chap15_2010

chap15_2010 - Chapter 15 Control Methods Control is the...

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Chapter 15 Control Methods
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Control is the heart of Six Sigma Customers are demanding higher levels of product quality at a lower cost, improved responsiveness, and added value. + Producers must struggle to satisfy technical, performance, schedule, and cost expectations of the customer. = Do it right the first time Eliminate product variation Delivery of offerings, which are defect free at a min. cycle time
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Six Sigma initiatives to reduce variation In the past, the pursuit of quality was more a philosophy than an art or science… these tools can change that. Design Design to standard parts Design to standard materials Robust design Design for assembly Design for reliability Design for simplicity Process Short-cycle manufacturing Process characterization Process standardization Statistical process control Material and Components Part standardization Transaction(s) standardization Supplier statistical process control (SPC) Supplier certification Material requirements planning
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Poka-Yoke Japanese for mistake proofing Poka (inadvertent error) Yokeru (avoidance) Design and implementation of actions to prevent errors, mistakes, or defects in our everyday activities and processes. Errors should not be considered inevitable. Any error type can be reduced considerably, if not eliminated altogether. http://www.youtube.com/watch?v=NrnloZ12KGs
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Common types of mistakes Incorrect processing Work pieces placed incorrectly Missing parts Wrong parts Wrong blue print or instructions Wrong piece processed Operation skipped or omitted Improper adjustment Equipment not set up properly Process improperly supersized Use of the wrong tool
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How are these examples of daily Poka-Yoke? Filling pipe insert keeps larger, leaded- fuel nozzle from being inserted Gas cap tether does not allow the motorist to drive off without the cap Gas cap is fitted with ratchet to signal proper tightness and prevent over- tightening Parking garages have low clearance. To insure that cars entering the garage will fit, garages are fitted with a go/no-go gauge at the entrance. Hitting the swinging sign or pipe will not damage the vehicle as much as driving into a concrete beam. This iron turns off automatically when it is left unattended or when it is returned to its holder Examples from: http://facultyweb.berry.edu/jgrout/everyday.html
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Keys to implementing Poka-Yoke Utilize Failure Mode-Effects Analysis (FMEA) to identify opportunities. Use the highest principle possible. 1. Elimination 2. Replacement 3. Facilitation 4. Detection 5. Mitigation
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Statistical Process Control (SPC) SPC is a method of analyzing data over time and using the result of the analysis to solve manufacturing and processing problems Can be applied to almost anything that can be expressed with numbers of data. Control
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This note was uploaded on 12/03/2011 for the course EIN 5226 taught by Professor Staff during the Fall '11 term at FIU.

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chap15_2010 - Chapter 15 Control Methods Control is the...

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