European Safety and Reliability Conference 2003 ESREL 2003

European Safety and Reliability Conference 2003ESREL 2003 A proposal for managing and engineering knowledge of stochastics in the quality movement Ron S. Kenett, M. F. Ramalhoto and John Shade M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 Vision: Statistical community SHOULD mimic the approach adopted by the medical community M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 Physicians: Perform a diagnosis of an illness and only then prescribe the necessary treatment. Statistical Consultants: Similar approach.(Assessments are followed by discussions of various organizational remedies which are then translated into detailed implementation plans.) Physicians: Always supposed to assume some responsibility for the follow up of the prescribed treatment. Statistical Consultants: Not always involved in the implementation phase. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 Assuring the ethical dimension of doing medicine is crucial for Physiciansbusiness reputation. They are organized regionally and world-wide in order to meet these responsibilities towards their customers. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 A model of a disease (failure or problem of some sort) is created based on medical literature and advice from experts in the diagnosis and treatment of the disorder. This model is usually introduced as a Clinical Practice Guideline (CPG) under the supervision of the Institute of Medicine (IM). M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 PAPER PROPOSAL: Statistical Community (in business or academia) to organize themselves to ASSUME RESPONSABILITIES similar to that of Physicians. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 FOR THAT WE NEED: • Identify and create diagnostic tools and “treatments” of the CPG type. (SQM LIBRARY) • Build a large network of TRANSDISCIPLINARY specialists that can work cooperatively.(ESRA/ENBIS/…) M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 RATIONAL: The business performance gains (possible through enhanced products and process quality control) have become well established, and are available. Substantial further gains in industrial competitiveness can come from more effective “asset utilization” that result from scientifically based product, process and reliability, maintenance and safety planning, as well as environmental sustainability awareness. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 • The recent interest in combining Six Sigma/Design For Six Sigma (DFSS) with Lean Manufacturing is a result of this evolution. • Keeping in mind that Reliability is Quality over time and Maintenance is a Reliability Function, the SQM, Stochastics for the Quality Movement, concept was introduced as part of an “extended quality movement” concept integrating also the reliability and the maintenance cultures. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 The “SQM Library” concept, is introduced in order to identify and create diagnostic tools and best practice methods in managing and engineering stochastics for the extended quality movement. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 For instance: Methodology leaders in business, such as master black belts in six sigma programmes, should benefit from a clear and comprehensive assessment of what their statistical practitioners might tackle, and how. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 SQMembraces all the non-deterministic (and the relevant deterministic) quantitative methods relevant to industry, business and governmental institution practices. It includes, for instance, statistical process control, maintenance, reliability and quality improvement methods, experimental design, risk analysis, as well as decision support systems, simulations, management statistics, graphical methods, key performance indicators, measurement systems, and the various interactions relevant to improvement and innovation. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 The SQM library has been first introduced and developed by Ramalhoto (1999 and 2002), Kenett and Shade (2001), Shade and Kenett (2001) and Kenett (2002) within ENBIS, the European Network for Business and Industrial Statistics, and Pro-ENBIS, a Fifth Framework Thematic network funded under the Growth program. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 The SQM Library will be organized in an intelligent and updated manner in order to be easy to use, very informative and complete. It will also include SQM research, education and training sites, computation, applications, statistical consultancy, quality improvement and innovation, Six-Sigma, free software, standards, data banks, relevant European Commission Directives etc’… M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 The first part of the SQM Library(2nd part under study) consists of: • Profiles of Industry/Business/Governmental institutions; • Statistical consulting pattern models; • Case-Studies of lessons learned and success stories; • SQM Software links and resources, and; • an SQM survey of companies, consultants and academics. The next sections provide an outline, with examples, of the SQM Library. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 1 - INDUSTRY PROFILES Industry profiles are here illustrated by the semiconductors industry. Similar profiles will be made available for other industries. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 The Semiconductors Industry Manufacturing of semiconductors: It is a process that goes from raw silicon at one end to encapsulated microchips at the other. There are dozens of stages and hundreds of tasks involved. "http://www.sematech.org/public/news/mfgproc/mfgproc.htm" for some details of the process. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 HOT RESEARCH AREA: Some recent announcements suggest that 300mm diameter wafers with sub-90 nanometer features are moving closer to production. Getting these to high levels of yield is a challenge for managers and engineers. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 References Statistical techniques have been widely applied in semiconductor manufacturing, not least due to the efforts of SEMATECH: http://www.sematech.org. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 References: For a report on the semiconductor industry (also downloadable as a pdf file): "http://www.semi.org/report/index.html" For more details and perspective on projected developments over the next 5 to 7 years: http://www.sematech.org http://public.itrs.net./Files/2001ITRS/ExecSum.pdf ). M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 References For news and information on conferences see: http://www.semiconductoronline.com http://www.sst.pennet.com http://www.semi.org http://public.itrs.net http://www.semiconductor2k.com M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 2 - STATISTICAL CONSULTING PATTERNS M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 In the literature there are many different proposals for the description of those desirable properties e.g. Alexander, Isihikawa et al, 1977, Coad 1992, Gamma, Helm et al 1995. An example from Alexander, Isihikawa et al, 1977 is the following: Name: it should be short and as descriptive as possible Examples: one or several diagrams/drawings illustrating the use of the pattern, Context: it focuses on the situation where the pattern is applicable, Problem: it is a description of the major forces/benefits of the pattern as well as its applicability constraints Solution: it details the way to solve the problem, it is composed of static relationships as well as dynamic ones describing how to construct an artefact according to the pattern. Variants are often proposed along with specific guidelines for adjusting the solution with regards to special circumstances. Sometimes, the solution requires the use of other patterns. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 3. SQM SURVEY The first version of the survey questionnaire is now in a pilot phase and consists of: • Company profile. • Lists of reliability models and techniques in use, ready to use, needed. • Lists of maintenance management models and techniques in use, ready to use, needed. • Lists of control charts models and techniques in use, ready to use, needed. • Lists of acceptance sampling models and techniques in use, ready to use, needed. • Lists of economical design models and techniques in use, ready to use, needed. • Lists of cost-benefit models and techniques in use, ready to use, needed. • Lists of inventory/supply-chain models and techniques in use, ready to use, needed. • (i) Lists of data quality techniques in use, ready to use, needed. • Lists of quality improvement and innovation models and techniques in use, ready to use, needed. • List of scientific and technical periodicals that exist in the company and are of practical or theoretical interest. • List of the Conferences, workshops attended. • List of SQM web-sites or other technical sites visited. • Type of long-life training/learning attended (including distance learning, for instance, internet and open university courses). M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 4. CONCLUSIONS AND FINAL REMARKS Many authors in books and papers have discussed the role of statisticians in the quality movement (Bisgaard, 1991, Hahn and Boardman, 1985, Hogg, 1985, Joiner, 1985). We go further and propose the development of an SQM library in the context of an extended quality movement whose aim is to establish a profession using medicine as a role model. This proposal is very demanding in terms of human resources and funding. An initial attempt at its implementation is achieved through ENBIS and Pro-ENBIS. Physicians have an enormously wealthy industry behind them, operating now for several decades. The statistical community could significantly gain from adopting such a model. M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003ESREL 2003 Acknowledgement This paper is supported by funding from the “Growth” program of the European Community and was prepared in collaboration by member organizations of the Thematic Network - Pro-ENBIS- EC contract number G6RT-CT-2001-05059 M. F. Ramalhoto - Instituto Superior Técnico Lisbon - Portugal

European Safety and Reliability Conference 2003 ESREL 2003