Professional Documents
Culture Documents
Table Of Contents
Mean = 22.4
Process Performance
Essential Terms
45
40
35
30
25
20
15
10
Variation
11 42
units
5
0
1
10
11
12
13
14
15
Measurement Number
Driving Factors
We are facing dramatic changes due to the
influence of information technology and global
competition
Our customers have more choices and demand
and expect more from our products and services
We are continually being asked to do more with
less, to work in different ways, to provide better
service, to provide better quality at smaller cost,
etc.
Clockspeed
Importance of Data
Data are the link between the doing and
improving activities
Without data:
Everyone is an expert; discussions create more heat then light
Historical memory is poor
Difficult to get agreement on:
What the problem is
What success looks like
Progress made
Lack of training
Threat to authority
Fear of statistics
Too busy
Unwillingness to change
Dont want to be confused by the facts
Example
Here are some of our own processes:
S
Manufacturing
-Nypro
-Epson
-AT&S
-Plastics
-LCDs
-PCBs
-Inspection
-SMT
-BLT
-Assembly
-Blackberry!
-T-Mobile
-Verizon
-End-Users
Root cause
analysis
-Blackberry
user
-Faulty device
-Information
about problem
or question
-7-step problem
solving method
-Interaction with
other teams
-New
information on
device failures
-Final report
Recruitment
-People
submitting
resumes
-OD
-Resumes
-Developing
criteria
-Interviews
-Evaluation
-Potential
candidates
-Ultimately, new
employee
-My manager
-Rest of RIM
Laboratory
Measurement
- People who
want
measurements
- Devices for
measurement
-Measurement
and evaluation
-Report
generation
- Information
and analysis of
measurements
- People who
want
measurements
Process Measures
Key to successful management and improvement
of processes
Tracking process measures over time will enable
analysis:
Assessing current performance levels
Determining if the process has shifted compared to
historical data
Determine if minor or major adjustments to the process
are needed
Predict future performance
Identify CTQs
Critical to Quality Characteristics:
Features that significantly impact the final cost,
performance, or safety of a product when the CTQs vary
from nominal
Gives understanding of what quality looks like to
customer
Allow team to validate that the project is focused on
important issues to the customer
Need accurate definitions of CTQs
After identification of CTQs these will be the parameters
used for measuring
Number of Hours
30
25
20
15
10
5
0
1
Measuremnt Number
10
11
12
13
Common-Cause Variation
Always Present
Process is unstable
Process is stable
Problem
Solved?
Yes
Follow Up Training
Problem Solving
What Is a Problem?
A Problem Is Defined As a Discrepancy Between an Existing
Standard or Expectation and the Actual Situation.
Standard
Discrepancy
LEVEL
Actual
TIME
Problem Solving
Growing
Propriety Information, Strictly Confidential, Internal Use Only
Fishbone Diagram
Pareto Chart
Problem
Histogram
Problem
5 Whys
Run Chart
Why
Why
Why
Why
Why
Root Cause
Scatter Plot
Control Chart
Pictograph
Containment
Pareto Analysis
Containment Process
5-Why Analysis
Decision Matrix
Control Charts
Descriptive Statistics
Gantt Chart
Check Sheet
Trend Chart
Error-Proofing
Is / Is not (Stratification
Analysis)
Brainstorming
Histogram
Lessons Learned
Database
Flow-Charting
Work Flow Analysis
Benchmarking / Best
Practices
Fault Tree Analysis
Scatter Diagram
Supplier Input Process
Output Customer
(SIPOC)
Concentarion Diagram
Design Of Experiment
Linear Regression
Analysis
Hypothesis Testing
Paynter Chart
Capability (Quality0 Index
Multi-vari
Process Flow Map
P-Diagram / Parameter
Design
Quality Function
Development: Voice of
the Cutomer, Voice of the
Process
Design Of Experiment:
Full Factorial, Fractional
Factorial
Test to Failure
Statistical Tolerancing
Control &
Standardize
PDCA
Pareto Chart
5 Why Analysis
The following example demonstrates the basic process of 5 Why:
Problem: Car will not start. (ICAR Problem description)
Why? - The battery is dead. (first why)
Eg. today we might just change the battery..
Why? - The alternator is not functioning. (second why)
Why? - The alternator belt has broken. (third why)
Why? - The alternator belt was well beyond its useful service life
and has never been replaced. (fourth why)
Why? - I have not been maintaining my car according to the
recommended service schedule. (fifth why, root cause)
Why 5 Why??? Its simple, its logical, its effective and everyone can do it.
Isnt it time we
Stop swatting at flies and fix the hole in the screen door Stephen R. Covey
How is it done?
Decide which quality characteristic, outcome or effect
you want to examine (may use Pareto chart)
Backbone draw straight line
Ribs categories
Medium size bones secondary causes
Small bones root causes
Flow Chart
Exercise
Prioritization Matrices
* Prioritization Matrix is a
method to encourage the team
approach for comparing each
criterion and option to every
other criterion and option in a
decision making situation.
* It facilitates team decision
making and minimizes the
effect of individual biases and
assumptions
Tree Diagram
Recognize the
Efforts of the
Team
Define
the
Problem
Implement
& Verify
Interim
Solutions
Problem
Description
Lessons
Learned
Prevent
Recurrence of
the Problem/
Root Cause
Data Collection
& Analysis
Define
Standardize
Improvements
Measure
Control
Act
Check
Plan
Root Cause
Analysis
Analyze
Do
Improve
Evaluate
Results
PDCA
DMAIC
7 Step
Identify &
Verify Root
Cause
Implement &
Validate
Permanent &
Corrective
Actions
8D
Propriety Information, Strictly Confidential, Internal Use Only
Solution
Planning &
Implementation
Choose &
Verify
Permanent
Corrective
Actions &
Preventive
Actions
Problem description
S204 open pin was the top #1 SMT defects on Tachyon II board in the week of Aug 23
It contributed 34% to the total SMT defects
Manpower
Material
Bad solder
paste
Reflow
profile
Part poorsolderability
Stencil
aperture
blocked
Not enough
heat
Part pin
Coplanarity
Issue
S204 Open
Pin
Pad design
PCB Design
S201 too
closed to the
shield
Placement
issue
Oven need
calibration
Design
Machine
The reason why we didnt have this problem before is that, due to RF concerns, the
pad was modified for the new rev board
Eliminate
S204 Open
Pin Defects
Long term
solution
Modify the
PCB design
Add solder
mask on pad
Decision
When
Who
Next
Proto
Surinder
Next
Rev
PCB
Designe
rs
N/A
N/A
Change pad
layout