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Transcript of Blended Lean Six Sigma Black Belt Training – ABInBev Week One Review ©2010 ASQ. All Rights...
Blended Lean Six Sigma Black Belt Training –
ABInBev
Week One Review
©2010 ASQ. All Rights Reserved.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Last Time We …
• Defined our project
• Leaned our processes
• Learned statistical techniques
• Validated our measurement system
• Created standard work
• Conducted hypothesis tests
• Practiced coaching Green Belts
Let’s do a quick review before starting the new material.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Define Phase
Created the project charter – the critical first step in any LSS project
Collected Voice of the Customer
High-level process map (SIPOC)
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Lean Defined
A philosophy and set of methods where waste is identified
continuously and eliminated passionately.
A complete lean system should have: Techniques/Tools
Management (mindset and accountability)
Organizational Environment (skills, culture, and behaviors)
Waste is any activity (or inactivity) that consumes resources
and do not add value to the customer through the product
or service.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Key Terms
Value-adding activities transform the product in a way the customer would be willing to pay for.
Daily Operating TimeTAKT Time=
Daily Customer Requirement
Value stream is a series of activities, both those that create value and those that do not, required to deliver a product or service.
Value stream mapping is a tool used to document (map) all activities of a value stream to clearly see waste and variations.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
The Eight Wastes
DEFECTS
8Wastes
EXTRA PROCESSING
EXCESS INVENTORY
EXCESS TRANSPORTATION
OVERPRODUCTIONEXCESS MOTION
WAITING
UNUSED CREATIVITY
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
5 S
SORT involves sorting through the contents of the workplace and removing unnecessary items.
STRAIGHTEN involves putting the necessary items in their place and providing easy access.
SHINE involves cleaning everything, keeping it clean daily, and using cleaning to inspect the workplace and equipment for defects.
STANDARDIZE involves creating visual controls and guidelines for keeping the workplace organized, orderly, and clean.
SUSTAIN involves training and discipline to ensure that everyone follows the 5S standards.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Basic Statistics
Seven basic probability rules1. All events have a probability between 0 and 1.2. The sum of all possible probabilities of defined events is equal to 1.00.3. The probability of an event not occurring is equal to the probability of
the event occurring subtracted from 1.0.4. If events are mutually exclusive, the sum of the probability of
occurrence of these events is equal to 1.5. The probability of the joint occurrence of independent events is the
product of the probability of each event.6. The probability of occurrence of either or both non-independent
events is the sum of the probability of each independent events minus the probability of joint events.
7. The probability of observing two dependent events is the product of the probability of the first event and the conditional probability of the second event, given that the first has occurred.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 1
Assume a sample is selected from a normally distributed population with a mean of 12 oz and a standard deviation of .01 oz.
1. What percent of the sample would be expected to have a value greater than 12.02?
2. What percent of the sample would be expected to have a value less than 11.99?
3. Ten percent of the sample would be expected to have X or less. What is X?
Find the answers and draw graphs of the results using Minitab.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 2
Assume a fair coin is flipped 100 times.1. What is the probability of exactly 50 heads?2. What is the probability of greater than 60 heads?
Assume a process creates .01 defects per unit. One hundred units were sampled. What is the probability there will be:
3. Zero defects?4. Two defects?
Find the answers with Minitab.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Measurement Systems Analysis (Gage R&R)
Repeatability and reproducibility are typically the primary contributors to measurement error
ObservedVariation
Actual ProcessVariation
MeasuredVariation
Long-TermProcessVariation
Short-TermProcessVariation
VarianceDue toInstrument
VarianceDue toOperators
Repeatability Calibration Stability Linearity Reproducibility
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 3
A Green Belt conducted a gage R&R on a bottling line. He had three operators measure the temperature of the product at 20 locations in the line three times each. He sent the data in Temperature Measurement.mtw. What would you recommend?
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Error Proofing
Error proofing is a systematic approach for anticipating and detecting potential defects and preventing them from reaching the customer (internal or external)
• Proactive identification and prevention
• Prevent first
• Do not allow defects from going further
• Intentionally designed, not by chance
• At the source—close to the origination
• Inexpensive first
• Transparent to the operator
• Absolutely reliable
2012 American Society for Quality.All Rights Reserved.
Page 14 Process Capability – ABI Black Beltv1.1
Defining Process Capability
Principle: process capability is a ratio of process
variability to design tolerance.
Process width
Design width
It is measured in several ways.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Process Capability Terms
See formulae on next page.
Cp – Short-term process capability For a limited period of time (not including shifts and drifts) Does not consider process centering Also known as process entitlement
Cpk – Short-term process capability index For a limited period of time (not including shifts and drifts) Does consider process centering
Pp – Long-term process capability For an extended period of time (including shifts and drifts) Does not consider process centering
Ppk – Long-term process capability index For an extended period of time (including shifts and drifts) Does consider process centering
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Specification Width(s)Short-Term Process Width
=
Specification Width(s)Long-Term Process Width
=
Lesser of: or
Lesser of: or
Capability Formulae
Cp =
Pp =
Cpk=
Ppk=
USL - LSLProcess sigma =
2 USL-LSL
6 st
USL-LSL6 lt
X-LSL3 lt
USL-X3 lt
USL-X3 st
X-LSL3 st
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 4
A Green Belt collected data on the fill volumes in cans. The specification limits are 11.995 to 12.005 with a target of 12. The data is in six pack spc. What is the capability of this process?
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Standard Work
Documents layout and flow process sequenceAlso documents:
• Standard W.I.P.• Quality checks• Safety precautions
Posted in cellIncludes visual work instructions for each
operation
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Hypothesis Testing
Enables us to determine if there is a statistically significant difference between the characteristics of interest of samples of data.
© 2010 ASQ. All Rights Reserved.20
Testing Method Selection Matrix
Variable Type Attribute Y Count Y Continuous Y
Discrete X
1 or 2 TreatmentsProportions
3 +TreatmentsChi Square
1 or 2 Treatments Poisson
3 + Treatments Chi Square
1 or 2 TreatmentsT tests
3 +TreatmentsANOVA
Continuous XLogistic Regression
Logistic Regression
Least Squares Regression
There are many types of hypothesis tests we will learn to use depending on the type of data available for the inputs (Xs) and outputs (Ys).
© 2010 ASQ. All Rights Reserved.21
Your Turn 5
A Green Belt collected data on Gross Line Yield before and after a process change. Did the change make a statistically significant improvement (more is better) on Gross Line Yield? The data is in Gross Line Yield.mtw.
© 2010 ASQ. All Rights Reserved.22
What’s Next?
• Completing our set of hypothesis testing tools• More lean tools• Designed experiments• Control plans• Design for Six Sigma
Let’s get started!
Blended Lean Six Sigma Black Belt Training –
ABInBev
Answers to Week One Review Your Turn
©2010 ASQ. All Rights Reserved.
© 2010 ASQ. All Rights Reserved.24
Your Turn 1 Solution 1
Calc>Probability Distributions>Normal
This will give the probability of less than 12.02, which we will subtract from 1 to get the answer. Minitab returnsNormal with mean = 12 and standard deviation = 0.01
x P( X <= x )12.02 0.977250
So .02275 would be greater than 21.02 oz.
© 2010 ASQ. All Rights Reserved.25
Your Turn 1
Assume a sample is selected from normally distributed population with a mean of 12 oz and a standard deviation of .01 oz.
1. What percent of the sample would be expected to have a value greater than 12.02?
2. What percent of the sample would be expected to have a value less than 11.99?
3. Ten percent of the sample would be expected to have X or less. What is X?
Find the answers and draw graphs of the results using Minitab.
© 2010 ASQ. All Rights Reserved.26
Your Turn 1 Solution 1 Graph
Graph>Probability Distribution Plot
© 2010 ASQ. All Rights Reserved.27
Your Turn 1 Solution 1 Graph
© 2010 ASQ. All Rights Reserved.28
Your Turn 1 Solution 1 Graph
40
30
20
10
0X
Densi
ty
12.02
0.02275
12
Distribution PlotNormal, Mean=12, StDev=0.01
© 2010 ASQ. All Rights Reserved.29
Your Turn 1 Solution 2 Graph
Control+e to return to the last dialog box
© 2010 ASQ. All Rights Reserved.30
Your Turn 1 Solution 2 Graph
40
30
20
10
0X
Densi
ty
11.99
0.1587
12
Distribution PlotNormal, Mean=12, StDev=0.01
© 2010 ASQ. All Rights Reserved.31
Your Turn 1 Solution 3 Graph
Control+e to return to the last dialog box
© 2010 ASQ. All Rights Reserved.32
Your Turn 1 Solution 3 Graph
40
30
20
10
0X
Densi
ty
0.1
1211.99
Distribution PlotNormal, Mean=12, StDev=0.01
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 2
Assume a fair coin is flipped 100 times.1. What is the probability of exactly 50 heads?2. What is the probability of greater than 60 heads?
Assume a process creates .01 defects per unit. One hundred units were sampled. What is the probability there will be:
3. Zero defects4. Two defects
Find the answers with Minitab
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 2 Solution 1
Calc>Probability Distributions>Binomial
Binomial with n = 100 and p = 0.5
x P( X = x )50 0.0795892
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 2 Solution 2
Control+e to return to the last dialog box
This will return the probability of 60 or less. Subtract from 1 to get the probability of greater than 60.Binomial with n = 100 and p = 0.5
x P( X <= x )60 0.982400
The probability of greater than 60 heads is .0176.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 2 Solution 3
Calc>Probability Distributions>Poisson
.01 * 100 = 1
Poisson with mean = 1
x P( X = x )0 0.367879
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 2 Solution 3
Control+e to return to the last dialog box
Poisson with mean = 1
x P( X = x )2 0.183940
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 3
A Green Belt conducted a gage R&R on a bottling line. He had three operators measure the temperature of the product at 20 locations in the line three times each. He sent the data in Temperature Measurement.mtw. What would you recommend?
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 3 Solution
Assistant>Measurement Systems Analysis
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 3 Solution
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 3 Solution
the study.variation. The process variation is estimated from the parts inThe measurement system variation equals 7.8% of the process
100%30%10%0%
NoYes
7.8%
ReprodRepeatTotal Gage
48
36
24
12
0
30
10
%Study Var
and is 2.5% of the total variation in the process.same item. This equals 31.7% of the measurement variationThe variation that occurs when different people measure the-- Operator and Operator by Part components (Reproducibility):7.4% of the total variation in the process.times. This equals 94.8% of the measurement variation and isoccurs when the same person measures the same item multiple-- Test-Retest component (Repeatability): The variation thatreproducibility to guide improvements:total gage variation is unacceptable, look at repeatability andExamine the bar chart showing the sources of variation. If the >30%: unacceptable 10% - 30%: marginal <10%: acceptableGeneral rules used to determine the capability of the system:
Number of parts in study 20Number of operators in study 3Number of replicates 3
Study Information
Variation by Source
(Replicates: Number of times each operator measured each part)
Comments
Gage R&R Study for TemperatureSummary Report
Can you adequately assess process performance?
This is a good measurement system.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 4
A Green Belt collected data on the fill volumes in cans. The specification limits are 11.995 to 12.005 with a target of 12. The data is in six pack spc. What is the capability of this process?
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 4 Solution
Assistant>Capability Analysis
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 4 Solution
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 4 Solution
12.004
12.000
11.996
Mean
631561491421351281211141711
0.02
0.01
0.00
Range
Normality Test
Results PassP-value 0.737
(Anderson-Darling)
Xbar-R ChartConfirm that the process is stable.
Normality PlotThe points should be close to the line.
Capability Analysis for Can 1, ...Diagnostic Report
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 4 Solution
60
HighLow
Z.Bench = 1.32
> 0.50.10.050
NoYes
P = 0.433
12.01112.00812.00512.00211.99911.99611.99311.990
LSL Target USL
Actual (overall) capability is what the customer experiences. spec limits.percentage of parts from the process that are outside the-- The defect rate is 9.29%, which estimates thetarget (p > 0.05).-- The process mean does not differ significantly from theConclusions
Upper Spec 12.005Target 12Lower Spec 11.995
Customer Requirements
Mean 12.000Standard deviation 0.0029754
Actual (overall) capability Pp 0.56 Ppk 0.56 Z.Bench 1.32 % Out of spec 9.29 PPM (DPMO) 92893
Process Characterization
Does the process mean differ from 12?
Actual (overall) CapabilityAre the data inside the limits and close to the target?
Comments
Capability Analysis for Can 1, ...Summary Report
How capable is the process?
Process control in marginal and capability is poor
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 5
A Green Belt collected data on Gross Line Yield before and after a process change. Did the change make a statistically significant improvement (more is better) on Gross Line Yield? The data is in Gross Line Yield.mtw.
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 5 Solution
Assistant>Hypothesis Test
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 5 Solution
2012 American Society for Quality.
All Rights Reserved.Page Week One Review –ABI Black Beltv1.1
Your Turn 5 Solution
807672686460
GLY Before
GLY After
of GLY After (p < 0.05).The mean of GLY Before is significantly less than the mean
> 0.50.10.050
NoYes
P = 0.000
0-2-4-6-8
results of the test.samples. Look for unusual data before interpreting the-- Distribution of Data: Compare the location and means ofthat the true difference is between -7.9204 and -3.7796.the difference from sample data. You can be 90% confident-- CI: Quantifies the uncertainty associated with estimatingless than GLY After at the 0.05 level of significance.-- Test: You can conclude that the mean of GLY Before is
Sample size 20 20Mean 65.79 71.64 90% CI (64.41, 67.17) (70.027, 73.253)Standard deviation 3.5650 4.1725
Statistics GLY Before GLY After
-5.85(-7.9204, -3.7796)
Distribution of DataCompare the data and means of the samples.
Mean TestIs GLY Before less than GLY After?
90% CI for the DifferenceDoes the interval include zero?
Difference between means* 90% CI
* The difference is defined as GLY Before - GLY After.
Comments
2-Sample t Test for the Mean of GLY Before and GLY AfterSummary Report
He can conclude a statistically significant improvement was made.