How to submit an Assignment In response to customers like you, we have added a peach-colored box for each deliverable. We have done this to make it clear (and consistent) the areas of the project that will be reviewed to your instructor. Project: Deliverable: Student last name: Manufacturing Project Improve phase - gen. sol. Johnson What is the control chart telling you? There is a point out of control at subgroup #15. I would try to figure out why that happened. We would also recalculate the control limits because there is evidence the process has changed. What is the average of subgroup 1? What is the average of subgroup 2? What is the average of subgroup 3? What is the average of subgroup 4? What is the average of subgroup 5? What is the average of subgroup 6? What is the average of subgroup 7? What is the average of subgroup 8? 22 34 23 22 25 23 29 27 Read this! To send each assignment to your instructor: Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the peach-colored box, then while holding down on that button, drag to Read the LOWER-RIGHT corner of the box. This will highlight the entire peach-colored box. Release the mouse button. Do a CTRL-C. This will copy what has been highlighted. Go to your Villanova website and follow this sequence: 1. COURSE MENU 2. CLASS ROSTER 3. Click on your instructor's email envelope icon 4. Type "Check My Work - ASSIGNMENT NAME - PROJECT NAME" in the SUBJECT box. 5. Click once inside of the message box 6. Do a CTRL-V. This will paste your deliverable into this box. Don't be concerned if after you paste it, the appearance of the text is out of alignment. It will straighten out after you hit SEND. 7. SEND Check your SENT ITEMS folder afterward to see how it straightened out. 8. DO NOT SEND ANY ATTACHMENTS UNLESS YOUR INSTRUCTOR SPECIFICALLY ASKS YOU TO!! VERY IMPORTANT!! Be sure to submit your assignments for grading as you complete each one and following the submission scheduled posted on the message board - DO NOT WAIT UNTIL THE END OF THE COURSE TO SEND THEM ALL IN. NOTE THAT THE ENTIRE PROJECT MUST BE 100% CORRECT BY ONE WEEK BEFORE THE END OF CLASS OR YOU WILL FAIL THE PROJECT AND THE COURSE. This means that you must submit ALL of your assignments far enough in advance of the project completion deadline to allow time for all necessary corrections to be made. Following the submission schedule is the best way to ensure that you have enough time to finish the project by the completion deadline - failure to meet the submission due dates can result in failing the course. Very few assignments are correct on the first submission and many require multiple rework attempts, so don't procrastinate! this! This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your Excel software. If you see Data Analysis already listed under the Tools tab, you are set. If you do not see Data Analysis follow the instructions in the Green tab. Excel 2003 instructions Excel 2003 or earlier versions of Excel example This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your 2007 Excel software. If you see Data Analysis already listed under the DATA tab, you are set. If you do not see Data Analysis follow the instructions in the Green tab. Excel 2007 instructions Excel 2007 example Manufacturing Project Lovell Levelers, Inc. is a major provider of specialized parts for the automotive industry. LLI's biggest customer, Specific Motors was not a delighted customer this month. In fact, last Monday, the executive vice president of Specific Motors headquarters, Phyllis Kendall was diverted from a return trip from Singapore to drop in unexpectedly at the LLI plant. There was nothing routine about this visit. She made it explicitly clear that Specific Motors was disappointed with the level of quality relative to the leveler plates. In particular, she was disappointed with the current average of rejects at the rate of 1,350 defects per million opportunities (DPMO) that has created a cost of poor quality of just over $256,000 per quarter for them. She said the industry standard is 50 DPMO and if we do not get the level of quality to the industry standard within the next six months, LLI will lose Specific Motors as a customer. The student will be a Black Belt working for LLI. The specifics about their company: CEO Bill Lovell GM Mary Nichols Sponsor John Hopps Finance Cindy Jenkins Process owner Leroy Miller Master BB Dennis Kens Manufacturing Mitch Freese Design Engineer Al Nelson Quality Debbie Judson Objective: A problem statement needs to be developed. There needs to be a business case so that management will buy-in to having the team working on the project. The scope of the project also needs to be decided upon. This is important to ensure a likely successful completion. If the scope is too broad, a success may not be realized for years, or may not happen at all. Instructions for you: Create a project charter based "Create a charter?" upon the information in the introduction. (see "The project" tab below) In reality, you would fill in a charter with team members' names, stake holders, etc. We are not interested in those details for this simulation, but we do want to see what you come up with for four (4) items: Problem statement, business case, goal and project scope. How to submit an Assignment TARGET ASSIGNMENT DATE - Submit in Week 3 or earlier Project: Deliverable: Student last name: Manufacturing 2015 Project charter YEISER What is the business case? (Use no more than two sentences.) Lovell Levelers has an unsatisfied customer and they risk losing the customer if they do not raise their level of quality with their level plates. Currently the customer is losing lots of money due to the cost of poor quality. "Business Case?" What is the problem statement? (Use no more than two sentences.) Lovell Levelers is not currently meeting the industry standard of 50 DPMO with their leveler plates and if they do not meet the industry standard within the next 6 months they will lose their largest customer, Specific Motors. "Problem Statement" What is your goal statement? (Use one sentence.) "Goal Statement" 50 DPMO in less than 6 months is our goal. What is the project scope? (This is not your goal statement! Use one sentence.) The scope begins at the manufacturing of the leveler plate and ends at packaging them for shipment. "The project scope?" Use the "DPMO to Sigma Level Relationship" table provided in the online textbook to find the approximate sigma values to 1 decimal place. Be sure to use the results based on the Motorola 1.5 sigma shift. HINT: BEFORE YOU "INTERPOLATE" BETWEEN TWO TABLE VALUES, ASK YOURSELF IF THESE VALUES FOLLOW A STRAIGHT LINE RELATIONSHIP!! Objective: The Black Belt team did a pareto analysis of the data and determined that three factors were causing over 95% of the problem with the leveler plates. Those factors are, the length of the plates, the width of the plates, and the thickness of the plates. You need to know if it is reasonable to assume that these three 'product parameters' are normally distributed. Instructions for you: 1. Construct three (3) histograms for the three data sets. 2. Interpret each of the histograms to determine whether the assumption of normality is reasonable. Data: Length 10.67 10.74 10.68 10.72 10.66 10.69 10.70 10.72 10.69 10.68 10.72 10.70 10.70 10.73 10.75 10.73 10.69 10.68 10.70 10.77 10.72 10.69 10.66 10.69 10.63 10.68 10.73 10.74 10.65 10.69 10.70 10.72 10.75 10.71 10.72 Upper Spec Lower Spec Target Width 11 10.5 10.75 7.66 7.45 7.55 7.51 7.57 7.55 7.53 7.53 7.56 7.52 7.58 7.55 7.53 7.56 7.58 7.55 7.55 7.54 7.57 7.54 7.55 7.55 7.56 7.54 7.56 7.56 7.55 7.54 7.55 7.56 7.57 7.54 7.55 7.54 7.55 7.53 7.54 7.55 Thickness 0.551 0.546 0.546 0.554 0.546 0.542 0.545 0.538 0.552 0.547 0.546 0.545 0.546 0.548 0.546 0.543 0.548 0.545 0.553 0.539 0.549 0.541 0.543 0.545 0.549 0.546 0.545 0.540 0.541 0.545 0.547 0.543 0.545 0.546 0.547 0.56 0.54 0.55 Histograms in Excel 2003 Histograms in Excel 2007 More on Bin Ranges 2 10.65 1 0.538 Objective: Your boss wants to know the limits of expected variation. You know there is another shipment coming in next week and based upon this week's run, and assuming that the process is normally distributed, you can calculate/predict the limits of expected variation by calculating the mean and standard deviation for this data and then using the properties of the normal distribution to estimate the limits of the expected variation. The Mean and StDev in Excel 2003 The Mean and StDev in Excel 2007 Expected variation Instructions for you: 1. Calculate the average for length. 2. Calculate the standard deviation for length. 3. From these calculations, determine the expected variation. ( Use + or - 3 sigma) You may complete this assignment by hand, as taught in the lecture. You may use Excel, or you may use a calculator or other software. We explain the fundamentals of the calculations, so that you learn the mechanics and the meaning of standard deviation. This basic approach gives you an understanding of standard deviation, which then allows you to be flexible in the tools that you use. Data: Data Upper Spec Lower Spec Target Length 10.67 10.74 10.68 10.72 10.66 10.69 10.70 10.72 10.69 10.68 10.72 10.70 10.70 10.73 10.75 10.73 10.69 10.68 10.70 10.77 10.72 10.69 10.66 10.69 10.63 10.68 10.73 10.74 10.65 10.69 10.70 10.72 10.75 10.71 10.72 374.600000 11 10.5 10.75 Decimal places in Excel Excel STORES the full decimal value of a number in its cells. But, you can adjust how many decimal values are VISIBLE in your spreadsheet. For example, if your average/mean was 2.4557643, Excel could display that number. Or, you can set your spreadsheet number to display the value to 6 decimal places, 2.455764. Following are the instructions for re-setting the number of decimal places that are visible in Excel for both Excel 2003 and Excel 2007. NOTE: Do not use 'rounded' data during your calculations. Excel 2003 Excel 2007 Project: Deliverable: Student last name: Manufacturing 2015 T Test YEISER State the null hypothesis::: Ho: = Xbar State the alt. hypothesis::: Ha: Xbar T test statistic (round to 6 decimal places): What is the critical value? -3.309137 2.0640 Use 6 decimal places. State your bottom-line conclusion in the words of the problem addressed by this study. (Do not use generic hypothesis test wording.) The methods are producing products with different thicknesses, there is 95% confidence that the means are statistically different. The null hypothesis can be rejected. Data for this deliverable: Site 1 Defect Type A 8 Defect Type B 9 Site 2 8 10 Site 3 7 8 Machine 1 Machine 2 Machine 3 0.546 0.573 0.573 0.526 0.592 0.57 0.587 0.571 0.527 0.563 0.556 0.572 Objective: A team member has been saying since day one that there is a correlation between temperature and the thickness. Should the team have listened? Construct a scatter diagram and calculate the correlation coefficient to see if she is correct. Instructions for you: Construct a scatter diagram to see if she is correct. And, if she is, we may have found a smoking gun toward a solution. Data: Data: Temp 154 153 152 152 151 151 151 151 151 151 151 151 151 151 151 151 150 150 150 150 150 150 150 150 149 149 149 148 148 148 147 147 146 146 145 Thickness 0.554 0.553 0.552 0.551 0.549 0.549 0.548 0.548 0.548 0.547 0.547 0.547 0.547 0.547 0.547 0.546 0.546 0.546 0.546 0.546 0.546 0.545 0.545 0.545 0.545 0.545 0.545 0.545 0.543 0.543 0.542 0.542 0.541 0.54 0.538 Scatter diagrams in Excel 2003 Scatter diagrams in Excel 2007 Correlation Coefficient - Excel 2003 Correlation Coefficient - Excel 2007 0.56 0.555 0.55 0.545 0.54 0.535 0.53 144 146 148 150 152 154 Project: Manufacturing 2015 Deliverable: DOE Design Choice Student last name: YEISER 1. What is the sign (+ or -) for the AxC interaction for the 4th trial? 2. What is the resolution as shown above? (III, IV, or V, or Full) 3. Given the teams goals and budget, what is your recommendation for the final design of this experiment? BE SPECIFIC AND USE THE CORRECT DESIGN NOTATION AND/OR TERMINOLOGY!! I would recommend to the team that we drop Time as a factor as it's negligable and move on with a Factorial Design with 4 factors and complete 8 runs. 4. What would the new resolution be under your recommendation in #3 above? (III, IV, or V) ::: will the generic confounding pattern be for your final design? (Do NOT give us the design generators or alias sets!) + Full IV The top two affects are the interactions of Temp with R.P.M. and Time with R.P.M. Objective: Lovell Levelers just reported that Specific Motors is a satisfied customer. The leveler plate quality is no longer an issue. In fact, they have not seen a single defect in six months! Phyllis Kendall made another surprise visit, but this time for a more pleasant reason. She presented each member of the team with a crisp, new $100 bill as a show of appreciation. But she also pointed out that we need to have a way to ensure that this problem will not crop up again. The team is one step ahead of her and explained that the thickness of the leveler plates is being monitored and controlled with an on-going XmR (Individuals and Moving Range) chart so that any assignable causes of variation will be detected and addressed quickly. The parameters affecting the product thickness are also being monitored with a capability study. Instructions for you: We want to make sure you can calculate control limits. You may construct the control chart by hand, or you may use a charting function in Excel. There are blank forms in the back of your notebook . Control Charts in Excel 2003 Control Charts in Excel 2007 1. 2. 3. 4. What is the upper control limit for the range? What is the upper control limit for the individuals? What is the lower control limit for the individuals? What would you do with the process? a. What would you recommend? b. Is the measurement system discriminate? c. Is thickness in statistical control? Help "I have no idea about this one" "I have no idea about this one" Data: Thickness data for XMR control chart 0.55100 0.0050 0.54600 0.0010 1a. Calculate R-bar Calculating R-bar in Excel 2003 0.54700 0.0010 0.54800 0.0010 Self check 0.54700 0.0000 0.54700 0.0090 1b. Calculate the Calculating R-bar in Excel 2007 0.53800 0.0080 upper control limit 0.54600 0.0040 for the range 0.54200 0.0010 "How do I do that?" 0.54300 0.0020 Self check 0.54500 0.0020 0.54700 0.0040 2 & 3. Calculate the 0.54300 0.0050 control limits for the 0.54800 0.0030 individuals 0.54500 0.0090 "How do I do that?" 0.55400 0.0050 Self check 0.54900 0.0030 0.54600 0.0010 0.54500 0.0080 0.55300 0.0040 0.54900 0.0080 0.54100 0.0010 0.54200 0.0030 0.54500 0.0010 0.54600 0.0060 0.55200 0.0060 0.54600 0.0000 0.54600 0.0010 0.54500 0.0020 0.54700 0.0010 0.54800 0.0010 0.54700 0.0020 0.54500 0.0050 0.54000 0.0050 0.54500 0.00347059 0.54611428571429 Be sure to review the week 11 virtual class for more information on SPC and measurement discrimination before you submit this! Objective: So far, so good. The process has been in control for the past four months. Phyllis isn't as well versed in Six Sigma as the team is, and it is her nature to question everything. So she has asked for a capability study to be performed on two key process factors that affect leveler thickness and wants to see this for the past 35 days of production. You are on the spot, but confident. You pull up the past 35 day's worth of data and you calculate Pp and Ppk for each of these factors. Is Phyllis going to be happy or is she going to be more skeptical? That is the 'question of the day.' Crunch the numbers--and you will find out. By the way--finish this deliverable correctly AND MAKE ALL OF THE CORRECTIONS REQUIRED ON THE PREVIOUS ASSIGNMENTS and you are finished with the project! Congratulations!!! Instructions for you: "Is it possible for me to do a selfcheck?" Instructions for you: 1. Construct histograms for each of the parameters. Note: The first parameter 'thickness' is the product parameter. The second parameter is thought to affect thickness. 2. Are the processes approximately normally distributed? 3. Calculate Pp and Ppk for each. Note: The upper and lower specifications are listed at the bottom of each column. You will need these to do the calculations. 4. Are the processes acceptable? "I'm lost" "Can I do this with the Data Analysis Toolpak in Excel 2003?" "Can I do this with the Data Analysis Toolpak in Excel 2007?" Data: Data: Thickness 0.548 0.550 0.552 0.554 0.552 0.547 0.547 0.552 0.549 0.548 0.549 0.549 0.550 0.551 0.549 0.550 0.551 0.550 0.550 0.553 0.548 0.552 0.551 0.550 0.549 0.551 0.551 0.550 0.551 0.550 0.549 0.550 0.551 0.549 0.550 19.253 #NAME? 0.550 Upper Specs Lower Specs Thickness 0.5600 0.5400 R.P.M. 4400 4400 4400 4400 4450 4450 4450 4450 4450 4450 4450 4450 4450 4500 4500 4500 4550 4600 4650 4650 4650 4700 4700 4700 4700 4700 4700 4700 4700 4700 4700 4750 4750 4750 4800 ### 4580.000 R.P.M. 8000 2000 4 9 4400 4450 2 3 0.547 0.548 #NAME? 3 1 1 3 4500 4550 4600 4650 7 9 6 4 0.549 0.55 0.551 0.552