/Low Volume Process
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Pr = (1 - ) LIMITS CENTRE LINE = 1.651
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Short Run/Low Volume Process L t U t 0.67610.391 0.8034.607 0.9603.779 0.8844.612 0.9603.779 0.67610.391 0.8844.612 0.67610.391 0.8335.435 0.67610.391 0.9264.105 0.9603.779 0.8844.612 0.9603.779 0.67610.391 0.9893.535 0.67610.391 0.9603.779 Action Limits by Job
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0 2 4 8 10 12 1234567891011121314151617181920 Job (t) U1tU1t L1tL1t Short Run/Low Volume Process
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Research Ideas Statistical input Decisions and inferences continue to lack statistical assessment Computer package incorporation of stochastic intervals/boundaries Graphics and graphical methods Inferences and monitoring tools Links to costs/losses and benefits
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