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Manufacturing

Blog posts and articles about using data analysis and statistics in quality improvement initiatives in manufacturing.

"You take 10 parts and have 3 operators measure each 2 times." This standard approach to a Gage R&R experiment is so common, so accepted, so ubiquitous that few people ever question whether it is effective.  Obviously one could look at whether 3 is an adequate number of operators or 2 an adequate number of replicates, but in this first of a series of posts about "Gauging Gage," I want to look at... Continue Reading
In its industry guidance to companies that manufacture drugs and biological products for people and animals, the Food and Drug Administration (FDA) recommends three stages for process validation: Process Design, Process Qualification, and Continued Process Verification. In this post, we we will focus on that third stage. Stage 3: Continued Process Verification Per the FDA guidelines, the goal of... Continue Reading

7 Deadly Statistical Sins Even the Experts Make

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To make objective decisions about the processes that are critical to your organization, you often need to examine categorical data. You may know how to use a t-test or ANOVA when you’re comparing measurement data (like weight, length, revenue, and so on), but do you know how to compare attribute or counts data? It easy to do with statistical software like Minitab.  One person may look at this bar... Continue Reading
People frequently have different opinions. Usually that's fine—if everybody thought the same way, life would be pretty boring—but many business decisions are based on opinion. And when different people in an organization reach different conclusions about the same business situation, problems follow.  Inconsistency and poor quality result when people being asked to make yes / no, pass / fail, and... Continue Reading
The line plot is an incredibly agile but frequently overlooked tool in the quest to better understand your processes. In any process, whether it's baking a cake or processing loan forms, many factors have the potential to affect the outcome. Changing the source of raw materials could affect the strength of plywood a factory produces. Similarly, one method of gluing this plywood might be better... Continue Reading
The ultimate goal of most quality improvement projects is clear: reducing the number of defects, improving a response, or making a change that benefits your customers. We often want to jump right in and start gathering and analyzing data so we can solve the problems. Checking your measurement systems first, with methods like attribute agreement analysis or Gage R&R, may seem like a needless waste... Continue Reading
We’ve got a plethora of case studies showing how businesses from different industries solve problems and implement solutions with data analysis. Take a look for ideas about how you can use data analysis to ensure excellence at your business! Boston Scientific, one of the world’s leading developers of medical devices, is just one organization who has shared their story. A team at their Heredia,... Continue Reading
There may be huge potential benefits waiting in the data in your servers. These data may be used for many different purposes. Better data allows better decisions, of course. Banks, insurance firms, and telecom companies already own a large amount of data about their customers. These resources are useful for building a more personal relationship with each customer. Some organizations already use... Continue Reading
I thought 3 posts would capture all the thoughts I had about B10 Life. That is, until this question appeared on the Minitab LinkedIn group: In case you missed it, my first post, How to Calculate B10 Life with Statistical Software, explains what B10 life is and how Minitab calculates this value. My second post, How to Calculate BX Life, Part 2, shows how to compute any BX life in Minitab. But... Continue Reading
This is an era of massive data. A huge amount of data is being generated from the web and from customer relations records, not to mention also from sensors used in the manufacturing industry (semiconductor, pharmaceutical, petrochemical companies and many other industries). Univariate Control Charts In the manufacturing industry, critical product characteristics get routinely collected to ensure... Continue Reading
In my last post, I discussed how a DOE was chosen to optimize a chemical-mechanical polishing process in the microelectronics industry. This important process improved the plant's final manufacturing yields. We selected an experimental design that let us study the effects of six process parameters in 16 runs. Analyzing the Design Now we'll examine the analysis of the DOE results after the actual... Continue Reading
I used to work in the manufacturing industry. Some processes were so complex that even a very experienced and competent engineer would not necessarily know how to identify the best settings for the manufacturing equipment. You could make a guess using a general idea of what should be done regarding the optimal settings, but that was not sufficient. You need very precise indications of the correct... Continue Reading
While the roots of Lean Six Sigma and other quality improvement methodologies are in manufacturing, it’s interesting to see how other organizational functions and industries apply LSS tools successfully. Quality improvement certainly has moved far beyond the walls of manufacturing plants! For example, I recently had the opportunity to talk to Drew Mohler, a Lean Six Sigma black belt and senior... Continue Reading
When I wrote How to Calculate B10 Life with Statistical Software, I promised a follow-up blog post that would describe how to compute any “BX” lifetime. In this post I’ll follow through on that promise, and in a third blog post in this series, I will explain why BX life is one of the best measures you can use in your reliability analysis. As a refresher, B10 life refers to the time at which 10% of... Continue Reading
If you need to assess process performance relative to some specification limit(s), then process capability is the tool to use. You collect some accurate data from a stable process, enter those measurements in Minitab, and then choose Stat > Quality Tools > Capability Analysis/Sixpack or Assistant > Capability Analysis. Now, what about sorting the data? I’ve been asked “why does Cpk change when I... Continue Reading
If you're just getting started in the world of quality improvement, or if you find yourself in a position where you suddenly need to evaluate the quality of incoming or outgoing products from your company, you may have encountered the term "acceptance sampling." It's a statistical method for evaluating the quality of a large batch of materials from a small sample of items, which statistical softwar... Continue Reading
Whatever industry you're in, you're going to need to buy supplies. If you're a printer, you'll need to purchase inks, various types of printing equipment, and paper. If you're in manufacturing, you'll need to obtain parts that you don't make yourself.  But how do you know you're making the right choice when you have multiple suppliers vying to fulfill your orders?  How can you be sure you're... Continue Reading
by Erwin Gijzen, Guest Blogger People who work in quality improvement know that the root causes of quality issues are hard to find. A typical production process can contain hundreds of potential causes. Additionally, companies often produce products with multiple quality requirements, such as dimensions, surface appearance, and impact resistance. With so many variables, it’s no wonder many companies... Continue Reading
A while back, I offered an overview of process capability analysis that emphasized the importance of matching your analysis to the distribution of your data. If you're already familiar with different types of distributions, Minitab makes it easy to identify what type of data you're working with, or to transform your data to approximate the normal distribution. But what if you're not so great with... Continue Reading
The Cp and Cpk are well known capability indices commonly used to ensure that a process spread is as small as possible compared to the tolerance interval (Cp), or that it stays well within specifications (Cpk). Yet another type of capability index exists: the Cpm, which is much less known and used less frequently. The main difference between the Cpm and the other capability indices is that the... Continue Reading