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DATA GATHERING
• What is Data ?
Data is a numerical expression of an activity.
TYPES OF DATA
CONTINUOUS DISCRETE
Measurable Subjective Assessment
e.g. :Length, Temperature e.g. :Score in a beauty
contest
Countable
e.g. :Number of defects
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WHICH OF THE BELOW ARE CONTINUOUS
AND DISCRETE DATA?
• Width of sheet
• No. of liners thinned
• Tubes rejected by Go- Nogo Gauge
• Diameter of Piston
• Height of a Man
• Sheet thickness
• Out of 100 sheets the numbers that meet the thickness 4 0.9
• Time taken to process a purchase order
• No. of bugs in a program
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XXX
B X
X = Dirt
D = Dent
S = Scratch
B = Bubble
No. inspected: _____
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STRATIFICATION
• The method of grouping data by common points or
characteristics to better understand similarities and
characteristics of data is called stratification.
• Such classification helps in obtaining vital
information by distinguishing and comparing data
in different class or strata.
• It also identifies the key strata to concentrate on.
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STRATIFICATION
• The purpose of stratification is to ascertain the
difference between different categories and to
analyze the reasons behind abnormal distribution.
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STRATIFICATION-AREA OF APPLICATION
• Raw Material
Quantity supplied, Delivery time, Rejection % -
supplier wise and batch wise.
• Production
Rejection percentage with respect to machine,
shift, operator, raw material, tool, jig and so on.
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NO ACTION
Measurement /
Random Sampling Observation
POPULATION Sample Data
ACTION
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ISI, SQC UNIT, BANGALORE SS-MEASURE PHASE
ISI, SQC UNIT, BANGALORE SS-MEASURE PHASE
Frequency plot 50
(Histogram)
Pareto chart 50
Scatter plot 24
Control chart 24
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WHAT IS VARIATION ?
• No two things in nature are alike.
• This is also true for manufactured products.
• This dissimilarity between two products for the
same characteristic is called variation.
• The variation may be or can be made to be so
small so as to make the product SEEM similar.
• When we say that 2 things are similar we actually mean
that it is not possible to measure the variation present
within the accuracy of the existing measuring equipment.
• Variation between 2 products are compared for SIMILAR
features or characteristics.
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TYPES OF VARIATION
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THIS IS BECAUSE....
OF CERTAIN FACTORS WHICH
• Affect the time he takes
• He cannot control
• Vary randomly
e.g. The traffic you encounter under normal course of travel
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Maximum deviation
Inherent
Aimed value Variability
(white noise)
Minimum deviation
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GRAPHICAL DISPLAY OF
VARIABILITIES
CASE I T
O
Assignable (Black noise) Assignable T
Variability Variability A
L
Inherent
Variability Aimed Value V
A
R
I
A
Assignable Assignable B
Variability I
Variability L
I
CASE II CASE III T
Y
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Good
repeatability
2. Repeatability
if variation is
small * The same person taking a
measurement on the same unit gets
the same result.
Data from repeated
measurement of
same item
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Time 1 4. Stability
Observed Measurements taken by a
value
single person in the same
Time 2 way vary little over time.
Observed
value
Good stability
if difference is
Small*
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5. Adequate Resolution
There is enough resolution in the
X measurement device so that the
X product can have many different
X X values.
X X X
X X X X
X X X X X
5.1 5.2 5.3 5.4 5.5
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MINITAB OUTPUT
Gage name:
Date of study:
Gage R&R (ANOVA) for legibility s Reported by:
Tolerance:
Misc:
4 4 Joe
Averag e
X=3.531 Martha
3 3
2 -3.0SL=2.238
2
1 1
0 form 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 3
R=0.6875
2
0 -3.0SL=0.000 1
0 reader Fred Joe Martha
50 3
0 1
Gage R&R Repeat Reprod Part-to-Part form 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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MINITAB OUTPUT
Gage R&R
Source %Contribution %Study Var
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Interpretation of MSA Results
Repeatability error shall be low.
If it is high, then,
a. Instrument is improper
b. Method of measurement is not OK
c. System improvement is required
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40
30
20
10
0
1 2 3 4 5 6 7 8
Number of Days for Approval
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WHAT
WHAT IS
IS THE
THE MEASURE
MEASURE
OF
OF CENTRAL
CENTRAL TENDENCY
TENDENCY OF
OF A
A SET
SET OF
OF
NUMBERS?
NUMBERS?
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MEASURES
MEASURES OF
OF DISPERSION
DISPERSION
The extent of the spread of the values from the
mean value is called Dispersion.
Smooth curve
Center of the bar interconnecting the
center of each bar
Units of
Measure
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NORMAL DISTRIBUTION
• If the frequency distribution of a set of values is
such that :
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Is the process free of special cause variation?
On the
On the shop
shop floor
floorthisthis isis aa control
control chart…
chart…
In reality
In reality itit isis aa process
process behavior
behaviorchart.
chart.
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IX Plot Points
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UCL=5.620
5
Concentration
Mean=4.45
LCL=3.280
3
0 1 2 3 4 5 6 7 8 9 10
Observation Number
PARETO DIAGRAM
• The Pareto Principle is generally used to prioritize
quality improvement projects to get most returns for the
resources invested.
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100
2000
80
Percent
60
Count
1000
40
20
0 0
Defect
Count 1115 430 145 140 120 120 115
Percent 51.0 19.7 6.6 6.4 5.5 5.5 5.3
Cum % 51.0 70.7 77.3 83.8 89.2 94.7 100.0
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PARETO ANALYSIS OF
PASSENGER COMPLAINTS AT AN AIRPORT
97 100
100
140 87
90
120 70
80
100 70
No. of complaints
Cum. percentage
50
60
80 50
60 40
26
40 30
20
20 10
0 0
Flight Baggage Service Refund Fares others
Problems
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160 75 80
140 70
60
No. of complaints
120 60
100 50
80 35 40
60 30
40 20
20 10
0 0
Late Missing or Fading Stains Creased Buttons Stretched
delivery wrong colours Missing or torn
items
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PARETO
PARETO DIAGRAM
DIAGRAM FROM
FROM MINITAB
MINITAB
Open MINITAB Worksheet.
-3s
- 3s +3s
+3
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USL - X
Cpu
3s
This gives us the positioning of the mean vis-a-vis the
USL and the relationship between the two.
X LSL
Cpl
3s
This gives us the positioning of the mean vis-a-vis the
LSL and the relationship between the two.
Cpk - Process Performance Index. This is important
+O
= Cpl ;for unilateral tolerance on lower side i.e..
X -Y
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LSL USL
SOME
SOME TYPES
TYPES LSL USL
LSL USL
LSL USL LSL USL
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A FEW TERMINOLOGIES
• Defect : Any non-conformity in a product or service
– e.g. Late delivery or no. of tubes rejected
• Units : The nos. checked or inspected
– 100 deliveries were monitored for being late, no. of units
are 100
– 1000 tubes were checked for oversize dia., no. of units
are 1000
• Opportunity : Anything that you measure or check for.
– Finished refrigerator is checked for 25 defects at final
inspection, the no. of opportunities is 25
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WHAT IS A DEFECT?
A defect is any variation of a required
characteristic of the product (or its parts) or
services which is far enough from its target value
to prevent the product from fulfilling the physical
and functional requirements of the customer, as
viewed through the eyes of your customer.
DEFINING AN UNIT
An 'unit' may be as diverse as
a:
Piece of equipment
Line of software
Order
Technical manual
Medical claim
Wire transfer
Hour of labour
Billable dollar
Customer contact
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TOP
TOP ==NO.
NO.OF
OFUNITS
UNITSCHECKED
CHECKEDxx
NO.
NO.OF
OFOPPORTUNITIES
OPPORTUNITIESOF
OFFALIURE
FALIURE
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DPO = DEFECTS
TOP
DPO = 25 = 0.01
2500
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100
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DPMO
DPMO = NO. OF DEFECTS x 106
NO. OF UNITS x OPP.
100 x 25
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DPMO==
DPMO DEFECTS
DEFECTS xx 10
6
106
TOPTOP
ATTRIBUTE DATA
EXAMPLE
EXAMPLE
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EXERCISE
• For a 100% inspection process, 10000 units are produced.
Each can be rejected for 8 different reasons. 100 were
rejected. What is the DPU, TOP, DPMO & DPO.
• For the above the next day 20 units were rejected such that
2 units had 3 defects & 1 unit had 2 defects rest all had 1
defect. Find the DPU,TOP, DPMO & hence DPO.
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CONTINUOUS DATA
Step 1: Ensure Gauge R&R (if the CTQ is measured using an
instrument) < 30%. Otherwise improve measurement
system
Step 2: Collect the data (Minimum of 50 readings) on the
CTQ’s as per the data collection plan.
Step 3: Check for trend or special cause using individual
control chart
Step 4: Plot Histogram (Follow MINITAB steps. GO TO: Stat
> Basic Statistics > Display Descriptive Statistics >Enter
Variables > ‘Click’ Graphs > ‘Tick’ Graphical
Summary>OK>OK
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CONTINUOUS DATA
Step 5: Read mean & standard deviation and interpret the
data as coming from Normal distribution if p > 0.05,
otherwise treat the data as non-normal.
Step 6: Do the process capability analysis as follows.
1. Stat > Quality Tools > Capability Analysis (Normal) > Enter Variable >
Sample Size = 1 > Enter Specification Limits ( L/ U/ or both) > Go to
Options>Remove the tick from Within subgroup analysis>OK>Stamp
> Use Variable (if the date/ Time/ Batch no. to be incorporated) > OK >
OK
2. Read Expected performance in PPM if the data is normal
3. Read Observed performance if the data is non-normal.
4. In either case go to PPM – Sigma conversion table and find the Sigma
rating.
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EXAMPLE (Normal)
Process Capability Analysis for Dia.
LSL USL
Process Data
USL 5.20000
Within
Target *
LSL 4.80000 Overall
Mean 4.96330
Sample N 50
StDev (Within) 1.06439
StDev (Overall) 1.04820
2 3 4 5 6 7 8
Cpm *
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EXAMPLE (Non-Normal)
LSL
USL
Process Data
USL 4.10000
Target *
LSL 2.90000
Mean 3.92903
Sample N 50
StDev (Overall) 4.52914
Overall Capability
Pp 0.04
PPU 0.01
PPL 0.08
Ppk 0.01
-10 0 10 20 30
Cpm *
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