Documenti di Didattica
Documenti di Professioni
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Customer
satisfaction
Customer satisfaction
Conformance to specifications
Value
Psychological impressions
Employee involvement
Cultural change
Teams
Continuous improvement
Kaizen
A philosophy
Not unique to quality
Problem solving process
Plan
Act Do
Study
Figure 5.2 – Plan-Do-Study-Act Cycle
Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 5–6
Six Sigma
Process average OK; Process variability OK;
too much variation process off target
X X
X X X
XX XX
X X X
X
X
X X
X X
Process
on target with
Reduce low variability Center
spread process
XX
X
X
X XX
X
Figure 5.3 – Six-Sigma Approach Focuses on Reducing Spread and Centering the Process
Define
Measure
Analyze
Improve
Control
Supplier
Manufactures
Yes Accept No fan blades
motors? Blade inspection TARGET: Firm A’s specs
Yes No
Accept
blades?
∑x i
x= i =1
n
ere
∑( x − x) 2
∑ i−
x 2
n
i
σ= i
or σ =
n −1 n −1
where
Mean
Distribution of
sample means
Process
distribution
25 Time
Figure 5.6 – Relationship Between the Distribution of Sample
Means and the Process Distribution
Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 5 – 14
Causes of Variation
Common causes
Random, unavoidable sources of variation
Location
Spread
Shape
Assignable causes
Can be identified and eliminated
Change in the mean, spread, or shape
Used after a process is in statistical control
Time
(a) Location
Time
(b) Spread
Time
(c) Shape
UCL
Nominal
LCL
Assignable
causes likely
1 2 3
Samples
UCL
Variations
Nominal
LCL
Sample number
UCL
Variations
Nominal
LCL
Sample number
UCL
Variations
Nominal
LCL
Sample number
UCL
Variations
Nominal
LCL
Sample number
where
R = average of several past R values and
the central line of the control chart
D3, D4 = constants that provide three
standard deviation (three-sigma) limits for the
given sample size
Size of Factor for UCL and LCL Factor for LCL for Factor for UCL for R-
Sample (n) for x-Chart (A2) R-Chart (D3) Chart (D4)
2 1.880 0 3.267
3 1.023 0 2.575
4 0.729 0 2.282
5 0.577 0 2.115
6 0.483 0 2.004
7 0.419 0.076 1.924
8 0.373 0.136 1.864
9 0.337 0.184 1.816
10 0.308 0.223 1.777
where
x = central line of the chart, which can
be either the average of past sample means or
a target value set for the process
A2 = constant to provide three-sigma
limits for the sample mean
1. Collect data
2. Compute the range
3. Use Table 5.1 to determine R-chart
control limits
4. Plot the sample ranges. If all are in
control, proceed to step 5. Otherwise,
find the assignable causes, correct them,
and return to step 1.
5. Calculate x for each sample
SOLUTION
Step 1: For simplicity, we use only 5 samples. In practice,
more than 20 samples would be desirable. The data
are shown in the following table.
Figure 5.10 – Range Chart from the OM Explorer x and R-Chart Solver for the
Metal Screw, Showing That the Process Variability Is in Control
Step 5: Compute the mean for each sample. For example, the
mean for sample 1 is
Figure 5.11 – The x-Chart from the OM Explorer x and R-Chart Solver for the
Metal Screw, Showing That Sample 5 is out of Control
where
σx = σ/ n
σ = standard deviation of the process distribution
n = sample size
x = central line of the chart
z = normal deviate number
x = 5 minutes
σ = 1.5 minutes
n = 6 customers
z = 1.96
The range chart is out of control since sample 1 falls outside the
UCL and sample 6 falls outside the LCL. This makes the x
calculation moot.
Tube Number
Sample 1 2 3 4 5 6 7 8 Avg Range
1 7.98 8.34 8.02 7.94 8.44 7.68 7.81 8.11 8.040 0.76
2 8.23 8.12 7.98 8.41 8.31 8.18 7.99 8.06 8.160 0.43
3 7.89 7.77 7.91 8.04 8.00 7.89 7.93 8.09 7.940 0.32
4 8.24 8.18 7.83 8.05 7.90 8.16 7.97 8.07 8.050 0.41
5 7.87 8.13 7.92 7.99 8.10 7.81 8.14 7.88 7.980 0.33
Avgs 8.034 0.45
σp = p( 1− p ) / n
p = the center line on the chart
and
UCLp = p + zσp and LCLp = p – zσp
EXAMPLE 5.3
Hometown Bank is concerned about the number of wrong
customer account numbers recorded
Each week a random sample of 2,500 deposits is taken and
the number of incorrect account numbers is recorded
The results for the past 12 weeks are shown in the following
table
Is the booking process out of statistical control?
Use three-sigma control limits, which will provide a Type I
error of 0.26 percent.
.0091 X
UCL
X X
X
.0049 X X
X Mean
X
X
.0007
X X
X LCL
| | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12
Sample
Figure 5.12 – The p-Chart from POM for Windows for Wrong Account Numbers,
Showing That Sample 7 is Out of Control
EXAMPLE 5.4
The Woodland Paper Company produces paper for the
newspaper industry. As a final step in the process, the paper
passes through a machine that measures various product
quality characteristics. When the paper production process is
in control, it averages 20 defects per roll.
a. Set up a control chart for the number of defects per roll.
For this example, use two-sigma control limits.
b. Five rolls had the following number of defects: 16, 21, 17,
22, and 24, respectively. The sixth roll, using pulp from a
different supplier, had 5 defects. Is the paper production
process in control?
SOLUTION
a. The average number of defects per roll is 20. Therefore
Figure 5.13 – The c-Chart from POM for Windows for Defects per Roll of Paper
b. Because the first five rolls had defects that fell within the
control limits, the process is still in control. Five defects,
however, is less than the LCL, and therefore, the process is
technically “out of control.” The control chart indicates that
something good has happened.
6 + 5 + 0 + 4 + 6 + 4 + 1+ 6 + 5 + 0 + 9 + 2
c= =4
12
σc = 4 =2
UCL c = c + zσ c = 4 + 2( 2 ) = 8
LCL c = c − zσ c = 4 − 2( 2 ) = 0
Nominal
value
Process distribution
Lower Upper
specification specification
Minutes
20 25 30
Nominal
value
Process distribution
Lower Upper
specification specification
Minutes
20 25 30
Six sigma
Four sigma
Two sigma
Lower Upper
specification specification
Mean
where
σ = standard deviation of the process distribution
EXAMPLE 5.5
The intensive care unit lab process has an average
turnaround time of 26.2 minutes and a standard deviation of
1.35 minutes
The nominal value for this service is 25 minutes with an
upper specification limit of 30 minutes and a lower
specification limit of 20 minutes
The administrator of the lab wants to have four-sigma
performance for her lab
Is the lab process capable of this level of performance?
30.0 – 20.0
Cp = = 1.23
6(1.35)
30.0 – 20.0
Cp = = 1.39
6(1.20)
Recall that a capability index value of 1.0 implies that the firm
is producing three-sigma quality (0.26% defects) and that the
process is consistently producing outputs within
specifications even though some defects are generated. The
value of 0.948 is far below the target of 1.33. Therefore, we
can conclude that the process is not capable. Furthermore,
we do not know if the problem is centering or variability.
Recall that if the Cpk is greater than the critical value (1.33 for
four-sigma quality) we can conclude that the process is
capable. Since the Cpk is less than the critical value, either the
process average is close to one of the tolerance limits and is
generating defective output, or the process variability is too
large. The value of Cp is less than the target for four-sigma
quality. Therefore we conclude that the process variability must
be addressed first, and then the process should be retested.
Loss (dollars)
Sample x R
1 601 24
2 602 10
3 582 22
4 602 32
5 604 24
Total 2,991 112
Average x = 598.2 R = 22.4
1 7 16 8
2 5 17 12
3 19 18 4
4 10 19 6
5 11 20 11
6 8 21 17
7 12 22 12
8 9 23 6
9 6 24 7
10 13 25 13
11 18 26 10
12 5 27 14
13 16 28 6
14 4 29 11
15 11 30 9
Total 300
Tues 17
Wed 15
Thurs 22
Fri 21
SOLUTION
a. From the table, the supervisor knows that the total
number of defective records is 300 out of a total sample of
7,500 [or 30(250)]. Therefore, the central line of the chart is
300
p= = 0.04
7,500
p( 1− p ) 0.04(0.96)
UCL p = p + z = 0.04 + 3 = 0.077
n 250
p ( 1 − p ) = 0.04 − 3 0.04(0.96) = 0.003
LCL p = p − z
n 250
Tues 17 0.068
Wed 15 0.060
Thurs 22 0.088
Fri 21 0.084
UCLc = c + z c = 3 + 3 3 = 8.20
LCLc = c – z c = 3 – 3 3 = –2.196
SOLUTION
a. For the process standard deviation of 25 calories, the
standard deviation of the sample mean is
σ 25
σx = = = 10.2 calories
n 6