Input

C/shaft bore axis

with w.r.t
respect to c/shaft
dowel bore
'0 to
0.113 '+/- 0.02
Time to Time variation Fixture to Fixture variation Part to Part variation A B
1 1 1 0.042 0.006
1 1 2 0.102 0.009
1 1 3 0.083 0.028

1 2 1 0.052 0.028
1 2 2 0.096 0.006
1 2 3 0.052 0.040

2 1 1 0.058 0.006
2 1 2 0.038 0.006
2 1 3 0.108 0.013

2 2 1 0.070 0.032
2 2 2 0.021 0.013
2 2 3 0.054 0.003

3 1 1 0.021 0.010
3 1 2 0.089 0.015
3 1 3 0.080 0.007

3 2 1 0.038 0.018
3 2 2 0.059 0.006
3 2 3 0.063 0.017

4 1 1 0.013 0.011
4 1 2 0.032 0.007
4 1 3 0.055 0.012

4 2 1 0.026 0.013
4 2 2 0.068 0.032
4 2 3 0.094 0.014

5 1 1 0.028 0.007
5 1 2 0.030 0.032
5 1 3 0.013 0.003

5 2 1 0.060 0.024
 5 2 2 0.017 0.011
5 2 3 0.028 0.008

6 1 1 0.075 0.009
6 1 2 0.034 0.008
6 1 3 0.062 0.007

6 2 1 0.077 0.015
6 2 2 0.013 0.002
6 2 3 0.039 0.008

7 1 1 0.048 0.030
7 1 2 0.010 0.019
7 1 3 0.050 0.027

7 2 1 0.033 0.014
7 2 2 0.007 0.010
7 2 3 0.049 0.040

8 1 1 0.031 0.012
8 1 2 0.017 0.024
8 1 3 0.058 0.006

8 2 1 0.036 0.011
8 2 2 0.025 0.022
8 2 3 0.030 0.016
9 1 1 0.082 0.024
9 1 2 0.054 0.006
9 1 3 0.032 0.035
9 2 1 0.049 0.015
9 2 2 0.040 0.009
9 2 3 0.061 0.041
10 1 1 0.054 0.011
10 1 2 0.027 0.008
10 1 3 0.037 0.003
10 2 1 0.033 0.032
10 2 2 0.047 0.009
10 2 3 0.023 0.010

0.04708 0.01530
Output
bore axis Idler bore Balancer
w.r.t axis w.r.t bore axis
input input w.r.t idler
bore bore bore

'+/- 0.02 '+/- 0.02 '+/- 0.02 lsl 0

C D E usl 0.113
0.019 0.031 0.017 0.052
0.018 0.078 0.024 0.096
0.013 0.047 0.016 0.052

0.035 0.057 0.028

0.038 0.105 0.064 112
0.022 0.079 0.030

0.040 0.050 0.037

0.033 0.018 0.075 56
0.025 0.075 0.018

0.013 0.068 0.008

0.006 0.057 0.013
0.032 0.071 0.033

0.027 0.024 0.016

0.028 0.077 0.040
0.028 0.064 0.030

0.011 0.025 0.056

0.020 0.056 0.027
0.004 0.040 0.020

0.025 0.030 0.031

0.025 0.034 0.032
0.014 0.033 0.019

0.006 0.008 0.025

0.024 0.079 0.024
0.013 0.071 0.018

0.013 0.035 0.022

0.034 0.042 0.072
0.013 0.015 0.021

0.026 0.032 0.024

0.036 0.045 0.041
0.038 0.008 0.021

0.029 0.053 0.042

0.016 0.016 0.031
0.017 0.035 0.064

0.013 0.071 0.081

0.019 0.013 0.019
0.028 0.017 0.032

0.010 0.067 0.014

0.021 0.033 0.055
0.040 0.070 0.009

0.015 0.018 0.025

0.036 0.083 0.053
0.012 0.051 0.034

0.025 0.058 0.043

0.027 0.062 0.022
0.018 0.038 0.020

0.012 0.055 0.031

0.033 0.052 0.018
0.015 0.066 0.043
0.013 0.043 0.035
0.034 0.039 0.023
0.018 0.072 0.035
0.024 0.060 0.040
0.011 0.047 0.038
0.043 0.029 0.051
0.021 0.051 0.024
0.010 0.035 0.032
0.022 0.057 0.011
0.018 0.073 0.025
0.023 0.028 0.046
0.038 0.007 0.058
 1 13.78
2 13.76
3 13.72
4 13.74
5 13.7
6 13.7
7 13.71
8 13.73
9 13.79
10 13.8
11 13.69
12 13.72
13 13.68
14 13.74
15 13.72
16 13.7
17 13.73
18 13.77
19 13.73
20 13.73
21 13.66
22 13.68
23 13.72
24 13.77
25 13.68
26 13.73
27 13.74
28 13.7
29 13.75
30 13.7
31 13.69
32 13.68
33 13.76
34 13.75
35 13.66
36 13.77
37 13.74
38 13.74
39 13.75
40 13.74
41 13.76
42 13.72
43 13.75
44 13.75
45 13.76
46 13.72
47 13.83
48 13.75
49 13.7
50 13.79
51 13.72
52 13.75
53 13.8
54 13.8
55 13.8
56 13.75
57 13.76
58 13.76
59 13.76
60 13.69
61 13.72
62 13.75
63 13.78
64 13.77
65 13.78
66 13.72
67 13.68
68 13.76
69 13.71
70 13.7
71 13.78
72 13.71
73 13.73
74 13.82
75 13.76
76 13.78
77 13.73
78 13.78
79 13.75
80 13.73
81 13.75
82 13.74
83 13.82
84 13.81
85 13.79
86 13.73
87 13.76
88 13.8
89 13.89
90 13.82
 91 13.7
92 13.73
93 13.76
94 13.81
95 13.7
96 13.78
97 13.78
98 13.79
99 13.72
100 13.84
101 13.83
102 13.81
103 13.76
104 13.82
105 13.81
106 13.82
107 13.74
108 13.69
109 13.78
110 13.82
111 13.73
112 13.74
113 13.78
114 13.84
115 13.69
116 13.69
117 13.78
118 13.76
119 13.73
120 13.8
121 13.86
122 13.74
123 13.86
124 13.82
125 13.74
126
 Spring
Length
after
coiling

Time to Time variation Fixture to Fixture variation Part to Part variation F1 F2

1 1 1 13.78
1 1 2 13.76
1 1 3 13.72
part to part Range 0.060
Fixture to Fixture variation Range of avg. #DIV/0!
time to time variation whole avg 13.753
2 1 1 13.74
2 1 2 13.70
2 1 3 13.70
part to part Range 0.040
Fixture to Fixture variation Range #DIV/0!
time to time variation whole avg 13.713
3 1 1 13.71
3 1 2 13.73
3 1 3 13.79
part to part Range 0.080
3 Fixture to Fixture variation Range #DIV/0!
3 time to time variation whole avg 13.743
3 2 3

4 1 1 13.80
4 1 2 13.69
4 1 3 13.72
part to part Range 0.110 0.000
4 Fixture to Fixture variation Range #DIV/0!
4 time to time variation whole avg 13.737
4 2 3

5 1 1 13.68
5 1 2 13.74
5 1 3 13.72
part to part Range 0.060 0.000
5 Fixture to Fixture variation Range #DIV/0!
5 time to time variation whole avg 13.713
5 2 3

6 1 1 13.7
6 1 2 13.73
 6 1 3 13.77
part to part Range 0.070 0.000
6 Fixture to Fixture variation Range #DIV/0!
6 time to time variation whole avg 13.733
6 2 3

7 1 1 13.73
7 1 2 13.73
7 1 3 13.66
part to part Range 0.070 0.000
7 Fixture to Fixture variation Range #DIV/0!
7 time to time variation whole avg 13.707
7 2 3

8 1 1 13.68
8 1 2 13.72
8 1 3 13.77
part to part Range 0.090 0.000
8 Fixture to Fixture variation Range #DIV/0!
8 time to time variation whole avg 13.723
8 2 3
9 1 1 13.68
9 1 2 13.73
9 1 3 13.74
9 part to part Avg. 0.060 0.000
9 Fixture to Fixture variation Range #DIV/0!
9 time to time variation whole avg 13.717
10 1 1 13.7
10 1 2 13.75
10 1 3 13.7
10 part to part Range 0.050 0.000
10 Fixture to Fixture variation Range #DIV/0!
10 time to time variation whole avg
 part to part max. of range 0.110
Fixture to Fixture variatio 0.000
time to time variation 0.042

0.120
56
0.060 0.042
0.04 0.042 0.100
0.08 0.042
0.049 0.042
0.11 0.042
0.06 0.042 0.080
0.08
0.07 0.042
0.07 0.042
0.09 0.042 0.060
0.06 0.042 0.060
0.05 0.042
0.0
0.040
0.04

0.020

0.000
1 2 3 4
 0.11

0.09

0.08

0.07 0.07
Column M
060 0.06 0.06 Column N

0.049 0.05

0.04

1 2 3 4 5 6 7 8 9 10 11
World Class Manufacturing Solutions

Variation Analysis

Part Details
Gage number
Characteristic Part number
Unit of Part Description Gage
Measurement description
Date Gage Least
Target Value count
Gage R&R
Tolerance value
Gage Bias
USL and
Study dates and Uncertainity
0.113 Shift (%)
LSL
0 Any other details
Data Grouping and Sample details
Number of Groups (Number of
time blocks x number of streams) 20

Number of Samples in Each group

(It is preferable to collect 5
samples continuously from the
process so that the inherent 3
variations are captured

Checking the consistency of part to part variation (Step 7)

Average Range (R-bar) (Round off to one decimal Samples D3 D4
more than the data) 0.0426 2 0 3.267
3 0 2.575
Upper Control Limit (UCL) = D4*R-bar (Round off 4 0 2.282
to the same decimal as data) 0.110 5 0 2.115
6 0 2.004
Lower Control Limit (LCL) = D3*R-bar 0
Yes
Is the Part to Part variation consistent
If the Part to Part variation is not consistent, STOP, do not proceed further. Plan for DOE

Is the Range Chart plotted Yes

Are the Stratification levels more than 3 Yes

If the stratification level is <=3, then the Part to Part variation is very less and the parameter does not
require any monitoring. STOP. Do not proceed further

Are there 7 consequtive points increasing, decreasing Yes / No If yes write

and one side of the Mean range causes (if
possible)

Rev: 1/Jan 2003 Page: 12/15

World Class Manufacturing Solutions

If the range contains patterns as described above, STOP. Plan for DOE

Estimating Part to Part variation (Step 9)

Sigma = R-bar/d2 (Round off to one decimal more 0.0252 Sample d2
than data) 2 1.128
3 1.693
6 * Sigma (Round off to the same decimal as data) 0.151 4 2.059
5 2.326
Overall Average (Round off to one decimal more 6 2.534
than data) 0.0471
Construction of Histogram (Step 10)
Number of Groups = Sqrt (Number of data points)
Range = Maximum Value - Minimum Value
Class Interval (C.I) = Range/Number of groups
Class Inverval (C.I) after rounding off to the same
decimal as data
Draw the Histogram here

Does the Overall Average lie in the group having

maximum frequency or in the adjacent groups
Yes/No
Is there a gradual decreasing trend in frequency on
both sides of the group having the maximum
frequency
Yes/No
Are there two Modes (Two groups having maximum
frequency) and both the groups are distinctly
seperated
Yes/No
Based on the above analysis, can you conclude that
the histogram is Normal Yes/No

Rev: 1/Jan 2003 Page: 13/15

World Class Manufacturing Solutions

Note: If the Histogram is non-normal, the estimated rejection which we do in the next step may not be
correct. Data transformation is required to correct non-normality
Rejection Analysis Using Sigma (Only for Normal distributions) (Step 11)

Average Z(USL) = (USL - Average)/Sigma 2.79

Sigma Z(LSL) = (LSL - Average)/Sigma -3.50000000000001

Projected Rejection % above USL
6 * Sigma (Based on the Normal table
Projected Rejection % below LSL
(Based on the Normal table)
USL
Cpk = Zusl/3,Zlsl/3
LSL

Rejection Analysis if the results above show rejection on one side higher than the other side
Target (Design) Z(USL) = (USL - Target)/Sigma

Sigma Z(LSL) = (LSL - Target)/Sigma

Projected Rejection % above USL
(Based on the Normal table
6 * Sigma
Projected Rejection % below LSL
USL (Based on the Normal table)
LSL Cpk = Zusl/3,Zlsl/3

Six Sigma Analysis (Step 13)

6 Sigma <= 75% of Tolerance
6 Sigma >75% of Tolerance and <=100% of tolerance
6 Sigma > Tolerance

Actions decided based on Six Sigma Analysis

6 Sigma > 75% of Tolerance and
6 Sigma <= 75% of Tolerance <=100% of tolerance 6 Sigma > Tolerance
Actual Part to Actual Part to Part Use Average and Range chart for Use DOE to reduce variation
Part variation variation > 50% of monitoring, but it has to be done with
<= 50% of tolerance 100% inspection
tolerance
Use Pre-control Use Average and Do DOE to reduce variation or to 100% Inspection
chart for Range chart for question the tolerance for that
monitoring monitoring parameter
Remove 100% inspection if done
on this parameter

Calculation of limits for Average if the decision taken is Average and Range monitoring
Sample A2
2 1.880
Average 3 1.023
4 0.729
UCL = Average + A2*R-bar 5 0.577
6 0.483

Rev: 1/Jan 2003 Page: 14/15

 Sample A2
2 1.880
World Class Manufacturing Solutions 3 1.023
4 0.729
5 0.577
6 0.483

LCL = Average - A2* R-bar

Select which of the following DOE tools will be used if 6 Sigma > Tolerance
DOE Tools selected for Process Improvement

Multi-Vari Analysis
Concentration Chart
Paired Comparison
Component Search
Product/Process Search
Variable Search
Full Factorial
B Vs C Test
Scatter plot for Process optimization
EVOP (Evolutionary Operations) for Process
Optimization
Analysis Completed by Reviewed and Approved by Date

Rev: 1/Jan 2003 Page: 15/15