Mini Tab 14 One Day Training 39403

Minitab 14 Quality Statistics
A person without data is merely expressing an opinion.
Created by Paul White - Aston Martin Six Sigma Department
Introduction
Name Department Six Sigma / Minitab experience Why are you here today?
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Training Topics

What is Six Sigma? Introduction to Minitab Version 14 Manipulation of data Basic statistics Graphs Quality tools Measurement System Analysis R & R Control charts Normality testing Capability analysis Hypothesis Testing
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What is Six Sigma?

The function of a statistician is to make predictions, and thus to provide a basis for action W.E Deming
Is 99% Good Enough?

3.8-Sigma 99% Good
20,000 lost articles of mail per hour Unsafe drinking water for almost 15 minutes each day 5,000 incorrect surgical operations per week 1 missed putt per 9 holes of golf 10,700 defects per million opportunities
6-Sigma 99.99966% Good

Seven articles lost per hour Unsafe drinking water one minute every seven months 1.7 incorrect operations per week
1 missed putt per 163 years
3.4 defects per million opportunities

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Goals of Six Sigma

Reduce defects. Improve process capability. Improve customer satisfaction. Increase shareholder value. This ensures we are competitive, provides future security and opportunity for growth.
100% Inspection
100% Inspection Does it work?
F-Test Finished files are the results of many years of sceintific studies combined with the experience of many years of effort
F-Test
How many did you see? Have another look!
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F-Test
Did anyone change their mind?
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F-Test
Did you spot anything else?
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F-Test
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100% Inspection
100% Inspection Does it work?
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DMAIC Improvement Model
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Introduction to Minitab
Statisticians are people with tears wiped from their eyes
Introduction to Minitab
The 3 Minitab views - session folder, worksheet folder, project folder. 3 types of data entry numbers, text and dates. Importing text from other sources Creating, opening and saving projects and worksheets.
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Session and Worksheet Folders
The 2 main windows in Minitab The session folder & worksheet folder.
Select different views using icons
Session folder
Worksheet folder
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Project Folder
Multiple worksheets can be opened within the Select project manager same project.
File /New / New worksheet
Multiple worksheets
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3 Types of data
Minitab stores numbers, text and dates.
Numbers No symbol in column header, right aligned in cell
Date D in column header, left aligned in cell
Text T in column header, left aligned in cell
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Numeric Data Types

Attribute Variable
Caliper NO-GO GO
SHIPPING ORDER
QTY 1 3 10 2 UNIT $10.00 $1.50 $10.00 $5.00 DESCRIPTION TOTAL $10.00 $4.50 $10.00 $10.00
Error
Time
FAIL
PASS
TEMPERATURE
Thermometer
Electrical Circuit
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e Advantage of Variable Data
Attribute vs Variable Data
Variable
ibu Attr
te
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Attribute vs Variable Data

Variable Data Available earlier in the process, before defects occur. Illustrates short term trends allowing immediate action. A small amount of data is required to draw conclusions (minimum 30 individual readings). Attribute Data Defect related, only after the fault has occurred. Only illustrates long term trends. A large amount of data is required to draw conclusions (minimum 50 subgroups) Sometimes this is the only data available.
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Importing text from other sources
Easiest way is to copy & paste. However, an import function is available: File / other files / import special text.
Select data from another source (such as Excel) and copy to clipboard. Select destination cell in Minitab and paste from clipboard
Tip! Always title each column in the cell below the column reference number. this will make later analysis easier to interpret as the graphs will include your column description.
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Saving projects and worksheets
Save projects to correct destination.
File / Save project as
Change default saving location
Rename with relevant filename and date
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Manipulating Data
Facts are stubborn things, but statistics are more pliable
Manipulating Data
Erasing columns and rows Stacking columns and rows Transposing columns
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Erasing data
Erasing columns and rows
Select column and right click mouse
Delete cells
Tip! Undo function is available on the toolbar

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Stacking columns
Data / Stack / Stack Columns
Select columns to stack
Select stacked destination and subscripts
Click OK
Tip! Always store subscripts when stacking data, this will copy the column description to the adjacent data cell. This makes future analysis easier, to discriminate between data sets.
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Transposing data
Switch the data pattern from columns to rows.
Data / Transpose columns
Select columns to transpose
Select destination option
Click OK
Tip! If your data is already in Excel you can use the paste special function to transpose from columns to rows and vice versa! Use Minitab & Excel interchangeably to conduct data analysis.
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Basic Statistics
Statistics should be used the way a drunk uses a lamp post, more for support than enlightenment
Basic Statistics
Descriptive statistics Inferential statistics Graphical summary
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Descriptive Statistics
Stat / Basic statistics / display descriptive statistics.
Stat /Basic statistics / Display descriptive statistics
Select variables, click OK
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Descriptive Statistics
Descriptive statistics describe the sample we have gathered, tells us what is.
Session window output
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Measures of Average
Mean:
Calculated average. Sum of all individual values, divided by the number of samples.
Mode:
Most frequently occurring value.
Median:
The middle number when the values are sequentially arranged.
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Measures of Average
Mean
5, 5, 4, 2, 1, 1, 4, 5, 3, 2.
Mean = 3.2
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Measures of Average
Mode
5, 5, 4, 2, 1, 1, 4, 5, 3, 2.
Mode = 5
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Measures of Average
Median
5, 5, 4, 2, 1, 1, 4, 5, 3, 2.
Median =
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Measures of Average
Median
1, 1, 2, 2, 3, 4, 4, 5, 5, 5.
3+4 2 = 3.5
Median = 3.5
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Measures of Average
5, 5, 4, 2, 1, 1, 4, 5, 3, 2.
Mean = 3.2 Mode = 5 Median = 3.5
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Graphical Summary
Stat / Basic statistics / Graphical summary.
Stat / Basic Statistics / Graphical Summary
Select variable
Click OK
Tip! Note the confidence level of 95% in the option window. This applies to the inferential statistics that will be displayed in the graphical summary.
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Graphical Summary
Descriptive statistics describe the sample we have gathered, tells us what is. Inferential statistics allows us to infer about the population, tells us what probably is. Inferences are never definite, only stated with a degree of confidence.
Summary for Tool 1
A nderson-D arling N ormality Test A -S quared P -V alue M ean S tD ev V ariance S kew ness Kurtosis N M inimum 1st Q uartile M edian 3rd Q uartile M aximum 9.922 9.915 9 5 % C onfidence Inter vals
Mean Median 9.90 9.95 10.00 10.05 10.10 10.15
0.19 0.902 10.014 0.321 0.103 -0.003050 -0.106782 50 9.310 9.800 10.025 10.240 10.839 10.105 10.126 0.400
Normality test
Descriptive statistics
9.6
10.0
10.4
10.8
95% C onfidence Interv al for M ean 95% C onfidence Interv al for M edian 95% C onfidence Interv al for S tD ev 0.268
Inferential statistics
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Standard Deviation
Standard Deviation refers to the collective deviation of the entire data set
High Standard Deviation High Variability
Low Standard Deviation Low Variability
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Standard Deviation
5.26, 6.96, 5.90, 6.47, 6.14. xbar = 6.146 r = 1.70
r = 6.96 5.26 = 1.70 xbar = 6.146

-0.006
x
0.324
x
0.814
x-0.246 x
-0.886
x 7
5.26
5.5
5.9
6.14
6.47
6.5
6.96
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Standard Deviation
Calculating standard deviation is best shown in table format: (xbar = 6.146) Data x - xbar (x xbar)2
5.26 6.96 5.90 6.47 6.14

S=
-0.886 0.814
-0.246 0.324 -0.006
0.784996 0.662596 0.060516 0.104976 0.000036 = 1.61312
(x X) n-1
_2
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Standard Deviation
We can now use the formula: S=
S=
(x X) n-1 1.61312 4
_2
S=
0.40328
S = 0.635 (to 3 s.f.)

Tip! The square of the standard deviation is the variance.
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Normal Distribution
The distribution of area as a percentage:
0.135% 99.73% 95.44% 68.26% 0.135%
-3s
-2s
-1s
+1s
+2s
+3s
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Graphical Summary
Descriptive statistics describe the sample we have gathered, tells us what is. Inferential statistics allows us to infer about the population, tells us what probably is. Inferences are never definite, only stated with a degree of confidence.
Summary for Tool 1
Mean Median 9.90 9.95 10.00 10.05 10.10 10.15
0.19 0.902 10.014 0.321 0.103 -0.003050 -0.106782 50 9.310 9.800 10.025 10.240 10.839 10.105 10.126 0.400
Normality test
Descriptive statistics
9.6
10.0
10.4
10.8
Inferential statistics
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Graphs
A picture tells a 1,000 words
Graphs

Time series plot Histogram
Boxplot
Editing graphs Update graphs in real time
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Time Series Plot
Graph / Time series plot
Graph / Time Series Plot
Select simple option
Tip! Minitab 14 allows multiple time series plots on one chart if required!
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Time Series Plot
Graph / Time series plot

Select variable to plot Select time scale
Select stamp
Select stamp column
Click OK
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Tool 1
10.0 10.5 11.0 9.5
01/01/2006 05/01/2006
10/01/2006
Time Series Plot
15/01/2006
20/01/2006
Time Series Plot of Tool 1
Time series plot displays the trend over time
Date
25/01/2006 30/01/2006 04/02/2006 09/02/2006 14/02/2006 19/02/2006
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Histogram
Graph / Histogram.
Graph / Histogram
Select simple option
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Histogram
Graph / Histogram.
Select variable to graph
Click OK
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Histogram
A histogram shows the distribution of the data.

Histogram of Tool 1
16 14 12
Frequency
10 8 6 4 2 0 9.4 9.6 9.8 10.0 10.2 Tool 1 10.4 10.6 10.8
Tip! When copying graphs into other file formats, such as the 6 Panel template. Use edit / paste special and paste the graph as a picture to reduce the file size.
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Boxplot
Graph / Boxplot
Graph / Boxplot
Select Multiple Ys - Simple Option
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Boxplot
Graph / Boxplot
Select variables
Click OK
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Boxplot
A boxplot is a birds eye view of a histogram.

Boxplot of Tool 1, Tool 2, Tool 3
14 13 12 11
Whisker Median Inter quartile range middle 50%
Data
10 9 8 7 6 Tool 1 Tool 2 Tool 3
Tip! A boxplot is a very good tool to compare multiple distributions.

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Editing Graphs
Minitab 14 allows advanced graphical editing features.
Double click graph on area to be edited (as per Excel approach)
Use options box to edit graphical features
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Editing Graphs
Minitab 14 allows advanced graphical editing features.

Boxplot of Tool 1, Tool 2, Tool 3
14 13 12 11
Data
10 9 8 7 6 Tool 1 Tool 2 Tool 3

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Update Graphs in Real Time
Minitab 14 allows graphs to be updated as the data source changes.

A green cross indicates that the graph reflects the data source
If the data source changes, a yellow circle indicates that the graph does not reflect the data source.
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Graphs can be updated automatically or upon request.
Right click graph and select update graph now
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A green cross indicates that the graph has been updated.
Tip! The update graph function can be used on all graphs in the graph menu (except stem & leaf) and all control charts!
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Quality Tools
Statistics may be defined as a body of methods for making wise decisions in the face of uncertainty W.A.Wallis
Quality Tools

Pareto chart Cause and Effect Diagram Multi-Vari Chart
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Quality Tools
Stat / Quality Tools / Pareto chart
Stat / Quality Tools / Pareto Chart
Select columns for labels and frequencies
Click OK
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Quality Tools

Pareto charts are based on the 80 / 20 rule. Used to prioritise focus.

Pareto Chart of Characteristic
350 300 250 200 150 100 50
Widget Air Vent Poor Fit Camber adjustment Rear bumper poor fit Glovebox poor fit Wind noise Frt Door Water leak Rr Door Paint Defect - LH door Fascia - Poor Fit Flat battery Other
Characteristic
100 80 60 40 20 0
Cumulative frequency
Percent
Count
Faults
Count Percent Cum %
100 31.2 31.2
39 12.1 43.3
25 7.8 51.1
23 7.2 58.3
22 6.9 65.1
21 6.5 71.7
20 6.2 77.9
20 6.2 84.1
19 5.9 90.0
17 5.3 95.3
15 4.7 100.0
Results
Tip! Pareto charts should also be produced using COPQ for each defect.
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Cause & Effect Diagram
Conduct team brainstorm Stat / Quality tools / Cause & Effect Diagram
Stat / Quality Tools / C&E Diagram
Enter causes in columns or text
Click OK
Tip! Use 5 why analysis to drill down to root cause. Minitab 14 allows multiple sub branches to be entered in the option box.
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Cause & Effect Diagram
Use C&E to understand relationship between inputs and outputs.

BIW Door Panel
Measurements Material Personnel
G auge calibration N o gauge R&R N o measurement procedure
Burr on panel P anel dimensions Damaged panels
N ew Labour M aterial Handling P oor training
Panel Distortion
P oor lighting Temperature Humidity S tandardised Work S tock Rotation Build sequence S hims missing Location peg damage Wear on tool
Environment
Methods
Machines
Tip! The Six Sigma team should score the relationship between inputs & outputs using the C&E matrix to prioritise team focus.
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Multi-Vari Chart
Graphical analysis of means for different factors. Stat / Quality tools / Multi-Vari Chart
Stat / Quality Tools / MultiVari Charts
Enter response variable (y) and factor levels (x)
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Multi-Vari Chart
Stat / Quality tools / Multi-Vari Chart

Multi-Vari Chart for Torque by Supplier - Tool Number
56 55 54 53
Supplier Atlas Copco Bosch
Mean values displayed for each factor level
Torque
52 51 50 49 48 1 2 Tool Number 3
Displays main effects and interactions.
Multi-Vari charts can be used during a screening DOE to reduce KPIVs to the critical few.
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Measurement Systems Analysis

When you can measure what you are talking about and express it in numbers, you know something about it. But, when you cannot express it in numbers, your knowledge is of the meagre and unsatisfactory kind Lord Kelvin
Measurement Systems Analysis
MSA Overview Attribute Gauge R&R Variable Gauge R&R
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Measurement System Analysis
The purpose of Measurement System Analysis (MSA) is to ensure the information collected is a true representation of what is occurring in the process. MSA is the evaluation of measurement system variation in comparison to process variation.
Process Variation Measurement System Variation
MSA validation is required before commencing data collection.

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R
& R Repeatability and reproducibility.
Repeatability
Same
refers to the inherent variability of the measurement system.

operator Same part Same condition
Repeatability
is the within variation.

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R
Reproducibility
refers to the variation that occurs when different conditions are used to take the measurement.
Different
operator Different parts Different conditions

Reproducibility
is the between variation.

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R
Reproducibility
refers to the variation that occurs when different conditions are used to take the measurement.
Different
operator Different parts Different conditions

Reproducibility
is the between variation.

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Data Types
Attribute Variable
Caliper NO-GO GO
SHIPPING ORDER
QTY 1 3 10 2 UNIT $10.00 $1.50 $10.00 $5.00 DESCRIPTION TOTAL $10.00 $4.50 $10.00 $10.00
Error
Time
FAIL
PASS
TEMPERATURE
Thermometer
Electrical Circuit
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Attribute Gauge R & R Exercise

Scenario The process to stamp dots on a domino is highly variable. RFT data is required to evaluate process performance. Measurement system must be validated first.

Study Method 2 operators 2 measurements per operator 7 samples
N.B Only 7 samples used due to time constraints. A minimum of 30 samples required for Six Sigma projects.
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Measurement Procedure No. 1

Visually inspect all dominoes to identify samples with dots smaller than the master sample. Any non-conformance is considered a reject. Colour is of no consequence. You have been allocated 15 seconds to inspect each sample.
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Is the measurement system repeatable and reproducible?
What can be done to improve the measurement system?
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Measurement Procedure No. 2

Inspect all dominoes with the gauge provided. Ensure there are no spots smaller than the master sample. Any non-conformance is considered a reject. Colour is of no consequence.
You have been allocated 30 seconds to inspect each sample.
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Stat
/ Quality Tools / Attribute Agreement Analysis
Stat / Quality Tools / Attribute Agreement Analysis
Enter study information
Select data, samples and appraisers Click OK
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Attribute Gauge R & R Output

Graphical Output
Assessment Agreement
Date of study: Reported by: Name of product: 13/10/2006 Paul White BIW Panel Distortion
Session Window
Attribute Gage R&R Study Attribute Gage R&R Study for Result Within Appraiser Assessment Agreement
95.0% C I P ercent
Within Appraisers
100
80
Appraiser # Inspected # Matched Percent (%) Eric 7 7 100.0 ( 65.2, 100.0) John 7 7 100.0 ( 65.2, 100.0)
95.0% CI
Percent
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# Matched: Appraiser agrees with him/herself across trials.

40
20
Between Appraisers Assessment Agreement # Inspected # Matched Percent (%) 95.0% CI 7 7 100.0 ( 65.2, 100.0) # Matched: All appraisers' assessments agree with each other.
0 Eric Appraiser John
Graph displays actual % result and 95% confidence interval
Session window displays detailed results
Tip! A Kappa statistic is available to determine correlation within & between appraisers.
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Attribute Gauge R & R Summary
A typical Attribute Gauge R&R Study includes: 1 to 3 operators (measurement takers) 30 samples 2 to 3 trials (measurements) of each sample by each operator Samples that are typical of the process (pass & fail) An acceptable study is where 100% agreement between each operator and the Master Attribute has been achieved (if a Master Attribute is included). Analysis of the results from a failed study can identify where improvements need to be made: Operator training Standardised inspection process Measurement Procedure
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Variable Gauge R & R
R&R studies are conducted to ensure the data collected is a true representation of what is occurring in the process. The purpose of variable gauge R&R studies are to calculate the amount of measurement system variation in comparison to the process variation and the process tolerance.
A typical variable gauge R&R Study includes: 1 to 3 operators (measurement takers) 10 samples 2 to 3 trials (measurements) of each sample by each operator Samples that are typical of the process (in spec & out of spec)
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Variable Gauge R & R Exercise

Scenario Gandalfs Castle has been under siege from the Orcs for several days and he seems to be losing the battle. The main problem is that Gandalfs long range weapons the catapults keep missing the Orcs who are sheltering behind a ridge 200m away. They keep shooting either too long or too short. Gandalf wants to improve the accuracy of his catapults. But, before he can improve the accuracy Gandalf must ensure he can measure the distance repeatedly & reproducibly. Exercise Conduct variable r&r study on catapult shot length. 10 shots (or samples), 2 operators, 2 measurements per operator Record results on flip chart.
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Stat / Quality Tools / Gage Study / Gage R&R Study (Crossed)
Tip! A Nested Gage R&R Study is available for a destructive measurement study.
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Enter part no. Operator & Measurement Data
Tip! Always enter the process tolerance via the options box. It is imperative to compare measurement system variation against the process variation & the process tolerance.
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Variable R & R Pass Criteria

Gage R&R Study ANOVA Method Gage name: Tin Foil Reported by: Paul White Date of study: 16th February 2006 Tolerance: 0 +/-0.05 Source Total Gage R&R Repeatability Reproducibility Part-to-Part Total Variation Variance 19.62 17.73 1.89 1212.92 1232.55 StdDev (SD) 4.4299 4.2110 1.3752 34.8270 35.1076 %Contribution (of Variance) 1.59 1.44 0.15 98.41 100.00 Study Var (5.15*SD) 22.814 21.687 7.082 179.359 180.804 %Study Var (%SV) 12.62 11.99 3.92 99.20 100.00
% Contribution must be < 9%
Source Total Gage R&R Repeatability Reproducibility Part-to-Part Total Variation
% Study Variation must be < 30%
Distinct categories must be >=5
Number of distinct categories = 11
Tip! Gauge calibration does not negate the requirement to conduct an MSA. Calibration confirms the gauge is accurate, MSA ensures the whole measurement system is repeatable and reproducible.
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Variable R&R Pass Criteria
% Contribution Measurement System Variation as a percentage of Total Observed Process Variation (Variance)
% Study Variation
Measurement System Standard Deviation as a percentage of Total Observed Process Standard Deviation (using Standard Deviation)
% Tolerance Measurement Error as a percentage of Tolerance
Number of Distinct Categories Less than 5 indicates Attribute conditions

% Contribution R Y G
> 9% Unacceptable
2-9% Acceptable < 1% Good
% Study Variation (Process Control) R Y G

> 30% Unacceptable 11-30% Acceptable < 10% Good
% Tolerance (Product Control) R Y G

> 30% Unacceptable 11-30% Acceptable < 10% Good
# of Distinct Categories R Y G
< 5 Unacceptable
5-10 Acceptable > 10 Good
It is desirable to have ALL indicators
Green
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Variable R & R Diagnostic Graphs
Review the diagnostic graphs to identify sources of measurement system variation.

Gage R&R (ANOVA) for Measurement
Gage name: Date of study : V ernier 13/06/2006
Components of Variation
100
Percent
% Contribution % Study Var
Reported by : Tolerance: N/A
Paul White
Overall health of Measurement System
Measurement by Part
200
50
100
Repeatability & gauge linearity

1 2 3 Part 4 5
0 Gage R&R Repeat Reprod Part-to-Part
R Chart by Operator
30 1 2 200 UCL=17.32 _ R=5.3 LCL=0
Sample Range
Measurement by Operator
Repeatability
15
100
Reproducibility across operators

1 Operator 2
Xbar Chart by Operator

200
Sample Mean
2 200 _ _ UCL=109.4 X=99.5 LCL=89.5

Average
Operator * Part Interaction

Operator 1 2
Reproducibility
100
100
Reproducibility across parts
3 Part
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Catapult MSA
Analyse MSA data collected from catapult

Discuss results with team Present findings to class
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Variable Gauge R & R Summary
A typical Variable Gauge R&R Study includes: 1 to 3 operators (measurement takers) 10 samples 2 to 3 trials (measurements) of each sample by each operator Samples that are typical of the process.
An acceptable study is where the total gauge R&R is less than 30% of the process spread or tolerance. Distinct categories must be > = 5.
Analysis of the results from a failed study can identify where improvements need to be made: Standardised inspection process Operator training Measurement Procedure
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Summary MSA
At conclusion of the MSA, the Six Sigma team should know:
The measurement system is capable of gathering data that accurately reflects variation in the process. If there is measurement error, how big it is and a method of accounting for it. Measurement increments are small enough to show variation. Sources of measurement error have been identified
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Control Charts
Statistics is not a discipline like physics, chemistry or biology where we study a subject to solve problems in the same subject. We study statistics with the main aim of solving problems in other disciplines." - C.R. Rao
Control Charts
Introduction to Control Charts Control Limits In Control Out of Control Attribute control charts Variable control charts
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Control Charts
A control chart is a run chart with upper and lower control limits (not specification limits).
Control charts are used to detect and monitor process variation over time. Distinguishes between special and common cause. Data must be collected in real time.
It is important to record the voice of the process. Ensure all process events / changes are logged.
Can be used as a reference point to evaluate the impact of process changes. Serves as a tool for ongoing control.
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Control Limits
Control limits are calculated from the data from the process.
Upper Control Limit
9 8 7 5 4 3 2 1
Average
+/- 3 S.D 99.73%
Lower Control Limit
Control limits are not specification limits!
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In Control
A process is in control when all of the values are randomly spread between the control limits. To be in control means the process is consistent.
9 8 7 5 4 3 2 1
102
Out of Control
A process is out of control when one value exceeds the control limits. This is special cause variation.
9 8 7 5 4 3 2 1
103
Out of Control
A process is out of control when 9 readings fall on one side of the process average but inside the control limits. This out of control condition indicates a process shift.
9 8 7 5 4 3 2 1
104
Out of Control
A process is out of control when 6 readings in a row, display a continuous trend in an upward or downward direction. This out of control condition indicates process drift / wear.
9 8 7 5 4 3 2 1
SPC charts require real time data collection.

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Out of Control Rules
Tools / Options / Control Charts / Define Tests
Tools / Options/ Control Charts / Define Tests
Tests for special cause
Tip! Minitab uses Nelsons Test for Special Cause as they improved on the Western Electric Rules by aligning the probabilities of false alarm rates.
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Control Chart Selection

Start Attribute Is data Attribute or Variable? Variable
Attribute
Variable
Defects or Defective?
Is the subgroup sample size greater than 10?
Yes
Average & Standard Deviation - Xbar & S
Defective
Defects
No
Is the subgroup sample size contstant?
Is the amount of opportunities for defect contstant? Yes No
Is the subgroup sample size greater than 1
Yes
Average & Range - Xbar & R
Yes
No
No Individual & Moving Range - I & MR
p-chart
np-chart
u-chart
c-chart
Tip! There are other control charts available for special situations. A Cusum chart can be used when trying to detect small fluctuations in a process.
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P Chart
Stat / Control Charts / Attribute Charts / P-Chart
Stat / Control Charts / Attribute Charts/ P-Chart Select column with defective amounts
Select column with subgroup sample sizes in. I.e. Daily or weekly volume
Select OK
Tip! Use the scale options to display the date on the chart x-axis.
108
P Chart
A P Chart displays the proportion defective.

P Chart of No of cars with Defective Vent
0.4
1
0.3
Proportion
UCL=0.2338 0.2 _ P=0.1097
0.1
0.0
22/01/2006 24/01/2006 26/01/2006 28/01/2006 30/01/2006 01/02/2006 03/02/2006 05/02/2006 07/02/2006 09/02/2006
LCL=0
Date Tests performed with unequal sample sizes
Tip! The P Chart is based on the Binomial distribution pass or fail.

109
U Chart
Stat / Control Charts / Attribute Charts / U-Chart
Stat / Control Chart / Attribute Charts / U Chart

Select column with defects data
Select column with subgroup sample sizes in. I.e. Daily or weekly volume
Click OK
110
U Chart
A U Chart displays the no of defects per unit.

U Chart of No of Air Vents Defects
0.6
1
Sample Count Per Unit
0.5 0.4 0.3 0.2 0.1 0.0

22/01/2006 24/01/2006 26/01/2006 28/01/2006 30/01/2006 01/02/2006 03/02/2006 05/02/2006 07/02/2006 09/02/2006
UCL=0.2732 _ U=0.1300 LCL=0
Unequal subgroup sample sizes will create castellated control limits
Date Tests performed with unequal sample sizes
Tip! The U Chart is based on the Poisson distribution how many defects per item.
111
Variable Control Charts

Accuracy describes Centering Precision describes Spread
112
Individual & Moving Range Chart
Stat / Control Chart / Variables for Individuals / I&MR
Stat / Control Chart/ Variables for Individuals / I&MR
Select column with measurement data
Click OK
Tip! Always title your chart using the Labels option box. charts should have a title to aid reader interpretation.
All
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Individual & Moving Range Chart
I & MR chart shows the trend of individual data readings over time.
I-MR Chart of Tool 1
11.0 U C L=11.039
10.5 10.0 9.5 9.0

01/01/2006 06/01/2006 11/01/2006 16/01/2006 21/01/2006 26/01/2006
_ X=10.014
LC L=8.988 Date
31/01/2006 05/02/2006 10/02/2006 15/02/2006
Displays the trend over time of individual readings. This part of the chart shows the accuracy of the process .
Individual V alue
1.2
U C L=1.260
0.9 0.6 0.3 0.0

01/01/2006 06/01/2006 11/01/2006 16/01/2006 21/01/2006 26/01/2006
__ M R=0.386
LC L=0 Date
31/01/2006 05/02/2006 10/02/2006 15/02/2006
Displays the difference between consecutive readings. This part of the chart shows the precision of the process .
M oving Range
Tip! I & MR charts should be used to control process parameters (something that does not leave with the vehicle) I.e. Oven temperature, humidity, etc.
114
Average & Range Chart
Stat / Control Chart / Variables for Sub-Groups / Xbar & R
Stat / Control Chart/ Variables for Sub-Groups / Xbar & R
Select column with measurement data
Select subgroup size
Click OK
115
Average & Range Chart
Xbar & R chart shows the average reading per subgroup over time.
Xbar-R Chart of Tool 1
10.50 10.25 10.00 9.75 9.50 1 2 3 4 5 Sample U C L=1.629 6 7 8 9 10 LC L=9.569 _ _ X=10.014 U C L=10.458
Displays the trend over time of the subgroup average readings. This part of the chart shows the accuracy of the process .
Sample M ean
1.6
Sample Range
1.2 0.8 0.4 0.0 1 2 3 4 5 Sample 6 7 8 9 10 LC L=0 _ R=0.770
Displays the range for each subgroup. I.e. Difference between the highest & lowest reading within each subgroup. This part of the chart shows the precision of the process .
Tip! Xbar & R charts should be used to control process characteristics (something that leaves with the vehicle) I.e. Gap condition on a door, thickness of paint, wheel alignment etc.
116
Control Charts Summary
A control chart is a run chart with upper and lower control limits (not specification limits). Control charts are used to detect and monitor process variation over time. Distinguishes between special and common cause. It is important to record the voice of the process. Ensure all process events / changes are logged. Can be used as a reference point to evaluate the impact of process changes. Serves as a tool for ongoing control.
117
Normality Test
Are statisticians normal?
Normal Distribution
Data distribution characterized by a smooth, bell-shaped curve.
Normal Distribution
LSL
Target
USL
119
Normal Distribution
The distribution of area as a percentage:
0.135% 99.73% 95.44% 68.26% 0.135%
-3s
-2s
-1s
+1s
+2s
+3s
120
Normality Test
Stat / Basic statistics / Graphical summary.
Stat / Basic Statistics / Graphical Summary
Select variable
Click OK
Tip! Note the confidence level of 95% in the option window. This applies to the inferential statistics that will be displayed in the graphical summary.
121
Normality Test
It is imperative to conduct a normality test when assessing variable data. The normal distribution is described by the mean and standard deviation (the kurtosis & skewness provide additional info. about the shape of the curve). Control charts, process capability, 2 sample t-test and many other statistical procedures are based on the normal distribution.
Summary for Tool 1
Mean Median 9.90 9.95 10.00 10.05 10.10 10.15
Normality test P-Value > 0.05 indicates a normal distribution
0.19 0.902 10.014 0.321 0.103 -0.003050 -0.106782 50 9.310 9.800 10.025 10.240 10.839 10.105 10.126 0.400
9.6
10.0
10.4
10.8
122
Typical Distributions
The shape has a bell shape. It is symmetric.
The shape has two humps. It is bimodal.
The shape has a long tail. It is not symmetric.
The shape is flat.
There are one or more outliers.
123
Normality Test
Always conduct a normality test on variable data before conducting any statistical procedures. I.e. Process capability, hypothesis testing etc.
124
Process Capability
A knowledge of statistics is like a knowledge of foreign languages or of algebra; it may prove of use at any time under any circumstances
Process Capability
What
is Process Capability?
Process Capability. Process Capability.
Attribute
Variable
Sigma
as a measure of capability.
126
Process Capability
Capability analysis is a measure of how well a process is meeting the expectations of the customer.
It provides a current performance baseline for the process. It can be used as a reference point to evaluate the impact of process changes.
It can be displayed by several indices dependent on the data type.
127
Capability Indices
ATTRIBUTE DATA
DPO
DPU
DPMO
Cp
VARIABLE DATA
Cpk
Pp
Ppk
128
Attribute Process Capability
50 readings are required to calculate attribute process capability.

Determine if failure mode is defective or a defect.

Defective: Item is pass or fail. Defects: Item has multiple defects.
If item is defective use:
Defects Per Million Opportunities (DPMO).
If defects per item are being assessed, use:
Defects Per Unit (DPU).
129
DPMO
Calculate DPMO to identify baseline process capability. Unit (N) Defect (D) Opportunity (O) DPMO
DPMO = Total number of defects Total units Opportunities per unit D DPMO = N O 1,000,000
DPMO levels the playing field between different complexity processes. I.e. The supplier of a bolt may only have 2 opportunities for failure whilst the supplier of the incar entertainment system will have multiple opportunities due to a highly complex process.
130
1,000,000
DPMO in Minitab
Six Sigma / Product Report
Select Six Sigma / Product Report
Enter defects, units & opportunities
131
DPMO in Minitab
Six Sigma / Product Report
DPMO Metric DPMO graphical representation
Short-Term Sigma
It is imperative that the opportunities for failure are kept constant in the measure and the improve phases to validate the before and after condition. I.e. We are comparing apples with apples.
132
Variable Capability Analysis

Always assess for a stable process and a normal distribution before calculating variable capability indices. Normal Data: Cp / Cpk Pp / Ppk Non-Normal Data: Why is data non-normal? If non-normality is to be expected, conduct a box-cox transformation.
Cp / Cpk & Pp / Ppk indices are based on the normal distribution. Therefore, it is imperative to assess for stability & normality before calculating capability.
133

Variable process capability is the ability of a process output to fit between the maximum and minimum specification limits which have been defined by the customer/engineer.
Can this distribution from a process output fit between the specification limits of 5 1?
7
134

Capability is an assessment of: process spread as a ratio of the process tolerance. Cp / Pp
LSL USL
Process spread
Tolerance
Cpk / Ppk is the location of the process mean with respect to both process specification limits.
LSL
USL
Mean
135
Cp Examples
LSL USL
Cp =
Cp =
Cp =
Cp = 0.5
Cp =
1
136
Cpk Examples
LSL
USL
Cpkl = 1
X
Cpku = 1
Cpkl = 5
X
Cpku= 1
Cpku = 3
Cpkl = 1
X
Cpkl = 0.5
X
Cpku= 0.5
Cpkl = 3
Cpku = -1
137
Cp Example
Lower Specification Limit
Cp = 3.70
Upper Specification Limit
nominal
-3s
+3s
138
Cp Example
Once
Lower Specification Limit Upper Specification Limit
nominal How many times does the total process spread (+/- 3 standard deviations) fit inside the total tolerance?
139
Cp Example
Twice Once
140
Cp Example
3 times Twice Once
141
Cp Example
And 0.7
3 times Twice Once

nominal
How many times does the total process spread (+/- 3 standard deviations) fit inside the total tolerance?
142
Cp Example
Cp = 3.70
nominal
143
Cpk Lower Example

Once
nominal
How many times does half the total process spread (3 standard deviations) fit between the mean and the lower specification limit?
144
Cpk Lower Example

Twice
nominal
How many times does half the total process spread (3 standard deviations) fit between the mean and the lower specification limit?
145
Cpk Lower Example

3 Times
nominal How many times does half the total process spread (3 standard deviations) fit between the mean and the lower specification limit?
146
Cpk Lower Example

4 Times
147
Cpk Lower Example

5 Times
148
Cpk Lower Example

Cp = 3.70 Cpkl = 5.00
nominal
149
Cpk Upper Example

Once
nominal How many times does half the total process spread (3 standard deviations) fit between the mean and the upper specification limit?
150
Cpk Upper Example

Twice
151
Cpk Upper Example

And 0.4
152
Cp / Cpk Indices
Cp = 3.70 Cpku = 2.4
nominal
153
Group Exercise
Manually calculate Cp / Cpk
USL = 12 LSL = 8 Mean = 10.5 SD = 0.33
Cp =
Tolerance
6 x SD
Cpk L = Process Average - L.S.L.

3 x SD
Cpk U = U.S.L. - Process Average

3 x SD
154
Draw Process Capability
Use pencil & paper to draw the following distribution.

LSL = 8 Mean = 10.5 USL =12
10
11
12
13
1 Standard Deviation = 0.33

155
Relate Cp / Cpk to Archers Target

#1 #2
#3
#4
156
Normal Capability Analysis in Minitab
Stat / Quality Tools / Normal Capability Analysis
Select Stat / Quality Tools / Capability Analysis / Normal
Remember! It is imperative that stability and normality tests are conducted before calculating Cpk / Ppk indices.
157
Stat / Quality Tools / Capability Analysis / Normal
Select Column to assess
Enter subgroup size
Enter upper & lower spec. limits
Click OK
158
Stat / Quality Tools / Capability Analysis / Normal

Process Capability of Tool 1
LSL
P rocess Data LS L 8 Target * USL 12 S ample M ean 10.0137 S ample N 50 S tDev (Within) 0.331209 S tDev (O v erall) 0.322772
USL Within Overall

P otential (Within) C apability Cp 2.01 C P L 2.03 C P U 2.00 C pk 2.00 O v erall C apability Pp PPL PPU P pk C pm 2.07 2.08 2.05 2.05 *
Short Term Capability
Long Term Capability
8.4
O bserv ed P erformance P P M < LS L 0.00 P P M > U S L 0.00 P P M Total 0.00
9.0
9.6
10.2
10.8
11.4
12.0
E xp. Within P erformance P P M < LS L 0.00 P P M > U S L 0.00 P P M Total 0.00
E xp. O v erall P erformance P P M < LS L 0.00 P P M > U S L 0.00 P P M Total 0.00
For a process to be deemed capable, the Cpk must be >= 1.67 & the Ppk >= 1.33.
159
Cpk conversion to Sigma

To convert Cpk to Sigma we merely multiply the Cpk value by 3 to get the Sigma value. For example: Cpk of 1 = Sigma value of 3
Cpk of 0.5 = Sigma value of 1.5

By converting DPMO and Cpk to a Sigma value we can compare performance between attribute and variable processes.
The higher the Sigma value, the better the process.
160
Advantage of using Sigma

ATTRIBUTE DATA
DPO
DPU
DPMO
Cp
VARIABLE DATA
Cpk Ppk
Pp
}
161
Sigma is a universal measure of process performance.
Hypothesis Testing
Statistics is never having to say you are right
Hypothesis Testing
Hypothesis Testing Overview Hypothesis Testing - Proportions Hypothesis Testing Variances Hypothesis Testing - Means
163
Hypothesis Testing Overview
Provides objective solutions to questions which are traditionally answered subjectively.

Can be used to determine a difference in proportions, means and variances (standard deviation). Graphical analysis indicates a potential difference. Hypothesis testing infers a statistically significant difference (with a degree of confidence). A hypothesis test should always be conducted in the improve phase to validate the improvements to the baseline process capability.
164
Hypothesis Testing Roadmap

If P > 0.05, then fail to reject HO If P < 0.05, then reject HO Ensure the correct sample size is taken.
Levene's Test H O : 1 = 2 = 3 ... H A : i j fo r i j
(o r a t le a s t o n e is d iffe re n t)
Contingency Table HO: Data is normal HA: Data is not normal
START >>>
Variable or Attribute Data?
Attribute
1 or 2 Factor?
2 Factor
HO: FA Independent FB HA: FA Dependent FB Stat>Tables>Chi2 Test
Stat>Basic Stat>Normality Test or Stat>Basic Stat>Descriptive Statistics (graphical summary)
Variable
1 Factor 1-Proportion Test HO: P 1 = P t HA: P 1 P t

t = target
Stat>ANOVA> Homogeneity of Variance If HO is rejected, then you can go no further Fail to reject HO
2 or more levels
1, 2 or more levels?
Data not Normal
Is data normal?
1 Factor
1, 2 or more Factors?
1 or >1 Levels?
1 Sample 1 level to test
Stat>Basic Stat> 1-Proportion 2-Proportion Test
1 level
2 or more Factors Data Normal ANOVA or Multiple Regression 2 Samples 2 levels to test for each 2 levels Bartlett's Test HO: 1 = 2 = 3 ... HA: i j for i j
(or at least one is different)
2 levels or > 2 levels?
Test median or sigma?
HO: P 1 = P 2 H A: P 1 P 2 Stat>Basic Stat> 2-Proportion
2 levels only Mann-Whitney Test HO: M 1 = M2 HA: M1 M2 Stat>Non-parametric> Mann-Whitney 2 or more levels Test Medians
Test for sigmas Chi2 Test HO: 1 = t HA: 1 t

t = target
1, 2 or >2 levels?
More than 2 levels
Test for means
Stat>ANOVA>Homogeneity of Variance If sigmas are NOT equal, proceed with caution or use Welch's Test, which is not available in Minitab
1 level
1-Way ANOVA (assumes equality of variances) HO: m 1 = m 2 = m 3 ... HA: m i mj for i j

Mood's Median Test (used with outliers) H O: M1 = M 2 = M 3 ... H A : M i M j for i j

Stat>Basic Stat>Display Desc> Graphical Summary (if target sigma falls between CI, then fail to reject HO)
2 levels
Test for mean or sigma?
Test for means
Is Data Dependent?
Test for mean or sigma?
Test for means 1-Sample t Test HO: m1 = mt H A: m 1 m t

t = target
Stat>ANOVA>1-Way (then select stacked or unstacked data) No, Data is drawn independently from two populations Yes, Data is Paired
Stat>Non-parametric> Mood's test
1-Sample Wilcoxon or 1-Sample Sign HO: M 1 = Mt HA: M1 Mt

t = target
Kruskal-Wallis Test (assumes outliers) H O: M1 = M 2 = M 3 ... H A : M i M j for i j

Test for sigmas
Test for sigmas
Stat>Basic Stat> 1-Sample t Chi2 Test HO: 1 = t H A: 1 t

t = target
Stat>Non-parametric> and either 1-Sample Sign or 1-Sample Wilcoxon
2-Sample t Test F Test HO: 1 = 2 H A: 1 2 Stat>ANOVA> Homogeneity of Variance HO: m1 = m2 HA: m 1 m 2 Stat>Basic Stat> 2-Sample t (if sigmas are equal, use pooled std dev to compare. If sigmas are unequal compare means using unpooled std dev)
Paired t Test HO: m1 = m 2 HA: m 1 m2 Stat>Basic Stat> Paired t
Stat>Non-parametric> Kruskal-Wallis
Courtesy of Jeff Railton and Andy Batty of Seagate Technology. Revised: June 23, 1999
(Hypothesis Roadmap E.vsd)
Stat>Basic Stat>Display Desc> Graphical Summary (if target sigma falls between CI, then fail to reject HO)
165
Hypothesis Testing Proportions
Stat / Basic Statistics / 2 Proportions
Enter trials (sample size) & events (defects) in the option box
Click OK
166
Hypothesis Testing Proportions
P-Value < 0.05 indicates a significant difference
Either accept, or fail to accept the null hypothesis. It is assumed there is no difference unless proven otherwise. I.e. Innocent until proven guilty!
167
Hypothesis Testing Variances
Stat / Basic Statistics / 2 Variances
Enter variables to compare
Click OK
Always conduct a normality test before conducting a hypothesis test on variable data.
168
Hypothesis Testing Variances

Test for Equal Variances for Tool 1, Tool 2
F-Test Test Statistic P-Value Test Statistic P-Value 0.04 0.000 57.07 0.000
Standard deviation & confidence interval
Tool 1
Lev ene's Test
P-Value < 0.05 indicates a significant difference
Tool 2
0.5 1.0 1.5 95% Bonferroni Confidence Intervals for StDevs
2.0
Tool 1
Tool 2
10 Data
11
12
13
14
Use the F-Test statistic for normal data and Levenes Test statistic for non -normal data.
169
Hypothesis Testing Means
Stat / Basic Statistics / 2 Sample t
Enter variables to compare
Select equal variances if applicable Select boxplot Click OK
Always conduct a normality and 2 variances test before conducting a 2 Sample T test. However, if the sample sizes are equal, the requirement to conduct a 2 variances test is not applicable.
170
Hypothesis Testing Means
P-Value >= 0.05 infers that the means are from the same population
If the P is low, the null must go!

171
Summary

What is Six Sigma? Introduction to Minitab Version 14 Manipulation of data Basic statistics Graphs Quality tools Measurement System Analysis R & R Control charts Normality testing Capability analysis Hypothesis Testing
172
Questions and Answers
Created by Paul White - Aston Martin Six Sigma Department

Sources: Ford Six Sigma Black Belt Training Material 2006 Ford Six Sigma Green Belt Training Material Version 5.0 Jaguar SPC Training Material 2004
173

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Minitab 14 Quality Statistics

A person without data is merely expressing an opinion.

Created by Paul White - Aston Martin Six Sigma Department

What is Six Sigma?

Is 99% Good Enough?

6-Sigma 99.99966% Good

1 missed putt per 163 years

3.4 defects per million opportunities

Goals of Six Sigma

Did anyone change their mind?

Did you spot anything else?

DMAIC Improvement Model

Session and Worksheet Folders

File /New / New worksheet

Minitab stores numbers, text and dates.

Numbers No symbol in column header, right aligned in cell

Date D in column header, left aligned in cell

Text T in column header, left aligned in cell

Numeric Data Types

e Advantage of Variable Data

Attribute vs Variable Data

Attribute vs Variable Data

Importing text from other sources

Saving projects and worksheets

Save projects to correct destination.

File / Save project as

Change default saving location

Rename with relevant filename and date

Erasing columns and rows

Select column and right click mouse

Tip! Undo function is available on the toolbar

Select columns to stack

Select stacked destination and subscripts

Switch the data pattern from columns to rows.

Data / Transpose columns

Select columns to transpose

Select destination option

Descriptive statistics Inferential statistics Graphical summary

Stat / Basic statistics / display descriptive statistics.

Stat /Basic statistics / Display descriptive statistics

Select variables, click OK

Session window output

Stat / Basic statistics / Graphical summary.

Stat / Basic Statistics / Graphical Summary

High Standard Deviation High Variability

Low Standard Deviation Low Variability

r = 6.96 5.26 = 1.70 xbar = 6.146

5.26 6.96 5.90 6.47 6.14

0.784996 0.662596 0.060516 0.104976 0.000036 = 1.61312

S = 0.635 (to 3 s.f.)

Time series plot Histogram

Time Series Plot

Graph / Time series plot

Graph / Time Series Plot

Select simple option

Time Series Plot

Graph / Time series plot

Select stamp column

Time Series Plot

Time Series Plot of Tool 1

Time series plot displays the trend over time

Select simple option

Select variable to graph