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QS 326 Spring 2003 Data Based Improvement Team Xtreme David Heath Lawrence Derr Crystina Sawyer Fernando Cardosa Caleb

QS 326 Spring 2003 Data Based Improvement Team Xtreme David Heath Lawrence Derr Crystina Sawyer Fernando Cardosa Caleb Ziebold Justin Lynch. Product Focus: Data Based Improvement Project Goal:

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QS 326 Spring 2003 Data Based Improvement Team Xtreme David Heath Lawrence Derr Crystina Sawyer Fernando Cardosa Caleb

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  1. QS 326 Spring 2003 Data Based Improvement Team Xtreme David Heath Lawrence Derr Crystina Sawyer Fernando Cardosa Caleb Ziebold Justin Lynch

  2. Product Focus: • Data Based Improvement • Project Goal: • Study And Apply The Concept Of Continuous Improvement Through The Reduction Of Process Variation Using Data Based Analysis Methods And Tools • Data Based Analysis Methods And Tools: • Gathering Accurate Data And Using Valid Samples • SOPs, Checklist And Attribute Charting • SPC, X-bar, R-bar And Variable Charting • Process Capability Determination • Gauge Repeatability And Reproducibility • Quality Characteristic Determination

  3. Project Study Subject: Our Team Has Chosen To Develop And Use A Simulated Company For This On-Line Project. The Team Has Decided To Use A Relatively Common Product That Is Processed In A Way Familiar To Most Team Members. The Simulated Product That The Team Has Chosen To Study Is A High-Energy Bouncy Ball. This Product Is Familiar To All Team Members, Is Processed In A Way That Most Team Members Have Had At Least Some Exposure To, And Has Quality Characteristics That Can Readily Be Adopted For Study In This Course.

  4. Company Background: Balls To The Walls Is A High Volume Supplier Of High-Energy Bouncy Balls. The Company Recently Found Itself Increasingly Pressured By Cost Down Demands From Its Customers And Global Competition. The Company Has Decided To Initiate An Aggressive Cost Savings Program Aimed At Reducing Scrap And Improving Throughput. Up To This Point The Company Has Had No Real Quality Plan In Place. The Company Has Been Fortunate Enough To Have An Experienced Workforce That Can Control Most Major Quality Issues. The Operators Have Always Had A Strong Say In Quality, But They Tend To Rely On Intuition And Memory Rather Than Facts. A Cross-Functional Team Has Been Put Together And Given The Opportunity To Establish The New Quality System. The Team Has Decided To Base Its Quality System On The TS-16949 (2002) Quality Manuals. The Team’s First Focus Will Be On The Data Based Analysis Since This Should Allow For The Greatest Opportunity For Scrap Reduction In The Shortest Amount Of Time.

  5. Product Overview The Xtreme Ball A Product Of Balls To The Walls

  6. Quality Characteristic Analysis Changing Over From Atribute To Variable Data The Xtreme Ball

  7. Must Withstand Adverse Conditions ... From The Toughest Customers

  8. Phase I Tool Presentations 15-17

  9. Phase Portfolio • RCAs: Regular Critique Assessments • 5 RCAs That Increase In Scope And View. • The RCAs Allow Team Members To Research And Give Input • On Data Based Analysis Methods And Tools. • SDAs: Standard Dedicated Audits • Used To Apply The Technical Content Of The Toolkits To The • Project Objectives. • Each Team Member Researches And Applies Gained Knowledge.

  10. Tool #15 “Statistical Foundations For Data Based Improvement, Lean, Six Sigma Solutions” • Tool #15 Objectives • ISO 9000 Steamlined: TS 16949 2002 Basis For Quality Systems. • Sampling, Gathering Accurate Data. • Attribute Charting, Checklist Systems. • SPC, X-bar And R, Variable Charting. • Cp And Cpk Definitions And Capability. • Repeatability And Reproducibility In Measurement. • Quality Characteristic Foundations, Changing Relatioships. • Six Sigma, Solving Problems, Reducting Variation, Making • Improvements.

  11. Tool #15 Objectives • ISO 9000 Steamlined: TS 16949 2002 Basis For Quality Systems. • Sampling, Gathering Accurate Data. • Attribute Charting, Checklist Systems. • SPC, X-bar And R, Variable Charting. • Cp And Cpk Definitions And Capability. • Repeatability And Reproducibility In Measurement. • Quality Characteristic Foundations, Changing Relatioships. • Six Sigma, Solving Problems, Reducting Variation, Making • Improvements.

  12. Relation Of Toolkit 15 To Project • RCAs • Introduction To Various Statistical Foundations. • Data Based Analysis. • Continuous Improvement. • SDAs • General Start Up Analysis. • Training/Infrastructural Change. • Prioritization. • Pareto Charting.

  13. Tool #16 “Attribute Data, The Obvious Starting Point For Lean,Six Sigma Service” • Tool #16 Objectives • Statistical Principles In Quality. • Normal Curve, Variation And Standard Deviation. • Attribute Data Concepts. • P Chart Steps For Attribute Data. • Attributes, Checklists And Charting. • Quality Characteristics, Accurate Data And Variable Charting. • Team Based Problem Solving, Six Sigma Variation Reduction.

  14. Tool #16 Objectives • Statistical Principles In Quality. • Normal Curve, Variation And Standard Deviation. • Attribute Data Concepts. • P Chart Steps For Attribute Data. • Attributes, Checklists And Charting. • Quality Characteristics, Accurate Data And Variable Charting. • Team Based Problem Solving, Six Sigma Variation Reduction.

  15. Relation Of Toolkit 16 To Project • RCAs • Introduction To Various Statistical Foundations. • Data Based Analysis. • Continuous Improvement. • SDAs • Data Collection System. • Attribute Statistical Process Control. • Standard Deviation Calculation. • Pareto Charting.

  16. Tool #17 “Variable Data, Comparisons To Attribute Charting For Six Sigma, Lean Service” • Tool #17 Objectives • Sampling Issues And Characteristics - Defining Cp • And Cpk, Capability, Lean. • Attribute Data Reviewed, Variable Data Pursued For Six Sigma. • Additional Lean Benefits And Motivation Related To SPC. • Constructing X Bar And R Charts. • Improved Understanding Of Average And Range. • Short Or Mini Runs, Pre-Control And Trending, Six Sigma Maturing. • Attribute Versus Variable Systems - Advantages And Disadvantages. • Phasing The Charts Out. • Preliminary Simplified Design Of Experiments.

  17. Relation Of Toolkit 17 To Project • RCAs • Introduction To Cp And Cpk, Capability, Lean. • Construction Of X Bar And R Bar Charts. • Short Runs, Precontrol, Trending. • SDAs • General Inspection Systems. • Variable Statistical Control Process. • Variable Data Short Run Precontrol. • Preliminary Systematic Design Of Experiements.

  18. Phase II Tool Presentations 18-20 Develop Planning And Policy Changes To Allow For Data-Based Decision Making And Continuous Improvements Based On Six Sigma, Lean

  19. Tool #18 “Basic Measurement, Geometric Relationships, Broader Data-based Issues” • Tool #18 Objectives • Foundational Metrology And Measurement Issues. • Accurate Data, Total Quality Systems, Kaizen, Lean, Six Sigma. • Metrology And Inspection System Services In Quality. • Historical Background On Metrology. • Form, Fit, Finish And Function, Geometric Underpinnings. • Foundational Metrological And Measurement Issues. • Basic Measureable Features in Geometric Dimensioning. • Basic Principles And Devices For Measurement And Data Collection. • Shifting Toward The Metric System. • Surface Quality: Focused Foundational Metrological Issue.

  20. Relation Of Toolkit 18 To Project • RCAs • Introduction To Basic Metrological Principles And Tools. • Accurate Data, TQM, Kaizen, Lean, Six Sigma. • Continuous Improvement. • SDAs • Measurement Systems Analysis, Evaluation 1. • Measurement Systems Analysis, Evaluation 2. • Return On Investment. • Man Machine Analysis.

  21. Tool #19 “Gauge Repeatabilty And Reproducibility (R&R)” • Tool #19 Objectives • Lean, Six Sigma Opportunities Through Proper Gauge Use. • Identifying Important Features And Quality Characteristics. • Evaluating Gauges And Determining Measurement Error. • The Broader Quality System And How It Relates To Gauge R&R. • Evaluate The Crossfunctional Team Role In Six Sigma, Lean. • Data And Documentation For Lean, Six Sigma, Kaizen.

  22. Relation Of Toolkit 19 To Project • RCAs • Present Ideas And Develop A Basic Plan For Six Sigma, Lean. • Introduce Sources And Methods For Determining Gauge R&R. • Develop Improved Method For Information Flow, Documentation. • SDAs • Gauge Reproducibility And Repeatability System I. • Determine Gaugue R&R For Bounce Height Measurement Fixture. • Gauge Reproducibility And Repeatability System II. • Develop An Effective Way Of Evaluating The Current Quality Control System. • Gauge R&R, Training, Traditional, Infrastructural Change. • Man Machine Analysis And Effective Use Of Resources, Lean.

  23. Tool #20 “Capability, Charts And Quality Characteristics Analysis: Transitioning Six Sigma And Lean” • Tool #20 Objectives • The Broader Quality System and Six Sigma. • Procedures, Capability Explanation, Definitions of Cp and Cpk. • Relationships To Variation, Six Sigma, Factors and Charts. • Kaizen, Lean, Reducing Variation and Solving Problems. • The Out of Control Conditions of Trends, Outliers and Fliers. • Quality Characteristics, Customers, Suppliers and Lean. • Lean Quality, Engineering and Manufacturing and How They • Relate to Inspection, Attribute and Variable.

  24. Relation Of Toolkit 20 To Project • RCAs • Improve Capability By Improving The Overall Quality System. • Improve Communication And Reduce Variation Through The Use Of • Charts, Kaizen And Lean. • Improve The Capability Index To 1.33. • SDAs • Capability Calculation: Determine The Organization’s Current • Capability. • Capability, Calculation Analysis Two: Interpretation Of • Organization’s Capability • Capability And Characteristic Evaluation System: Identify Evaluation • Method. • Capability, Training, Tradition, Infrastructural Change: Identification • And Recommendation For Improving Organization’s Training.

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