6σ M

Module - 3

Detailed Contents

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Module - 3

Chapter Sub Chapter details Slide Numbers

Number
1 1.1 - Introduction to Minitab 3-11
1.2 – Doing Multivari analysis using Minitab 12-36
1.3 - Doing Factorial analysis using Minitab 37-53
1.4 - Doing Variation analysis using Minitab 54-65
1.5 - Process Optimization for Single response 66-115
1.6 - Process Optimization for Multiple responses 116-122

2 2.1 – Introduction to Problem definition tools 123-126

2.2 – Problem definition tool # 1 – Process mapping 127-176
2.3 – Control Planning for all SSV’s 177-194

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Module - 3
Chapter – 1 – Data analysis using Minitab

1. Introduction to Minitab

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What is Minitab

 Software for analyzing data

 Should be used only for complicated analysis which
takes more time
 Not required for the following tools
 Paired comparison
 Product/Process search
 Component Search
 Modified Component Search
 Concentration chart

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Analysis in Minitab

 Multi - Vari analysis

 Using Graphical technique
 Using ANOVA (Analysis of Variance)
 Using Test of Equal variances
 Box Plots
 Factorial analysis
 Variation analysis
 Box Plots
 Histogram
 Normality test
 Process optimization for multiple responses

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Minitab Environment
Menu options

Sessions Window

Data Window

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File menu

•Used for Managing Files

•The files can be saved as
•Worksheet
•Project
•Work sheet will save only the data
•Project will save all the analysis results along with
the data

! Warning
If not saved as Project file, all the
analysis results will be lost

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Stat menu

• Thisis the key menu for all the

analysis
•All analysis options are in this menu

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Graph menu

• This menu is used for making

different types of graphs like
histogram, Box plot

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Windows menu

• Is
used for switching windows
containing different analysis

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Folders

Used to access all graphs

Used to access all

worksheets

Used to access
sessions window

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Module - 3
Chapter – 1 – Data analysis using Minitab

2. Multi-vari analysis using Minitab

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Multi-Vari analysis

 There are two types of analysis we can do in Minitab

 Graphical analysis
 Numerical analysis
 Technique used will be ANOVA (Analysis of Variance)

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Feeding data

Type the column titles in the order as given:

a. First should always be ‘Time’
b. Last column should always be ‘Response’
c. Last but one column should always be ‘Part’
d. In between columns should be streams, in the
order of Top to down approach (Starting from the
first level to the last level)

Type the data for the Multi-spindle data given in training material Slide number: 172
Save the ‘Worksheet’ using File -> Save Current worksheet option. Give a suitable name

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Feeding data – Changing from Numeric to Text

Note the change in the

‘Part’ column

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Graphical analysis – Multi-Vari

•Select in Stat -> Quality tools

-> Multi-vari chart as shown
in the screen

What the selected option does

is displayed in this region

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Graphical analysis – Multi-Vari

• Double click “Response” in

the left box to select
“Response”
•Select the factors in the
following order
• Factor – 1 – Part
• Factor – 2 - Tool
• Factor – 3 – Spindle
• Factor – 4 – Time

Click OK to get the graphs

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Graphical analysis – Multi-Vari

Blue line is Spindle to

Spindle variation

Part to Part
Tooling to Tooling variation
variation

Based on the Visual analysis, What is your conclusion? Which variation

is highest

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Graphical analysis – Multi-Vari

Graph will always be displayed

with the vertical line as the ‘Factor-
1

Check the title for how the graph is

displayed . Factor -1 / Factor - 4

Graph will always be displayed

‘Factor-4’ wise

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Graphical analysis – Multi-Vari

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Graphical analysis – Multi-Vari

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Graphical analysis – Multi-Vari

All analysis done will be displayed

in this window

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Numerical analysis – Multi-Vari

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Numerical analysis – Multi-Vari

• Select Response in the

Response box
•Select the factors from the
highest level to the lowest
level in the Factors box
•Click OK after selection

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Numerical analysis – Multi-Vari

•Results are displayed in the

Sessions window as shown in
the picture
•Check the % of Total
column. This gives the %
contribution of each of the
variation
•Find out which has the
highest percentage

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Test of Equal Variances – Multi -vari

• When we are find out the Stream to Stream variation in Multi-vari analysis, we are
checking whether one stream is different from the other stream based on the “Averages
of the stream values”
•Some times, we may also have to check whether the “Variation” within the one stream
is same as “Variation” within another stream. (Eg: variation within all the spindles are
same are different)
•This will also give us the clue about whether something is wrong in any stream or not
•To do this, we will be doing the “Test of Equal variances”
•Use this tool, when the conclusion in Multi-vari analysis shows that “Part to Part
variation” is highest and we have to further investigate whether are there any
differences within the streams in the Part to Part variation
•The methodology is discussed in the next slides

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Test of Equal Variances – Multi -vari

Select
Stat -> ANOVA -> Test
of equal variances

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Test of Equal Variances – Multi -vari

Select the Response and

select the “Stream” in
Factor block for which we
have to check the
difference in the variances

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Test of Equal Variances – Multi -vari

• Check the P-value under

‘Levene’s test.
•If the P value is <= 0.05,
then the variations in
certain streams are less
than certain streams
•If the P value is > 0.05,
the variation in all the
streams are almost same
•In this data, Spindle 3,4
& 6 are having less
variation compared to
Spindle 1,2 & 5

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Test of Equal Variances – Multi -vari

Test for Equal Variances for Response • The analysis shows that
95% Confidence Intervals for Sigmas Factor Levels
the variations within all
J1 the jigs are same and
Bartlett's Test there is no difference in
J2
Test Statistic: 17.481
the variation
P-Value : 0.008
J3

J4

Levene's Test
J5
Test Statistic: 1.512

J6 P-Value : 0.172

J7

2 3 4

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Test of Equal Variances – Multi -vari

• This analysis shows that

the Bottom to Top
variation are different and
the Top variation is more
than Bottom

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Box Plots

 Box plots are used to check whether are there any

outliers in the data within the streams
 The outlier is indicated with an “*” mark in the graph
 This indicates that the variation in that stream is
inconsistent and we have to identify the SSV’s related
to this inconsistency in that stream

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Box Plots

Select Graph -> Box plot to get

the Box plots

This is minimum value

This is 25% point

This is 50% point

This is 75% point

This is minimum value

Indicates abnormal data

(Outlier)

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Box Plots

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Box Plots

Select Response in the ‘Y’

column and the Stream for
which we have to study the
outlier in the ‘X’ column

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Box Plots

The ‘*’ in SP6 indicates that

there is inconsistency in
Spindle -6 data

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Module - 3
Chapter – 1 – Data analysis using Minitab

3. Factorial analysis using Minitab

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Factorial analysis

•Select Stat -> DOE ->

Factorial -> Create Factorial
Design

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Factorial analysis

Select “2-level factorial”

Select the number of factors

as 2 for our data

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Factorial analysis

Select “Designs” and select “Full

Factorial”

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Factorial analysis

Click “Factors” to get the

screen shown
Type “- +” in the Level values
for both the factors and type the
name of the factors

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Factorial analysis

Click “Options” to get the

screen shown
Deselect “Randomize runs”
box

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Factorial analysis

Type the responses in the

column as shown

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Factorial analysis

Select DOE -> Factorial ->

Define customer factorial
design

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Factorial analysis

Double click and select the

factors Housing cover and
Housing

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Factorial analysis

Click “Low/High” button to get

the screen above
Select “OK” in the screen

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Factorial analysis

Select DOE-> Factorial ->

Analyze Factorial Design

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Factorial analysis

Select “Response” in the

Response block

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Factorial analysis

Click “Results” button to get

the screen
Select “Coefficients and
ANOVA table” option

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Factorial analysis

Click “Graphs” button to get

the screen
Select “Pareto” checkbox

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Factorial analysis

Pareto – Displays the

contribution of the parameters
visually

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Factorial analysis

The results are displayed in the

session window

Contribution of the parameters

Linear equation

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Factorial analysis – Factorial plots

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Module - 3
Chapter – 1 – Data analysis using Minitab

4. Variation analysis using Minitab

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Step #1 – Checking consistency of Part to Part variation

Select Control charts -> R

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Step #1 – Checking consistency of Part to Part variation

Double click to select

“response” and type the sample
size

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Step #1 – Checking consistency of Part to Part variation

Range chart is displayed as

shown.
Check the Part to Part variation
for the patterns discussed
during the training

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Step #2 – Checking for Normality

Select Graph-> Histogram and

get the histogram to check for
normality

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Step #2 – Checking for Normality

Select Stat -> Basic Statistics -

> Normality test to do a
statistical normality test

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Step #2 – Checking for Normality

If P-value is <= 0.05, it

indicates that the distribution is
“NOT NORMAL”.
If P-Value is > 0.05, it indicates
that the distribution is
“NORMAL”

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Step #3 – Estimating P-P variation and the rejection
percentage

Select Quality tools ->

Capability analysis (Normal)

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Step #3 – Estimating P-P variation and the rejection
percentage

Double click to select the

response
Feed the subgroup size
Define the USL and LSL

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Step #3 – Estimating P-P variation and the rejection
percentage

Click “Estimate” to get the

screen as shown
Select “R-bar” option

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Step #3 – Estimating P-P variation and the rejection
percentage
StDev (Within) is the Sigma
(Part to Part) variation.
Multiply this with 6 to get the
Estimated Part to Part variation

Look the Exp “Within”

Performance to find out the
estimated rejection due to part
to part variation

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Step #4 – Checking consistency of Time to Time variation with
respect to Part to Part variation

Select Stat -> Control charts ->

X-bar to get the X-bar chart

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Module - 3
Chapter – 1 – Data analysis using Minitab

5. Process optimization for single response

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Optimization for Single response

 Let us now use Minitab to optimize for a Parameters - +

Single response Table Speed (rpm) 70 80
 Let us use the following data for doing this Rod feed (mm/min) 60 51
optimization
Weld current (Amp) 145 180

Sl no A B C Response
Table speed Rod feed Weld
(RPM ) (mm/min) current( in
amps)
1 - - - 10 , 9.80 , 9.30
2 + - - 9.0
3 - + - 9.3
4 + + - 9.30
5 - - + 10.5
6 + - + 10
7 - + + 9.80
8 + + + 8 , 7.50 , 7.70

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Analysis Phase – Using Minitab

•Select Stat -> DOE ->

Factorial -> Create
Factorial Design

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Analysis Phase – Using Minitab

Select “2-level factorial”

Select the number of factors

as 3 for our data

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Analysis Phase – Using Minitab

•Select “Designs” and

select “Full factorial”

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Analysis Phase – Using Minitab

•Select “Factors”
•Type the name of the
parameters
•Type the “Actual” low and
high settings

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Analysis Phase – Using Minitab

•Select “Options”
•Deselect “Randomize
runs”

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Analysis Phase – Using Minitab

•Type the response

•When you type the
response, please see the
combination in actual
setting and then feed the
response

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Analysis Phase – Using Minitab

•Select Stat -> DOE ->

Factorial -> Define
customer factorial design

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Analysis Phase – Using Minitab

•Select the Factors

•Select the factors in the
same order as we had
created the table

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Analysis Phase – Using Minitab

•Select “Low/High”
•Select “OK”
•Even though we do not do
anything in this screen, we
have to do this step, since
there is a logical problem in
the software

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Analysis Phase – Using Minitab

•Select Stat -> DOE ->

Factorial -> Analyze
factorial design

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Analysis Phase – Using Minitab

•Select the Response

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Analysis Phase – Using Minitab

•Click “Graphs”
•Select “Pareto”

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Analysis Phase – Using Minitab

•Click “Results”
•Select “Coefficients and
ANOVA table”

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Analysis Phase – Using Minitab

•The Pareto of the effects is

displayed
•From this we can find out
which parameters are
having important
contributions

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Analysis Phase – Using Minitab

•Click the “Sessions”

button
•You can see the effects of
various parameters and the
effects of interactions
displayed

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Analysis Phase – Using Minitab

•You can also see the co-

efficient for making the
equation displayed.
•Please note that these co-
efficient are Actual and not
coded
•Hence we can make the
Actual equation

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Analysis Phase – Using Minitab

•Select STAT -> DOE ->

Factorial -> Factorial plots

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Analysis Phase – Using Minitab

•Select Main effects plot

and Interaction Plot

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Analysis Phase – Using Minitab

•Select “Setup” button

against the Main effect plot
•Select the response
•Move all the three
parameters to the selected
side

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Analysis Phase – Using Minitab

•Do the same for

Interaction plot

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Analysis Phase – Using Minitab

•Select Option
•Select “Draw full
interaction plot matrix”

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Analysis Phase – Using Minitab

Main Effects Plot (data means) for Response

•Main effect plot will be

5 0
70 80 51 60 14 18
displayed
9.8

9.6
Response

9.4

9.2

9.0
Tab speed Wire feed Current

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Analysis Phase – Using Minitab

Interaction Plot (data means) for Response

70 80 51 60 14 5 18 0

Tab speed 10.0 •Interaction plot will also

80
9.5 be displayed
9.0
70

Wire feed 10.0

9.5
60
9.0
51

Current 10.0

9.5
180
9.0
145

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Analysis Phase – Using Minitab

 After we had done the factorial analysis, now we

have to find out the Optimal setting. This is done in
two stages in Minitab
 First stage is to find out whether is there a optimal setting
possible
 If it is possible, then we find out the optimal setting using
Minitab
 If it is not possible, then we have to find out the optimal
setting using Excel

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Analysis Phase – Using Minitab

•Select STAT -> DOE ->

Factorial -> Overlaid
contour plot

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Analysis Phase – Using Minitab

•Select the Response

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Analysis Phase – Using Minitab

•Select ‘Contours’
•Feed the Lower and Upper
boundary
•Calculation of the Upper
and Lower boundary
procedure is given in the
next slide

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Analysis Phase- Using Minitab

 Calculating the Upper and Lower boundary for Y

 If nature of Y is ‘Lower the Better’
 Lower Boundary = USL – 2.8*d
 Upper Boundary = USL – 2.3*d
 d = Average of ranges, which we have calculated in the
first step
 If the nature of Y is ‘Higher the Better’
 Lower Boundary = LSL + 2.3*d
 Upper Boundary = LSL + 2.8*d
 If the nature of Y is ‘Nominal the Better’
 Boundary1 = Target – 25% of tolerance
 Boundary2 = Target + 25% of tolerance

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Analysis Phase- Using Minitab

 Calculating the Upper and Lower boundary for Y

 For example we are discussing,
 Lower Boundary = 8.88 gms
 Upper Boundary = 9.18 gms

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Analysis Phase – Using Minitab

•If the response is attribute,

the we would have
collected the data in batches
•Feed the Lower boundary
as ‘0’ and Upper boundary
as 0.1

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Analysis Phase – Using Minitab

•We have to select two

parameter for software
control
•Select the parameters
which are smoothly
variable parameters for
software control
•In this example, out of 3,
any 2 can be selected since
all the three are smoothly
variable

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Analysis Phase – Using Minitab

•Once we have given two

parameters for software
control, we have to decide
where we are going to set
the other parameters
•For this Select ‘Settings’
•Type the setting of the
other parameters,
whichever is favorable
•In this example, current is
the other parameter and we
are deciding to set at 145
Amps and not 180 Amps,
since 145 is favorable

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Analysis Phase – Using Minitab

•If we get ‘White area’ then

optimal setting is possible
within the Design boundary
and we can proceed further
in Minitab to get the
Optimal setting
•If we do not get ‘White
area’, then optimal setting
is not possible within the
Design boundary and we
have to go to Excel to find
out the Optimal setting

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Analysis Phase – Using Minitab

•Select STAT -> DOE ->

Factorial -> Response
optimizer

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Analysis Phase – Using Minitab

•Select the Response

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Analysis Phase – Using Minitab

•Select Setup
•Feed the Lower boundary
•Feed the Upper boundary
•Feed the Target value as
(Upper boundary + Lower
bounday)/2
•By default, the goal should
always be ‘Target’
•By default, Weight should
always be 1

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•If the response is attribute,

then feed the lower
boundary as 0
•Upper boundary as 0.1
•Target = 0.05

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Analysis Phase – Using Minitab

• The optimal settings are

displayed in ‘Red’
•If d = 1, then the setting
gives response exactly the
target value
•If d is <1, then the setting
give the response away
from the target but within
the boundary
•d is called ‘Local
optimality’

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Analysis Phase – Using Minitab

•The settings given have to

be fine tuned, based on the
process
•Click on the setting, and
the value can be edited

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Analysis Phase – Using Minitab

•Change the Current setting

to 145 amps, since this is
the setting where we had
found earlier that there is a
optimal solution possible
•Change the other
parameters to get the
highest d value
•Use the Interaction plot to
see how the parameter has
to be changed
(increased/decreased)

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Analysis Phase – Using Minitab

•The following is the

Optimal setting in terms of
quality, cost and
productivity for the
example which we are
discussing
•Table speed – 80 rpm
•Rod feed – 59 mm/min
•Current – 145 Amps

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Analysis Phase- Using Minitab

 If we do not get white area in the Overlaid contour

plot, then we have to go to excel
 Build the equation in excel using the actual
co-efficients
 Actual co-efficients can be got from the sessions
window

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Analysis Phase- Using Minitab

•After making the equation,

feed a known combination
of setting and check
whether are we getting the
same response
•Only after this proceed for
optimization

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Analysis Phase- Using Minitab

•Decide which parameters

has to be set and at what
setting
•We have to decide the
parameters which are speed
and cost related and set it at
the favorable setting
•In this case, Current is set
at 140 amps and Table
speed is set at 80 rpm

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Analysis Phase- Using Minitab

•Select Tools -> Goal Seek

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Analysis Phase- Using Minitab

•Select the cell in which we

have programmed the
equation in ‘Set cell’
•Type the desired value of
Y required in ‘To value’. In
this case let us say we want
7 gms
•Select the parameter which
we want to calculate in ‘By
Changing cell’

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Analysis Phase- Using Minitab

•The setting required for

Wire feed will be displayed
•Fine tune to make it
practical in the process
•In this case the optimal
setting are
• Table speed – 80 rpm
•Wire feed – 85 mm/min
•Current – 140 amps

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Analysis Phase- Using Minitab

 We can work out various settings like this and then

select the best one as our Optimal setting
 It is always better to do the Optimization in Excel
instead of Minitab, since in Minitab optimization can
be done only within the Design boundary
 In Excel, we can go outside the design boundary and
get the best of best setting in terms of quality,
productivity and cost

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Module - 3
Chapter – 1 – Data analysis using Minitab

6. Process optimization for Multiple

responses

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Optimization for Multiple response

• Steps are exactly same as the steps we did for Optimization of single
response, except that we have to key in all the responses and do the analysis
by selecting all the responses
•Let us use the data given below for Multiple response optimization

B C Height Crack Strength

(Y1) (Y2) (Y3)
1.19 3 150
- -
1.245 2 130
+ -
1.26 0 128
- +
1.37 1 125
+ +

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Optimization for Multiple response

Feed the following

responses for optimization

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Optimization for Multiple response

White area indicates that the

solution is possible

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Optimization for Multiple response

Feed the Goals for each of

the responses as given.
Use the same guideline as
we discussed in the earlier
slides

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Optimization for Multiple response

Best setting is given in red.

‘D’ gives the Global
optimality, considering all
the three responses
‘d’ gives the Local
optimality for each response

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Optimization for Single response
Optimization beyond Design boundary
If we have to optimize beyond the “Design boundary”, build the
linear equation in “Uncoded terms” in excel
Do optimization using Excel

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Module - 3
Chapter – 2 – Problem Definition tools
(Define Phase tools)

1. Introduction Problem definition tools

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Introduction to Problem definition tools

 Problem definition tools are used to come up with clear

definition
 These tools help in identifying all the SSV’s before we start the
application of the DOE
 These tools ensure that the “Brainstorming” is done in a
systematic way to get all the SSV’s instead of just listing the
SSV’s direclty
 All the tools in Problem definition are mostly “Analytical” tools
 The application of these tools to define the problem depends on
the complexity of the six sigma project selected

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Introduction to Problem definition tools

 The following are the problem definition tools

 Pareto
 Process flow diagram
 Calibration
 Gage Repeatability and Reproducibility study
 Out of the above tools, Process mapping is an
analytical tool and is discussed in the next slides

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Introduction to Problem definition tools

Name of the Tool Application in Problem definition Type of tool

Pareto -Identify the Defect that needs to be taken up as -Data based

the project
-Select the Part number for the application of

Phase II
Process flow diagram - To clearly understand the Process sequence Analytical
and come up with list of SSV’s
Calibration - To find out the instrument related variation Data based

Gage R&R studies - To find out the variation due to method of Data based
checking

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Module - 3
Chapter – 2 – Problem Definition tools

2. Process flow diagram

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Process flow diagram
 Is done to analyze the sequencing of the
processes
 Is a knowledge base for identifying the
SSV’s
 Process flow diagram is required only if the
problem nature is complicated (eg: Process
that is creating the problem is not known)
 Process flow diagram is constructed for the
Part number selected for analysis
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Process flow diagram

 Process steps and the activities below them

that are done to realize the produce
 Desired outcomes of the Process steps
 Incoming sources of variations
 Process characteristics for the process step
 Sequencing of the process steps

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Process flow diagram
Process type : Machining
Sq.no Process step Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING 1.SPAN SIZE I.P.
2.P.C.D. R/O I.P.
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1. MATERIAL HARDNESS 1.SPAN SIZE B.P. 1.MANDREL O.D.

2.SPAN SIZE (110) 2.P.C.D. R/O B.P. 2.R/O ON THE CENTERS OF MACHINE
3.P.C.D. R/O (110) 3.T.T.C.E. B.P. 3.CUTTING OIL TEMPERATURE
4.SURFACE FINISH ON TOOTH 4.T.C.E. B.P. 4. FIXTURE R/O
FLANK (110) 5.SURFACE FINISH ON TOOTH B.P. 5.CLAMPING PRESSURE OF CENTERS
5.MINOR DIA. (090) FLANK 6. BLUNT CUTTER
6.O.D. R/O (090) 6.NO HOB MARKS/TOOL MARKS V.P.
7. UNFILL (030) 7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE

2.HOLE DIA.
3.VISUAL INSPECTION

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Process flow diagram
• Since Process flow diagram is an analytical tool, each
information has to be arrived at based on certain logical questions
•To ensure that the Process flow diagram is “Value added” in
Problem definition, please follow the rules and questions given in
the subsequent slides for capturing each information
•For easy reference, wherever we have to ask a question the icon

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Step : 1 – Identifying Process steps and
activities under process steps
 To identify and list down the process steps ask the following questions
 Can the parameter that are generated on the product (hardware) after the process step
me measured and controlled during production
 If the answer is ‘yes’, write it as a process step, otherwise, do not write that as a
process step.
 Give a unique number for each process step for identification
 We need to write all the Process steps from the beginning till end for the Part number
selected
 If there is a 100% inspection done as a part of the process as a separate stage (one operator,
whose job is only to inspect), then inspection should be listed as a Process step
 Example: Heat treatment process, should it be written as one process step, or should we
write 10. Carburizing 20. Soaking 30. Quenching 40. Tempering as four process steps.
 Question to be asked to decide is “Can the parameters generated after carburizing be
checked and controlled during production”. Can the parameters generated after Soaking be
checked and controlled during production

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Step : 1 – Identifying Process steps and
activities under process steps
 Example – Press shop
 In a Press shop, we have the following five process steps
 Blanking
 Drawing
 Trimming
 Punching 5 holes
 Punching 10 holes
 Should these be written as separate Process steps or should everything be comined
and written as one process step ?
 Answer: Depends on how the production line is designed. If there is an automatic
movement of blank from one station to another station and the outcomes cannot be
controlled at every intermediate stage, then it has to be combined and written as one
process step. If the process steps are independent and the output of each process step
can be measured and controlled, then it has to be written as separate process steps

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Step : 1 – Identifying activities

 Ask the following questions in the same order to find out

and write the activities within each process step
 Is the activity done on each and every part or each and
every assembly
 Is the activity done by a person
 Is there a possibility of a mistake happening when the
person does that activity
 The activities under the process step should be written only
when it answers “yes” to all the above three questions

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Step:1 – Identifying activities - Examples

 Extrusion
 Feeding of Stock to Hopper
 Extrude
 Pass through Cooling conveyor
 On line cutting
 Booking of Extrudate
 Which of the above activities should be listed as an
activity?
 Answer:

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Step:1 – Identifying activities - Examples

 Machining in CNC machine
 Load the component in the collet and clamp
 Close the Door
 Open the Door
 Unload the component
 Which of the above activities should be listed as an
activity ?
 Answer:

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Step:1 – Identifying activities - Examples

 Forming
 Assemble the die and set the press
 Load the blank in the die
 Push the Button to operate the press
 Unload the drawn component
 Visually check for surface defects
 Which of the above activities should be listed as an
activity ?
 Answer:

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Step:1 – Identifying activities - Examples

 Assembly
 Place adaptor on fixture
 Place the motor assembly on the adaptor
 Put three screws and tighten
 Unload the assembly from the fixture
 Check the torque of the three screws
 Which of the above activities should be listed as an
activity ?
 Answer:

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Step:1 – Identifying activities - Examples

 Welding
 Load middle channel X-member / LH assy. S/S / RH assy.
S/S / Rear X-member on fix no. 1 and Actuate pneumatic
Clamps.
 Bolting front X-member with bolt
 MIG Weld as per process sheet
 Which of the above activities should be listed as an
activity ?
 Answer:

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Step:1 – Identifying activities

Sq.no Process step Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING

120 DE-BURRING

130 SHAVING

140 INSPECTION

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Summary for Step - 1

 Write process step only when the parameter generated in the
process step can be monitored and controlled
 Write the activities based on the following three questions
 Is the activity done on each and every part or each and every assembly
 Is the activity done by a person
 Is there a possibility of a mistake happening when the person does that
activity
 Process steps and the activities with each step has to be written
for all the processes for the part number selected for analysis

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Step : 2 – Identifying Desired Outcomes

 Desired outcomes are written for each process step

 Do not write outcomes for every activity within the process step
 Outcomes should be generated in that Process step
 Ask the following question for every process:
 After completing the process, what are the parameters that are
generated on the product
 Desired outcomes of a process, need not always be measurable (eg:
Adaptor should not be placed upside down)
 Write all the desired outcomes of the process. Do not restrict to
Outcomes that are being inspected currently
 Write the desired for all the process steps

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Step : 2 – Identifying Desired 3

Outcomes
 To ensure that all the possible outcomes are captured think of the
outcomes in the following categories. After writing the outcome, also
identify the category it belongs to
 There are five categories of outcomes that we have to think of when we
are writing the desired outcomes for every process step
 Blue Print (BP) – Outcomes that are dimensional and are the final
dimensions for the customer
 In-process (IP) – Outcomes that are dimensional and are stage dimensions
and will get processed further
 Engineering Specifications (ES) – Outcomes that are properties of material
(Physical, metallurgical, chemical, mechanical)
 Visual Parameters (VP) – Outcomes that are checked visually (eg: surface
defect, rust, dents, grinding marks etc..)
 Geometric dimensions (GD) – Parameters that are shape related

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Step 1 – Identifying outcomes – GD outcomes

Form Controls
Flatness Straightness Roundness Cylindricity

Orientation Controls
Perpendicularity
( Squareness) Angularity Parallelism

Location Controls

Position Symmetry Concentricity

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Step 1 – Identifying outcomes – GD outcomes

Composite Controls

Circular runout Total runout

Profile Controls

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Step : 2 – Identifying Desired Outcomes

 When identifying outcomes, ask the question “What are the

desired outcomes after completing the process”. Do not ask
the question “Why is this process done”.
 Example:
 Putting ID cover in a Cold rolled coil is a process. What
is the outcome of this process??
 Answer: We should not write the outcome as “To
prevent coil from collapsing”. This is the function of the
ID cover.
 The correct outcome is “Cover should be flush with the
coil face” (generated after the process)

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Step : 2 – Identifying Desired Outcomes

 Do not write the outcomes as “proper

loading” , “proper location” etc.. Write what
is the expected outcome in proper loading
“Should butt against the face of the plate”,
“Should not be loaded upside down”
 Sometimes, when writing outcomes, think
what are all the outcomes that are not
expected from the process and write the
“opposite” of these as “Desired outcomes”
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Step : 2 – Identifying Desired 3

Outcomes
Sq.no Process step Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING 1.SPAN SIZE I.P.
2.P.C.D. R/O GD
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1.SPAN SIZE B.P.

2.P.C.D. R/O GD
3.T.T.C.E. B.P.
4.T.C.E. B.P.
5.SURFACE FINISH ON TOOTH B.P.
FLANK
6.NO HOB MARKS/TOOL MARKS V.P.
7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE BP

2.HOLE DIA. BP
3.VISUAL INSPECTION VP

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Step : 2 – Identifying Desired 3

Outcomes
 Desired outcomes has to be identified for all the process
steps listed for the Part number selected
 After we had identified the outcomes of all the process,
mark the process step where the Problem is generated. There
may be more than one process steps that are generating the
problem
 The next analysis in the Process mapping has to be done
only for the Marked process steps and not for all the process
steps

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Step : 2 – Identifying Desired 3

Sq.no Process step

Outcomes
Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING 1.SPAN SIZE I.P.
2.P.C.D. R/O GD
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1.SPAN SIZE B.P.

2.P.C.D. R/O GD
3.T.T.C.E. B.P.
4.T.C.E. B.P.
5.SURFACE FINISH ON TOOTH B.P.
FLANK
6.NO HOB MARKS/TOOL MARKS V.P.
7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE BP

2.HOLE DIA. BP
3.VISUAL INSPECTION VP

The next analysis should be done only for Process step no. 130

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Step : 3 – Identifying Incoming sources of
variations

 Incoming sources of variation are identified only

for the marked Process steps
 These are variations in the input material. There are
two types of incoming sources of variation
 Raw material (Input material to the first process
or materials used for assembly at each station)
 Input from the “Previous Processes”

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Step : 3 – Identifying Incoming 3

sources of variations
 List down all the raw material defects/variations
that are coming based on the data/experience
 Ask the question “out of this, which are all the
problems that are going to affect the “desired
outcomes” of the process under analysis
 Write the incoming variations, only if the raw
material defects/variations are going to affect the
desired outcomes of the process

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Step : 3 – Identifying Incoming 3

Sq.no Process step

sources of variations
Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING 1.SPAN SIZE I.P.
2.P.C.D. R/O I.P.
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1. MATERIAL HARDNESS 1.SPAN SIZE B.P.

2.P.C.D. R/O B.P.
3.T.T.C.E. B.P.
4.T.C.E. B.P.
5.SURFACE FINISH ON TOOTH B.P.
FLANK
6.NO HOB MARKS/TOOL MARKS V.P.
7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE

2.HOLE DIA.
3.VISUAL INSPECTION

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Step : 3 – Identifying Incoming 3

sources of variations
 Second type of incoming sources of variation are the problems coming
from the “previous process steps”
 The outcomes of “all the previous process steps” can come as a problem
to the Process step under analysis
 Assume there are no inspections and these will come to the process step
under analysis
 Identify the previous process step “outcomes” which will affect the
“Desired outcomes” of the process step under analysis
 When writing the Previous process step outcomes as incoming sources
of variation, also write the process step within bracket

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Step : 3 – Identifying Incoming 3

sources of variations
PROCESS FLOW DIAGRAM
COMPONENT DESCRIPTION - BULL GEAR (6M) PART NO. - 05080000
PROC. PROC. INCOMING SOURCES OF PROC.FLOW DESIRED OUTCOMES / IDENTITY- PROCESS CHARACTERISTICS /
NO. DESCR. VARIATION DIAGRAM PRODUCT CHARACTERISTICS FICATION PARAMETERS
10 BLANK CUTTING 1.BLANK LENGTH I.P.
2.PERPENDICULARITY OF FACE I.P.

20 HEATING 1.BLANK TEMPERATURE I.P.

30 FORGING/ 1.DIE RELATED DIMENSSIONS I.P./B.P.

TRIMMING/ 2.THICKNESS OF FORGING I.P.
PIERCING 3.NO MIS-MATCH I.P./B.P.
4.NO PITS B.P.
5.NO FOLDS B.P.
6.NO BEND
7. NO UNFILL
8.NO DAMAGE
9.NO BURNING E.S.
10.GRAIN FLOW E.S.

40 NORMALISING 1.MICRO STRUCTURE E.S.

2.SURFACE HARDNESS E.S.

50 SHOT BLASTING 1.NO SCALING V.P.

60 ROUGH BLANK 1.BLANK O.D. I.P.

TURNING 2.BLANK THICKNESS I.P.
3.FACE R/O I.P.
4.R/O ON O.D. I.P.
5.CHAMFER I.P.

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sources of variations
70 FINAL BORING/ 1.BORE DIA. I.P.
FACING 2.BOSS THICKNESS I.P.
3.THICKNESS OF RIM I.P.
4.STEP HEIGHT BOSS/RIM B.P.
5.CHAMFER B.P.

80 FINAL O.D. / 1.O.D. SIZE B.P.

FACE TURNING 2.THICKNESS OF RIM B.P.
3.THICKNESS OF BOSS B.P.
4.STEP HEIGHT BOSS/RIM B.P.
5.O.D. R/O I.P.
6.FACE R/O I.P.
7.PARALLELISM OF FACES B.P.
8.CHAMFER B.P.

90 BROACHING 1.DIA. BETWEEN PINS B.P.

2.MAJOR DIA. B.P.
3.MINOR DIA. B.P.
4.FACE R/O B.P.
5.FORM GAUGE FITTMENT B.P.
6.NO DRAG MARKS B.P.
7.O.D. R/O

100 DRILLING 1.HOLE DIA. B.P.

2.HOLE DEPTH B.P.
3.HOLE CO-ORDINATES B.P.
4.DE-BURRING B.P.

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2-2
Step : 3 – Identifying Incoming 3

sources of variations
Sq.no Process step Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING 1.SPAN SIZE I.P.
2.P.C.D. R/O I.P.
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1. MATERIAL HARDNESS 1.SPAN SIZE B.P.

2.SPAN SIZE (110) 2.P.C.D. R/O B.P.
3.P.C.D. R/O (110) 3.T.T.C.E. B.P.
4.SURFACE FINISH ON TOOTH 4.T.C.E. B.P.
FLANK (110) 5.SURFACE FINISH ON TOOTH B.P.
5.MINOR DIA. (090) FLANK
6.O.D. R/O (080) 6.NO HOB MARKS/TOOL MARKS V.P.
7. NO UNFILL (030) 7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE

2.HOLE DIA.
3.VISUAL INSPECTION

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2-2
Step : 3 – Identifying Incoming 3

sources of variations
• Identify the Incoming sources of variations also for the
previous process steps which have “marked outcomes”
•These will give input for identifying the second level SSV’s
when we are doing funneling in M&A Phase

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Step 3: Incoming sources of 3

variation
PROCESS FLOW DIAGRAM
COMPONENT DESCRIPTION - BULL GEAR (6M) PART NO. - 05080000
PROC. PROC. INCOMING SOURCES OF PROC.FLOW DESIRED OUTCOMES / IDENTITY- PROCESS CHARACTERISTICS /
NO. DESCR. VARIATION DIAGRAM PRODUCT CHARACTERISTICS FICATION PARAMETERS
10 BLANK CUTTING 1.BLANK LENGTH I.P.
2.PERPENDICULARITY OF FACE I.P.

20 HEATING 1.BLANK TEMPERATURE I.P.

30 FORGING/ BLANK TEMPERATURE (020) 1.DIE RELATED DIMENSSIONS I.P./B.P.

TRIMMING/ 2.THICKNESS OF FORGING I.P.
PIERCING 3.NO MIS-MATCH I.P./B.P.
4.NO PITS B.P.
5.NO FOLDS B.P.
6.NO BEND
7. NO UNFILL
8.NO DAMAGE
9.NO BURNING E.S.
10.GRAIN FLOW E.S.

40 NORMALISING 1.MICRO STRUCTURE E.S.

2.SURFACE HARDNESS E.S.

50 SHOT BLASTING 1.NO SCALING V.P.

60 ROUGH BLANK 1.BLANK O.D. I.P.

TURNING 2.BLANK THICKNESS I.P.
3.FACE R/O I.P.
4.R/O ON O.D. I.P.
5.CHAMFER I.P.

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3
2-2

variation
70 FINAL BORING/ 1.BORE DIA. I.P.
FACING 2.BOSS THICKNESS I.P.
3.THICKNESS OF RIM I.P.
4.STEP HEIGHT BOSS/RIM B.P.
5.CHAMFER B.P.

80 FINAL O.D. / RUNOUT ON OD (060) 1.O.D. SIZE B.P.

FACE TURNING 2.THICKNESS OF RIM B.P.
3.THICKNESS OF BOSS B.P.
4.STEP HEIGHT BOSS/RIM B.P.
5.O.D. R/O I.P.
6.FACE R/O I.P.
7.PARALLELISM OF FACES B.P.
8.CHAMFER B.P.

90 BROACHING OD SIZE (080) 1.DIA. BETWEEN PINS B.P.

OD RUNOUT (080) 2.MAJOR DIA. B.P.
3.MINOR DIA. B.P.
4.FACE R/O B.P.
5.FORM GAUGE FITTMENT B.P.
6.NO DRAG MARKS B.P.
7.O.D. R/O

100 DRILLING 1.HOLE DIA. B.P.

2.HOLE DEPTH B.P.
3.HOLE CO-ORDINATES B.P.
4.DE-BURRING B.P.

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Step 3: Incoming sources of variation

Sq.no Process step Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING OD RUNOUT (080) 1.SPAN SIZE I.P.
OD SIZE (090) 2.P.C.D. R/O I.P.
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1. MATERIAL HARDNESS 1.SPAN SIZE B.P.

2.SPAN SIZE (110) 2.P.C.D. R/O B.P.
3.P.C.D. R/O (110) 3.T.T.C.E. B.P.
4.SURFACE FINISH ON TOOTH 4.T.C.E. B.P.
FLANK (110) 5.SURFACE FINISH ON TOOTH B.P.
5.MINOR DIA. (090) FLANK
6.O.D. R/O (080) 6.NO HOB MARKS/TOOL MARKS V.P.
7. NO UNFILL (030) 7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE

2.HOLE DIA.
3.VISUAL INSPECTION

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Step : 4 – Identifying the Process

3
2-2

characteristics
 This is the most important step which will
help us in getting all the possible SSV’s
 Write the Process characteristics only for the
“marked process step” (Process step where
the problem is generated) to start with
 Process characteristics for the other process
steps can be listed based on the results of the
funneling in M&A phase

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Step: 4 – Identification of Process characteristics

 There are six different types of Process characteristics

 Process parameters (Parameters that are set in the process
and can vary during production)
 Machine parameters (Parts of the machine which can worn
out)
 Processing material Parameters (eg: Coolant, cutting oil)
 Tooling related parameters
 Operator error related parameters (Method of operation)
 Work environment related parameters

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Step: 4 – Identification of Process characteristics

Category Parameter
Process Parameter a. Pouring temperature
b. Pouring time
c. Clamping pressure
d. Hydraulic oil temperature
e. Closing pressure
f. Heating time
g. Cushion pressure
h. Alphin bath temperature
i. Alphining time

Machine Parameter a. Head stock alignment

b. Tail stock alignment
c. Repeatability of slide
d. Wear out of Cam
e. Head stock to Tail stock alignment
f. Center bearing contact
g. Machine levelling
h. Dresser condition
i. Slide wear
j. Tail stock carbide pad wear

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Step: 4 – Identification of Process characteristics

Category Parameter
Processing material a. Coolant contamination
b. Pointage of the cleaning media
c. Ph of the phosphating bath
d. Viscosity of draw oil
e. Core strength – Nail hardness value

Tooling related parameter a. Punch and Die clearance

b. Bead clearance in drawing operation
c. Bead radius
d. Vent hole position
e. Tool wear
f. Hardness of the tool
g. Tool shank diameter

Operator error related parameter a. Wrong clamping

b. Transfer time of billet
c. Placement of billet in the die
d. Glass removal method after blanking
e. Method of application of paint

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Step: 4 – Identification of Process characteristics

Category Parameter
Work environment related parameters a. Noise
b. Vibration
c. Humidity
d. House keeping
e. Lighting
f. Dust

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Step : 4 – Identifying the Process
characteristics
 Identifying the Process parameters
 List down all the process parameters that are set in the machine
before production (eg: speed, feed, pressure, time, temperature)
 Ask the question, which of these set parameters can vary during
production. Follow the rules given below to identify the parameters
that can vary
 Any parameter that has a closed loop control system cannot vary and should not
be listed as process parameter (eg: if temperature is controlled using automatic
temperature controlled), then temperature cannot vary and should not be listed
as a process parameter
 Any parameter that does not have closed loop control system can vary and
should be listed as a process parameter (eg: if the pressure does not have a
closed loop system, then pressure should be listed as a process parameter)

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Step : 4 – Identifying the Process
characteristics
 Identifying the Machine parameters
 List down all the parts in the machine that are moving during
production
 All the moving parts in the machine can get worn out over a period
of time
 Consider the Job holding devices, tool mounting devices also as
part of the machine (eg: Collet, Fixture )

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2-2
Step : 4 – Identifying the Process
characteristics
 Identifying the Processing material parameters
 Processing materials are the materials that are used as an aid in
processing (eg: Coolant, cutting oil, draw oil, phosphating bath)
 List down the parameters of the Processing material that can change
over a period of time (Ph, Pointage, Concentration, temperature)

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Step : 4 – Identifying the Process
characteristics
 Identifying the Tooling related parameters
 The definition to tool for our purpose is “any part of the machine
which is physically in contact with the product and does a
transformation on the product”
 List down the tool related parameters (eg: tool wear, breakage,
temperature, bead wear)

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2-2
Step : 4 – Identifying the Process
characteristics
 Identifying Operator error related parameters
 Check whether have we listed Activities under the process step. If
we had listed, it means that there are operators possible in the
process step
 List down what errors the operator can make when doing the
activity listed in the process step (eg: If “Loading of the
component” is listed as an activity, then the we should write what
error can happen during loading, eg: “Component not butting
properly against the collet face” or “component not clamped
properly”)
 If there are no activities listed for the Process step, then there will
not be any Operator error related parameters

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Step : 4 – Identifying the Process
characteristics
 Identifying Work environment related parameters
 Generally the following parameters are the work environment
related parameters
 Noise
 Vibration
 Dust
 House keeping
 Humidity
 Temperature
 Lighting
 List down, which of the above parameters are important for the
process step under analysis

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Step : 4 – Identifying Process characteristics

Sq.no Process step Incoming source of variation Symbol Desired outcomes Type Process characteristics
110 HOBBING 1.SPAN SIZE I.P.
2.P.C.D. R/O I.P.
3.ROOT DIA. B.P.
4.LEAD OF GEAR TOOTH I.P.
5.PROFILE OF GEAR TOOTH I.P.
6.NO. OF TEATH B.P.
7.SEMI TOPPING ON TOOTH B.P.
8.SURFACE FINISH ON TOOTH I.P.
FLANK
ROOT FILLET RADIUS B.P.

120 DE-BURRING 1.NO BURRS/SHARP EDGES V.P.

130 SHAVING 1. MATERIAL HARDNESS 1.SPAN SIZE B.P. 1.MANDREL O.D.

2.SPAN SIZE (110) 2.P.C.D. R/O B.P. 2.R/O ON THE CENTERS OF MACHINE
3.P.C.D. R/O (110) 3.T.T.C.E. B.P. 3.CUTTING OIL TEMPERATURE
4.SURFACE FINISH ON TOOTH 4.T.C.E. B.P. 4. FIXTURE R/O
FLANK (110) 5.SURFACE FINISH ON TOOTH B.P. 5.CLAMPING PRESSURE OF CENTERS
5.MINOR DIA. (090) FLANK 6. BLUNT CUTTER
6.O.D. R/O (090) 6.NO HOB MARKS/TOOL MARKS V.P.
7. UNFILL (030) 7.LEAD OF TOOTH B.P.
8.PROFILE OF TOOTH B.P.

140 INSPECTION 1.SPAN SIZE

2.HOLE DIA.
3.VISUAL INSPECTION

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Step : 5 – Showing the Process

3
2-2

sequencing
Manufacturing process
Normal sequence

Alternate sequence
Inspection

Manufacturing process with

multiple process streams

Storage

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Summary for chapter 2-2

 Process flow diagram is made to build the process knowledge
for getting the list of SSV’s
 Process flow diagram is made for the part number which has
been selected as part of the problem definition
 Five types of information are captured in the Process flow
diagram
 Process steps and the activities within the process step
 Desired outcomes of the process steps
 Incoming sources of variation
 Process characteristics
 Sequencing of the Process steps

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Exercise # 1

1. Make the Process flow diagram for the Part number

selected for the Individual BB Project

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2-3

Module - 3
Chapter – 2 – Identification of controls for
all the ssv’s listed in problem definition

Control Planning

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Control planning
 Controls analysis should be done for all the SSV’s identified in the
Problem definition
 This activity is done in the last phase of DMAIC (Control phase)
 There are two types of controls that are analyzed for every cause
 Controls that are currently present that detects the cause (Type ‘B’
controls)
 Controls that are currently present to prevent the cause (Type ‘C’
controls)
 If the existing controls are poor then new controls are identified and
added in the Control plan

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Controls Analysis
Controls that Detect
Controls that Prevents
the Failure mode after
the Failure mode Before
it happens (Product control)
it happens (Process control)
(Type –A controls)

Controls that Detects the Cause

Controls that Prevents the Cause
When it happens and in-turn
Prevents the Failure mode
(Type – C Controls)
(Type – B Controls)

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Controls Analysis
 First we have to analyze for Process controls
 Take one SSV at a time and ask the following
questions
 What is the current control we have to detect the
cause (Type ‘B’)
 What is the current control we have to prevent
the cause (Type ‘C’)
 We have to go through this analysis for every cause
(SSV) listed in the Problem definition

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Controls Analysis

 Controls that detect the cause

 Listing the following things are
mandatory
 Periodicity of checking
 Who does the checking
 If we do not have any defined period
currently nor the responsibility, then it is
as good as “No control”
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Controls Analysis

 Controls that prevent the cause

 Listing the following things are
mandatory
 Periodicity of replacement or change
 Who does the replacement
 If we do not have any defined period
currently nor the responsibility, then it is
as good as “No control”
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Controls Analysis

 Example of Controls that detect cause (Type

– B)
 Periodic monitoring of temperature in the
furnace
 Machine stopping automatically when the
coolant flow is not adequate
 Assembly line stopping when the air pressure
drops

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Controls Analysis

 Example of Controls that prevents cause

(Type – C)
 Replacement of coolant filter at some frequency
 Material inspection at the previous processes(for
input material related causes)
 Receiving inspection (for input material related
causes)
 Periodic machine maintenance checks

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Controls Analysis
CONTROL PLANNING
PROCESS Problem SSV CONTROL(TYPE-B) CONTROL (TYPE-C)

STEP

SHAVING SPAN SIZE 1.MATERIAL HARDNESS CHECK 5 SAMPLES EVERY LOT (INCOMING) NIL
VARIATION 2.SPAN SIZE (110) CHECK 1 SAMPLE EVERY 10 SAMPLE IN PROCESS 110 NIL
3.P.C.D. R/O (110) CHECK 1 SAMPLE EVERY 50 SAMPLES IN PROCESS 110 NIL
4.SURFACE FINISH OF TOOTH FLANK NIL NIL

5.MINOR DIA. (090) CHECK 1 SAMPLE EVERY 50 SAMPLES IN PROCESS 90 NIL

6.O.D. R/O (090) NIL NIL
7.UNFILL (030) 100% VISUAL CHECK IN 30 NIL
8.O.D. OF SHAVING MANDREL CHECK ONCE IN TWO MONTHS REPLACE MANDREL
EVERY YEAR
9.R/O ON O.D. OF SHAVING MANDREL CHECK ONCE IN TWO MONTHS REPLACE MANDREL
EVERY YEAR
10.R/O ON THE CENTERS IN MACHINE CHECK AT THE TIME OF SETTING NIL

11.CUTTING OIL TEMPERATURE NIL NIL

12.CLAMPING PRESSURE NIL NIL

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Controls Analysis – Type -A
 The last step in Controls analysis is to identify the Controls that we have current
to inspect or detect the problem. These controls are Type – ‘A’ controls
 First we have to analyze, whether are there any controls in place to detect the
problem in the Process step where it is generated (Detection immediately after it
is generated)
 Next, we have to analyze, whether are there any controls in place to detect
problem in downstream (subsequent processes) till dispatch
 All the controls currently in place for detecting the problem should be listed one
by one
 The following things have to be written for the control
 Frequency of detection
 Number of pieces checked for detection (Sample size)
 Who is detecting

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Controls Analysis
Control Planning
PROCESS FAILURE POTENTIAL CAUSES OCC CONTROL(TYPE-B) CONTROL (TYPE- CONTROL DET RPN

STEP MODE C) (TYPE -A)

SHAVING SPAN SIZE 1.MATERIAL HARDNESS 8 CHECK 5 SAMPLES EVERY LOT NIL
(INCOMING)
100% inspection
VARIATION 2.SPAN SIZE (110) CHECK 1 SAMPLE EVERY 10 NIL
using Micrometer by
SAMPLE IN PROCESS 110
Operator
3.P.C.D. R/O (110) CHECK 1 SAMPLE EVERY 50 NIL
SAMPLES IN PROCESS 110
4.SURFACE FINISH OF TOOTH NIL NIL 5 pcs every 2 hours
FLANK check by QA
5.MINOR DIA. (090) CHECK 1 SAMPLE EVERY 50 NIL
Pre-dispatch
SAMPLES IN PROCESS 90
inspection - 10 nos
6.O.D. R/O (090) NIL NIL
every lot
7.UNFILL (030) 100% VISUAL CHECK IN 30 NIL
8.O.D. OF SHAVING CHECK ONCE IN TWO MONTHS REPLACE MANDREL
MANDREL EVERY YEAR
9.R/O ON O.D. OF SHAVING CHECK ONCE IN TWO MONTHS REPLACE MANDREL
MANDREL EVERY YEAR
10.R/O ON THE CENTERS IN CHECK AT THE TIME OF SETTING NIL
MACHINE
11.CUTTING OIL NIL NIL
TEMPERATURE
12.CLAMPING PRESSURE NIL NIL

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3-1
Control Plan
 All the existing controls and the new controls are transferred to the Control Plan
document as shown
 Control plan is the Process standard to be used for the implementation of
controls

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Control Plan
Control Plan
Before 6σ After 6σ Process owner Date(Original) Date(Revised)
Control Plan Number

Part Name/ Description Team

Created by:

Name of Supplier Approval date Approved by:

Characteristics Methods
Part/ Machine Device Jig. Special
Process Name/ Operation Evaluation
Sample
Process Tools for Characterist Product/ Process
Description No. Product Process Measurement Control Method
Number Manufacturing ic Class Specification Tolerance Frequen
Technique size
cy

130 Gear Shaving MB Gear shaver 1 Span size 135.47/135.52 Micrometer 100% - Inspection
Micrometer 5 2 hrs Inspection
10 Lot Inspection
1.MAT ERIAL
HARDNESS
Hardness tester 5 Lot Inspection
2.SPAN SIZE
(110)
Micrometer 1 10 Inspection
3.P.C.D. R/O (110) Dial 1 50 Inspection
4.SURFACE
FINISH OF
T OOT H FLANK
5.MINOR DIA.
(090)
Micrometer 1 50 Inspection
6.O.D. R/O (090) Micrometer 1 50 Inspection
7.UNFILL (030) Visual 100% - Inspection
8.O.D. OF
SHAVING Micrometer Once 2 mth Checking
MANDREL
9.R/O ON O.D. OF
SHAVING Once Year Replace
MANDREL
10.R/O ON T HE
CENT ERS IN Dial Once Setting Inspection
MACHINE
11.CUT T ING OIL
T EMPERAT URE

12.CLAMPING
PRESSURE

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Control Plan
Control Plan after Six Sigma
Control Plan
Process owner Date(Original) Date(Revis ed)

Team
Created by:

Approval date Approved by:

Characteristics Methods
Special
Evaluation
Sample
Characteris t Product/ Process Reaction Plan
Product Proces s ic Clas s Measurement Frequen Control Method Resp. Recording (Y/N)
Specification Tolerance s ize
Technique cy

Span size 135.47/135.52 Micrometer 100% - Inspection Opr No Segregate and keep
Micrometer 5 2 hrs Inspection QA Yes Hold, reinspect
10 Lot Inspection QA Yes Hold the lot, reinspect
1.MAT ERIAL
HARDNESS
Hardness tester 5 Lot Inspection IQA Yes Hold the lot, reinspect
2.SP AN SIZE
(110)
Micrometer 1 10 Inspection 110 Yes Segregate and keep
3.P .C.D. R/O (110) Dial 1 50 Inspection 110 Yes Segregate and keep
4.SURFACE
FINISH OF Perthometer 1 shift Inspection 110 Yes Hold the lot, reinspect
T OOT H FLANK
5.MINOR DIA.
(090)
Micrometer 1 50 Inspection 90 Yes Segregate and keep
6.O.D. R/O (090) Micrometer 1 50 Inspection 90 Yes Segregate and keep
7.UNFILL (030) Visual 100% - Inspection 30 No Segregate and keep
8.O.D. OF
15
SHAVING Micrometer Once Checking Maint Yes Replace the mandrel
MANDREL days
9.R/O ON O.D. OF
SHAVING Once Year Replace Maint Yes -
MANDREL
10.R/O ON T HE
CENT ERS IN Dial Once Setting Inspection Opr No Correct and recheck
MACHINE
11.CUT T ING OIL
T EMP ERAT URE
Thermometer Once Shfit Checking Opr No Inform Maintenance
12.CLAMP ING
P RESSURE
Pressure gage Once 2 hrs Checking Opr No Inform Maintenance

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Summary for chapter 2-3

 Process mapping is done in the Problem definition if required
depending on the complexity of the problem
 If there are more processes that are suspected for generating the
problem, then Process mapping is done in the Problem
definition
 Two types of controls are identified in the Control phase for all
the SSV’s
 Controls that detect the cause (Type B control)
 Controls that prevent the cause (Type C control)
 Controls that are present to detect the problem (Type A control)
are also identified

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Exercise # 2

1. Do Control planning for all the SSV’s identified for the

Group project

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Assignments before coming for

Module # 4

 Continue with the individual project and

come with the presentation
 Complete the Process optimization
project selected after Module - 2
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End of Module - 3

Training Kit

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