Welcome! Please read this page (in particular) very carefully. Instructions You need to understand how to send your assignments (deliverables) to your instructor. The tabs (bottom of each sheet) in this document contain all of the deliverables expected of you. If you need help along the way, look for these special cells that have a red indicator Read me in the corner. It looks like the "Read me" box to the right: Simply slide your cursor over the red-cornered cell and you will get more information. The format for all of the deliverables is the same: The 'assignment objective' is in black font. The next segment is in green font. These are your instructions for that assignment. The blue font is the data (where applicable) for completing each the assignment. Software We are using Excel software for the projects. You may use other software to complete your projects, but please 'report' your answers in the Excel format described below. You may complete your assignments with any version of Excel software. All assignments can easily be completed with a basic copy of Excel. There is also an Add-In feature which is available for Excel that can be helpful, although it is not required. The Add-In feature comes free with each Excel package, although it may not be currently loaded into your copy. Following are the simple instruction for loading the Excel Add-ins for both Excel 2003 and Excel 2007. (Slide your cursor over the red-cornered cells to read) Excel 2003 Excel 2007 Excel Novice - Please read Project Timeline Follow the submission scheduled posted on the Main Discussion Board!! Remember that the entire project must be 1 100% correct and complete by no later than midnight EST one week (7 days) BEFORE the last day of class. THIS MEANS THAT ALL REQUIRED CORRECTIONS MUST HAVE BEEN COMPLETED CORRECTLY - JUST TURNING IN THE ASSIGNMENT IS NOT SUFFICIENT IF THERE ARE ANY ERRORS ON IT. Most people require 2 - 3 attempts per assignment to make all necessary corrections - so plan your time accordingly! Deliverables include: Project charter (target week 3 or sooner) Baseline sigma (week 4 or sooner) Histogram (week 5 or sooner) Expected variation (week 6 or sooner) t test ( week 7 or sooner) Chi square (week 8 or sooner) ANOVA (week 9 or sooner) Scatter diagram (week 10 or sooner) DOE (week 11 or sooner) Control chart (XmR) (12 or sooner) Pp Ppk (week 13 or sooner ) 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? 22 34 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? 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! 3 this! 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! 4 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 5 Excel 2007 example 6 7 8 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 9 The deadline for having all project assignments 100% correct is 7 days prior to the end of the course 10 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? Help "I have no idea about this one" "I have no idea about this one" b. Is the measurement system discriminate? c. Is thickness in statistical control? Data: Thickness data for XMR control chart 0.551 0.546 1a. Calculate R-bar 0.547 0.548 Self check 0.547 0.547 1b. Calculate the 0.538 upper control limit Calculating R-bar in Excel 2003 Calculating R-bar in Excel 2007 11 0.546 0.542 0.543 0.545 0.547 0.543 0.548 0.545 0.554 0.549 0.546 0.545 0.553 0.549 0.541 0.542 0.545 0.546 0.552 0.546 0.546 0.545 0.547 0.548 0.547 0.545 0.54 0.545 for the range "How do I do that?" Self check 2 & 3. Calculate the control limits for the individuals "How do I do that?" Self check Be sure to review the week 11 virtual class for more information on SPC and measurement discrimination before you submit this! Target Assignment Date - Submit in Week 14 or earlier YOU DO NOT NEED TO SUBMIT THE XmR CHART Project: Manufacturing 2015 Deliverable: XmR Chart Rausch Student last name: 12 0.003471 0.011349 0.555344 0.536884 Calculated R-Bar: Upper control limit for the range: Upper control limit for the individuals: Lower control limit for the individuals: Is there adequate discrimination? Explain your answer: Which chart did you use and exactly how many strata are there on that chart? How many should there be? ROUND YOUR FINAL RESULTS TO 6 DECIMAL PLACES. Type your answer here. Include which chart you used, how many strata there are on that chart, and how many strata you need for adequate discrimination. Check Check Check Check Help Based upon your analysis of the stability of this control chart, what would you do next? Help Type your answer here. How to submit an Assignment 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 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 - XmR Chart" 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. 13 Check Please 'hand-in' your assignments throughout the course. DO NOT SAVE THEM FOR THE END. Procrastinators: The deadline for having all project deliverables 100% correct is 7 days prior to the end of the course. 14 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. She asks for a capability study to be performed on these parameters and asks for a calculation two key factors that affect 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. 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 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 self-check?" 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 R.P.M. 4400 4400 4400 4400 4450 4450 4450 4450 15 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 Upper Specs Lower Specs Thickness 0.5600 0.5400 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 R.P.M. 8000 2000 How to submit an Assignment Target Assignment Date - Submit in Week 15 or earlier 16 YOU DO NOT NEED TO CREATE CONTROL CHARTS TO COMPLETE THIS ASSIGNMENT!! DO NOT SEND THE ACTUAL HISTOGRAMS UNLESS YOUR INSTRUCTOR ASKS YOU TO. Project: Manufacturing 2015 Deliverable: Pp Ppk Rausch Student last name: INSTRUCTIONS: (1) IF YOU SAY THE DISTRIBUTION IS NOT APPROXIMATELY NORMAL, GIVE THE CORRECT NAME FOR THE PATTERN YOU SEE IN YOUR HISTOGRAM. (2) BASE YOUR DECISION ON ACCEPTABILITY ON THE ASSUMPTIONS AND CRITERIA FOR Pp and Ppk DISCUSSED IN THE RECORDED LECTURES AND VIRTUAL CLASSES ON CAPABILITY. YOU DO NOT NEED TO CREATE CONTROL CHARTS FOR THIS ASSIGNMENT!! Thickness Pp (use 6 decimal places) Ppk (use 6 decimal places) Is this distribution approximately Normal? If it's not normal, what is the shape? Is this process acceptable? Explain your decision on acceptability. Check 2.111381 2.093284 Yes NA Yes? HINT! HINT! HINT! Round your Pp and Ppk results to 6 decimal places. R.P.M. Pp (use 6 decimal places) Ppk (use 6 decimal places) Is this distribution approximately Normal? If it's not normal, what is the shape? Is this process acceptable? Explain your decision on acceptability. 7.552945 6.495533 No Bimodal No 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 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: 17 Check HINT! HINT! HINT! 1. 2. 3. 4. 5. 6. COURSE MENU CLASS ROSTER Click on your instructor's email envelope icon Type "Check My Work - Pp, Ppk" in the SUBJECT box. Click once inside of the message box 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. Please 'hand-in' your assignments throughout the course. DO NOT SAVE THEM FOR THE END. Procrastinators: The deadline for having all project deliverables 100% correct is 7 days prior to the end of the course. 18