Lean Six Sigma

Measure Phase

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 Tools

 Process Map/Spaghetti Diagram

 Descriptive Statistics
 Histogram
 Scatter Plot
 Control Charts
 Reproducibility & Repeatability (Gage R&R)
 Capability Analysis, Cp, Cpk

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DMAIC –Measure Phase

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DMAIC –Measure Phase

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Process Map / Spaghetti Diagram

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 What is a Process Map?

 A process map is a graphical representation of the

flow of a process

 A detailed process map includes information that can

be used to improve the process, such as:
• Process Times
• Quality
• Costs
• Inputs
• Outputs

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 Types of Process Map

 Basic process map

 Detailed process map
 Work-flow (spaghetti diagrams)
 Top-down flowchart
 Deployment flowchart
 Opportunity flowchart
 Current State / Future state maps

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 Uses of a Process Map

 Identify areas for focus of improvement efforts

 Identify and eliminate non-value added steps
 Combine operations
 Assist root cause analysis
 Baseline for failure mode and effect analysis (FMEA)
 Identify potential controllable parameters for designed
experiments
 Determine needed data collection points
 Eliminate unnecessary data collection steps

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 Detailed Process Map Example

(Y's)
Surface cleanliness (Y's) (Y's)
- Removel of sand Acid free Surface cleanliness (dust / rust free)
- Removal of rust Debris removed Surface roughness
- 'Defect free'

UNCOATED
FITTINGS HANG ON
PICKLE RINSE SHOTBLAST STAND
(x's)
PENDANTS
(x's) (x's) C Time
C Make up of mix, Concentration and % of C Time C Shot size / mix of sizes
Hydrochloric Acid, Hydrofluoric Acid, Activol, Water N Product geometry N Humidity
C Pickling time N Operator S Type / Material / Original size of grit
S Age of mix / SG S Rocked / Not rocked N Effectiveness of seperator
N Quality of work / container S Method of packing N Product geometry
N Containers / tank N Condition of machine
N Product geometry N Dust arrestor condition
S Packing method S Amount of work being shotblast
N Operator C Time between pickle and shotblast
S Shotblast prior to pickling N Operator

(Y's)
Coating Quality
- Thickness of zinc / zinc alloy layers (Y's)
(Y's) (Y's)
- Uniformity of cov erage Zinc : Zinc Alloy thickness
Uniformity of flux Dry castings
- Total coverage Appearance (brightnes s)
No excess flux (removed by Drying Ov en) Warm castings
- Appearance Removal of ash (cleanliness)
- Roughness / tex ture
- Composition of c oating
Fitting temperature COATED
FITTINGS
DIP IN ZINC
LYE BATH DRYING TUNNEL WATER SPRAY KNOCK OFF
BATH / BUMP
(x's)
(x's) (x's)
C Speed of chain / time in bath
C Speed of chain (x's) S Water volume
C Temperature of ly e bath
S Temperature of tunnel S Quality of supplier / materials N Water temperature
C Make up of lye bath
N Geometry / Mas s of fittings C Temperature of zinc C Speed of chain
S Cleanliness of lye bath
N Humidity S Lev el of dross N Mass / Geometry of fittings
N Geometry of parts
S Air velocity S Lev el of lead (Rate of cooling)
S Pendant style / orientation of work
S Amount per pendant N Geometry / mass of fittings
S Weight of product per minute put through bath N Operator (Skimming surface / agitation of pendants) (Y's)
(Heat removal + heat pickup) S Quality of pendants Appearance
S Time from shotblast N Spec ifiacation (BS, ISO, EN) Smooth Finish
N Humidity S Rate of withdrawal
S Fluidity of zinc
N Power of bumper unit

RUMBLE
(x's)
C Time
C Number of fittings per load
N Geometry of fittings
S Condition of rumbling barrel

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 Process Maps

 Should include
• Major activities and tasks
• Sub-processes
• Process boundaries
• Inputs
• Outputs

 Documents reality, not how you think the process is

supposed to be completed

 Should identify opportunities for improvement

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 Steps for Process Mapping

 Scope the process

• Identify the start and end points of the process of
interest

 Document the top level process steps

• Create a flow chart

 Identify the inputs and outputs

• What are the results of doing each process step? (Y’s)
• What impacts the quality of each Y? (x’s)

 Characterise the inputs

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 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...
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 Example

Outputs (Y’s)
Diameter
Taper
Machining a shaft Surface finish
on a lathe

Inputs (x’s)
C Rotation speed
C Traverse speed
C Tool type
C Tool sharpness
C Shaft material
C Shaft length
C Material removal per cut
S Part cleanliness
C Coolant flow
N Operator
N Material variation
N Ambient temperature
S Coolant age

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Order Entry Process Map
As-Is

BEFORE
40 NVA STEPS

NOTE: FROM THE CUSTOMER’S

VIEWPOINT ALL OF ORDER ENTRY
IS NON-VALUE ADDED
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 Order Entry Process Map
New
REMEMBER: FROM THE CUSTOMER’S VIEWPOINT
ALL OF ORDER ENTRY IS NON-VALUE ADDED

We eliminated the steps that

BEFORE were NVA and
40 NVA STEPS UNNECESSARY (WASTE)

AFTER
11 NVA STEPS
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 Work-flow or Spaghetti Diagram

 A work flow diagram is a picture of the movements of

people, materials, documents, or information in a
process.

 Start by tracing these movements onto a floor plan or

map of the work space.

 The purpose of the work-flow diagram is to illustrate the

inefficiency in a clear picture.

 How can you make the map look simpler? What lines
can you eliminate?

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56 Frame (Small Motor) Assy & Fabrication - Before

x x xx
BEFORE KAIZEN: x
Area: 4640 sq ft xxx
Operator Travel: 3696 ft x
Product Travel: 1115 ft

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 Reproducibility &
Repeatability (Gage R&R)

“Data is only as good as the system that measures it. If you

can’t measure it, you can’t manage it.”
 The Science of Measurement

“I often say that when you measure what you are speaking
about and express it in numbers, you know something about it.”
LORD KELVIN,
1891

He clearly stressed that little progress is possible in any field of

investigation without the ability to measure. The progress of
measurement is, in fact, the progress of science.

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 Objectives

 Measurement Systems Analysis

 Key Terminology
 Variable Gauge R&R
• A tool for estimating measurement system error
• How to conduct a gauge R&R
• Minitab Output
 Gauge R & R Study Exercise

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 Measurement System Error

Precise but Accurate but Not accurate Accurate

not accurate not precise or precise and
precise

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 Definitions

 Variable Data
• Continuous measurements such as length, voltage, viscosity
 Repeatability
• Variation in measurements obtained with one gage when used
several times by one appraiser.
 Reproducibility
• Variation in the average of the measurements made by different
appraisers using the same measurement system.

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 What is GR&R?

Measurement Systems Analysis

How good is our
measurement
system?
2T = 2p + 2m

2T = Total Variance

2p = Process Variance
2m = Measurement Variance

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Gauge R&R Allows Control of the Measurement
System

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 Control Chart
 X bar Charts: An x bar chart is used to monitor the average
value, or mean, of a process over time. For each subgroup, the
x bar value is plotted. The upper and lower control limits define
the range of inherent variation in the subgroup means when the
process is in control.

 R Chart: An R Chart is a control chart that is used to monitor

process variation when the variable of interest is a quantitative
measure. Now, what does all this mean? These charts will allow
us to see any deviations from desired limits within the quality
process and, in effect, allow the firm to make necessary
adjustments to improve quality.

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 Example: GAGE R&R

 Manufacturing 30,000-foot-level metric (KPOV): A project was

to improve the capability/performance of the diameter for a
manufactured product. An MSA (Measurement System
Analysis) was conducted of the measurement gage.

 Five samples selected from a manufacturing process are to

represent the normal spread of the process.

 Two appraisers who normally do the measurements are chosen

to participate in the study.

 Each part is measured three times by each appraiser.

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Example: GAGE R&R

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Example: GAGE R&R

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EXAMPLE 12.1: GAGE R&R

Use Minitab for Gauge R&R

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Example : GAGE R&R

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Example 12.1: GAGE R&R

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Example 12.1: GAGE R&R

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Example 12.1: GAGE R&R

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 Variable Gauge R&R - What’s Involved?

3 Appraisers

1 Gauge

10 Parts

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 How to set up a Variable GRR Study

 Preparation & Planning

 1 Gauge
 3 Operators (Appraisers)
 10 Parts
 3 Trials
 Randomize the readings
 Code the parts (blind study) if possible
 3 Ops x 10 parts x 3 trails = 90 Data Points
 4 Ops x 10 parts x 3 trails = 120 Data Points

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Minitab Gage R&R Graphical Output

The number of distinct categories of

parts that the process is currently able
to distinguish (Must distinguish at
least 5 types of parts)

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 Acceptability Criteria

R&R Indices
 10% Acceptable Measurement System
10% - 30% May be acceptable based upon application,
cost of measurement device, cost of repair,
etc.
 30% Not acceptable. Measurement system
needs improvement.

Number of Distinct Categories Index

1 Unacceptable. One part cannot be
distinguished form another.
2-4 Generally unacceptable
 5 Recommended

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Minitab Gage R&R Graphical Output

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Minitab Gage R&R Graphical Output

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Minitab Gage R&R Graphical Output

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Minitab Gage R&R Statistical Output

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Minitab Gage R&R Statistical Output

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