Lecture Note
Analyze Phase
-
University:
California State University, Northridge -
Course:
MSE 618 | Six Sigma Quality Engineering Academic year:
2024
-
Views:
264
Pages:
34
Author:
Andres Hays
Six Sigma Quality
Engineering
Analyze Phase Process Map
Inputs characteristics
Cause & Effect
Fishbone Diagram (Minitab)
C&E Matrix (Excel)
Failure Mode & Effect Analysis (FMEA)
Process Capablity
Cpk
Cp
Minitab Tutorial
In this session you will learn how to:
· Produce X and R charts
· Produce histograms with normal curves
· Perform a process capability analysis
Detailed Process Map Example
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G
s Characterising Inputs
Inputs can be classified as one of three types
Controllable (C)
• Things you can adjust or control during the process
• Speeds, feeds, temperatures, pressures….
Standard Operating Procedures (S)
• Things you always do (in procedures or common sense things)
• Cleaning, safety….
Noise (N)
• Things you cannot control or don not want to control
(too expensive or difficult)
• Ambient temperature, humidity, operator... Example
Machining a shaft
on a lathe
C
C
C
C
C
C
C
S
C
N
N
N
S
Inputs (x’s)
Rotation speed
Traverse speed
Tool type
Tool sharpness
Shaft material
Shaft length
Material removal per cut
Part cleanliness
Coolant flow
Operator
Material variation
Ambient temperature
Coolant age
Outputs (Y’s)
Diameter
Taper
Surface finish The Eight Steps in Cause and Effect
Analysis
Define the Effect
Identify the Major Categories
Generate Ideas
Evaluate Ideas
Vote for the Most Likely Causes
Rank the Causes
Verify the Results
Recommend Solutions Cause & Effect (Fishbone Diagram)
Objectives
• To understand the benefits of Cause & Effect Analysis
• To understand how to construct a C & E Diagram
Analysis
• A method a work group can use to identify the possible causes of a
problem
• A tool to identify the factors that contribute to a quality characteristic Uses of C & E (Fishbone Diagram)
Visual means for tracing a problem to its causes
Identifies all the possible causes of a problem and how
they relate before deciding which ones to investigate
C & E analysis is used as a starting point for investigating
a problem C&E (Fishbone Diagram)
Effect
• The problem or quality characteristic
• The effect is the outcome of the factors that affect it
Effect Causes (Fishbone Diagram)
All the factors that could affect the problem or the quality
characteristic
Five Major Categories
• Materials
• Methods
• People
• Machines
• Environment Machine
Environment
Effect
Material
Methods
People Cause and Effect (Matrix)
Benefit
• Gain new knowledge and perspectives by sharing
ideas with others
• Helps us understand our processes
• Provides a basis for action
• Whenever a problem is discovered, using C&E
analysis forces us to take a proactive stance by
seeking out causes Rating of
Importance to
Customer
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
5
&
6
Total
Process Step Process Input
Lower Spec
Target
Upper Spec
0
0
0
0
0
0
0
0
0
0
0
0
0
Total
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
4 C&E Matrix
Instructions
This table provides the initial input to the FMEA and experimentation. When each of the output variables
(requirements) are not correct, that represents potential "EFFECTS". When each input variable is not correct, that
represents "Failure Modes".
1. List the process output variables
2. Rate each output on a 1-to-10 scale to importance to the customer
3. List process input variables (from the process map)
4. Rate each input's relationship to each output variable using a 0, 1, 3, 9 scale
5. Select the high ranking input variables to start the FMEA process; Determine how each selected input variable
can "go wrong" and place that in the Failure Mode column of the FMEA. FMEA
It is an approach to:
•
•
•
•
•
Identify potential failure for a product or a process
Estimate risks that are associated with causes
Determine actions to reduce risks
Evaluate product design validation plan
Evaluate process current control plan FMEA types
There are two types:
• Process: Will focus on Process Inputs
• Design: Will used to analyze product designs before
they are released to production The use of the FMEA
Improve processes before failure occur (Proactive
approach)
Prioritize resources to ensure process
improvement efforts are beneficial to customers
Track and document completion of projects
It is a living document. It will be updated and
reviewed all the time
Inputs & Outputs to FMEA
Inputs
Process Map
C&E Matrix
Process History
Process technical procedures
Outputs
Actions list to prevent causes
Actions list to detect failure modes
Document history of actions taken FMEA step-by-step
For each process input, determine the ways in
which the input can go wrong- the failure modes.
What can go wrong
with input
Potential Failure
Effects
What is the impact on
the Output Variables
(Customer
Requirements)
or internal
requirements?
Potential Causes
What causes the input
to go wrong?
O
C
C
How often does cause of FM
occur?
Process
Potential Failure
Step/Input
Mode
What is the
In what ways does the
process
input go wrong?
step/input under
investigation?
S
E
V
How sever is the effect to the
customer?
FMEA step-by-step
For each failure mode associated with the inputs,
determine the effects of the failures on the
customer.
What the effect
on outputs?
Potential Failure
Effects
What is the impact on
the Output Variables
(Customer
Requirements)
or internal
requirements?
Potential Causes
What causes the input
to go wrong?
O
C
C
How often does cause of FM
occur?
Process
Potential Failure
Step/Input
Mode
What is the
In what ways does the
process
input go wrong?
step/input under
investigation?
S
E
V
How sever is the effect to the
customer?
FMEA step-by-step
Identify potential causes of each failure mode.
What are
The causes?
Potential Failure
Effects
What is the impact on
the Output Variables
(Customer
Requirements)
or internal
requirements?
Potential Causes
What causes the input
to go wrong?
O
C
C
How often does cause of FM
occur?
Process
Potential Failure
Step/Input
Mode
What is the
In what ways does the
process
input go wrong?
step/input under
investigation?
S
E
V
How sever is the effect to the
customer?
FMEA step-by-step
List the current controls for each cause or failure
mode (Prevent/Detect).
How are these
Found or prevented?
Current Controls
Prevent
Detect
What are the existing controls and procedures
(inspection and test) that prevent/detect either
the Cause or Failure Mode?
Should include an SOP number. FMEA step-by-step
Create Severity, Occurrence, and Detection rating
scales.
– Severity of effect- importance of effect on customer
requirements. It is a safety and other risks if failure occurs.
» 1= Not Severe, 10= Very Severe
– Occurrence of cause- frequency in which a give Cause
occurs and creates Failure Mode. Can sometimes refer to
the frequency of a failure mode.
» 1= Not Likely, 10= Very Likely FMEA step-by-step
Create severity, Occurrence, and Detection rating
scales.
– Detection- ability to:
» Prevent the causes or failure mode from occurring or
reduce their rate of occurrence
» Detect the cause and lead to corrective action
» Detect the failure mode
» 1= Likely to Detect, 10= Not Likely at all to Detect FMEA step-by-step
Risk Priority Number:
• After rating we get the output on an FMEA Risk
Priority Number. It is calculated as the product
of Effects, Causes, and Controls
RPN= Severity X Occurrence X Detection
Effects
Causes
Controls FMEA step-by-step
Dynamics of the Risk Priority Number:
• The team defines the rating scales 1-10 for the
severity, Occurrence, and Detection ratings.
The team choose the levels and numbers:
• How severe is it: Not Severe
=1
Somewhat
=3
Moderately
=5
Very Severe = 10 FMEA step-by-step
Dynamics of the Risk Priority Number:
• The team defines the rating scales 1-10 for the
severity, Occurrence, and Detection ratings.
The team choose the levels and numbers:
• How often does it Occur?
Never/rarely
=1
Sometimes
=3
Half the time
=5
Always
= 10 FMEA step-by-step
Dynamics of the Risk Priority Number:
• The team defines the rating scales 1-10 for the
severity, Occurrence, and Detection ratings.
The team choose the levels and numbers:
• How well can you detect it?
Always
=1
Sometimes
=3
Half the time
=5
Never
= 10 FMEA step-by-step
Determine recommended actions to reduce high
RPN’s:
What can be done?
How well can you detect
cause or FM?
D
E
T
R
P
N
Actions
Recommended
Responsible
Actions Taken
What are the
Who is
What are the
actions for
responsible for the completed actions
reducing the
recommended
taken with the
occurrence of the
action?
recalculated RPN?
Cause, or
Be sure to
improving
include
detection? Should
completion
have actions only
month/year.
on high RPN’s or
easy fixes.
S
E
V
O
C
C
D
E
T
R
P
N FMEA step-by-step
Take appropriate actions and recalculate RPN’s
Assign responsible
Parties
How well can you detect
cause or FM?
D
E
T
R
P
N
Actions
Recommended
Responsible
Actions Taken
What are the
Who is
What are the
actions for
responsible for the completed actions
reducing the
recommended
taken with the
occurrence of the
action?
recalculated RPN?
Cause, or
Be sure to
improving
include
detection? Should
completion
have actions only
month/year.
on high RPN’s or
easy fixes.
S
E
V
O
C
C
D
E
T
R
P
N Process Capability Study Cpk & Cp
•Cpk incorporates information about both the process spread and the process mean, so
it is a measure of how the process is actually performing.
•Cp relates how the process is performing to how it should be performing. Cp does
not consider the location of the process mean, so it tells you what capability your
process could achieve if centered. Process Capability Study Non-normal distributions
•Use Capability Analysis (Nonnormal) to assess the capability of an in-control
process when the data are from the nonnormal distribution. A capable process is able
to produce products or services that meet specifications.
•The process must be in control and follows a nonnormal distribution before you
assess capability. If the process is not in control, then the capability estimates will be
incorrect.
•Nonnormal capability analysis consists of a capability histogram and a table of
process capability statistics
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