07_IMPROVE_Steps_7-8-9[68P][8.23MB]

GE Global Research Green Belt DMAIC Course

07: IMPROVE PhaseSteps 7,8, 9: It’s About Improving Processes and Products Using Designed Experiments and Other Tools . . .Fuel Economy

Correct Type II Decision Error (1- a) bType I Error

a

Correct Decision (1- b)

Octane Level

Air TempXbar/S Chart for Evaluations4.3 4.2 4.1 4.0 3.9 3.8 3.7 Subgroup 0 5 1 10 15 1 20 25 3.0SL=4.232 X=4.096 -3.0SL=3.959

X270 60 Y= 50 90 80

Sample Mean

0.6

1

Sample StDev

0.5 0.4 0.3 0.2 0.1 0.0 3.0SL=0.2409 S=0.1403 -3.0SL=0.03982

X1

Ver 2.1 October 2003

Proprietary to General Electric Company

Improve Phase Objectives

The benefits of Design of Experiments (DOE’s) Key concepts and terms associated with DOE’s Performing a simple full factorial and fractional DOE’s and interpreting the results Awareness of screening designs and higher level response surface designsVer 2.1 October 2003 Proprietary to General Electric Company

Table of Contents07: IMPROVE PhaseImprove Phase Steps Improve Phase& Common Tools Design of Experiments Terminology& Advantages 2-Level Factorial Basics– Main Effects and Interaction Plots Randomization& Replication Statistical Significance 2-Factor DOE Example& Analysis Residuals Analysis Testing for Curvature 23 Full Factorial (incl Class Exercise) Fractional Factorials Aliasing (Confounding) Screening Designs Foldover Designs and Blocking Response Surface Analysis - Introduction

Page5 6-7 8-11 12-15 16 17 18-21 22-26 27-31 32-35 36-38 39-41 42-48 49-51 52-54 55-56 57-62 63-65 66 67 3

Indicates Minitab File

R2& Adjusted R2 Response Surface Analysis– Class Exercise - DOE Reminders Setting Tolerances on X’s

GE DMAIC Book Of KnowledgeVer 2.1 October 2003

References If You Leave with SomethingProprietary to General Electric Company

The DMAIC ProcessDefine Tollgate1xx/xx/xx

Measure Tollgate2xx/xx/xx

Analyze Tollgate3xx/xx/xx

Improve Tollgate4xx/xx/xx

Control Tollgate5xx/xx/xx

DEFINE

MEASUREStep 1: Select CTQ Characteristics Step 2: Define Performance Standards Step 3: Measurement System Analysis (MSA)

ANALYZEStep 4: Establish Process Capability Step 5: Define Performance Objectives Step 6: Identify Variation Sources)

IMPPROVEStep 7: Screen Potential Causes Step 8: Discover Variable Relationships Step 9: Establish Operating Tolerances

CONTROLStep`10: Define and Validate the Measurement System on Xs Step 11: Determine Process Capability Step 12: Implement Process Control

Key Steps:

Step A: Identify Project CTQs

Step B: Develop Team Charter

Step C: Define Process Map

Overall Project Completion Percentage

0%70% 80% 90% 100%

10%

20%

30%

40%

50%

60%

Key DeliverablesRequired List of Project CTQs Team Charter High Level Process Map (COPIS or SIPOC) Tools That May Help Project Risk Assessment Stakeholder Analysis High Level Project Plan In Frame/Out of Frame Customer Survey Methods (focus groups, interviews, etc.) Req

uired QFD/CTQ Tree Operational definition, Specification limits, target, defect definition for Project Y(s) Measurement System Analysis Tools That May Help Data Collection Plan Gage R&R Detailed Process Map FMEA Pareto Analysis Required Baseline of Current Process Performance Normality Test Statistical Goal Statement for Project List of Statistically Significant Xs Tools That May Help Benchmarking Fishbone Diagram Box Whisker Plots Hypothesis Testing Regression Analysis Required List of Vital Few Xs Transfer Function(s) Optimal Settings for Xs Confirmation Runs/Results Tolerances on Vital Few Xs Tools That May Help Design of Experiments New Process Maps FMEA on new process Process Modeling Required MSA Results on Xs Post Improvement Capability Statistical Confirmation of Improvements Process Control Plan Process Owner Signoff Tools That May Help Control Charts Hypothesis Testing CAP Plan

Ver 2.1 October 2003

Proprietary to General Electric Company

IMPROVE Phase StepsDefine Measure Analyze Improve

DMAIC

Control

7. Screen Potential Causes Deliverable: Determine the Vital Few X’s That Are Causing Changes in Y.

8. Discover Variable Relationships Deliverable: Establish Transfer Function Between Y and Vital Few X’s. Determine Optimal Setting for the Vital Few X’s. Perform Confirmation Runs.

9. Establish Operating Tolerance Deliverable: Specify Tolerances on the Vital Few X’s.

Tools: Screening DOE

Tools: Factorial Designs

Tools: Simulation

Ver 2.1 October 2003

Proprietary to General Electric Company

What’s Improve Phase About. . . Develop an Improvement Strategy Determine which candidate x’s identified in the Analyze Phase are truly“critical X’s”. If possible, determine a quantitative transfer function that relates your Y to these critical X’s

DMAIC

Identify Improvement Actions Determine optimal settings for the X’s

Y= f(x)

Show the impact of the changes on meeting project or business objectives.

Validate the Improvement Demonstrate the validity of your identified improvement actions via additional experiments or a pilot study

Develop a Plan to Implement the Change It’s More than Just Designed ExperimentsVer 2.1 October 2003 Proprietary to General Electric Company

Common“Improve” ToolsBasic Process Map Fishbone Box Plot Time Order Plots Hypothesis Tests Linear Regression Mistake Proofing

DMAIC

Intermediate DOE Full Factorial Fractional Factorial Intro to Response Surface

Advanced DOE Response Surface Taguchi (Inner/ Outer Array)

Simulation Models Already Covered Covered in Improve Covered in DFSS Adv. Level III e.g. ProModel

Multivariate R …… 此处隐藏：8735字，全部文档内容请下载后查看。喜欢就下载吧 ……