Slide 1 : Chronic Problem? Solve it now !
Slide 2 : A problem is chronic,
when one does not know the (correct) root cause of the problem,
nor does he have the right tool to find the root cause. Shainin has developed
right strategies to solve such problems,
he has developed the right tools
to find solution to such problems.
Here is a case to illustrate.
Slide 3 : One Industrial Rubber Parts Manufacturer
had chronic high rejections in his calendering process. Calendering was the mostcritical process in the business.
In this process, rubber mix was rolled
between 2 rollers to get sheets of desired thicknesses.
The sheets were later vulcanised for further conversion into different products.
Slide 4 : Background Current Situation & Target The process produced 20 % Rejection. Rejected material was recycled.
This caused further damage in terms of deteriorated batches.
Target = 0 %
Slide 5 : Cp=0.25 Shainin recommends use of multivari if you have no clue to the possible solution.
Convert available data into various multivaris.
Here is one in the form of run chart ,
Showing thickness variation in a 40 kg batch in current production.
It uses 4 rolls of 10 kg each/ with thickness of 10mm, as input .
Slide 6 : Cp=0.25 See strong relationship
between input and output sheet thickness variation
Everytime a new roll is fed, thickness goes up
See 4 ups and downs
40 kg batch requires 4 rolls of 10kg as input
This clue was studies further First roll of 10 kg Fourth roll Second roll Third roll
Slide 7 : Cp=0.25 Look at this multivari very closely
As input roll is getting finished, thickness drops to a low value
Once a new roll is fed, thickness goes up quickly
see this happening 3 times
40 kg batch requires 4 rolls of 10kg as input
You miss this clue….. And you lose a possible solution.
Scatter diagram : Scatter diagram 8
Slide 9 : Cp=0.66
Slide 10 : Cp=0.66
Slide 11 : Cp=0.83
Slide 12 :
Slide 13 : Conclusion DOE can solve the toughest Quality problems,
In a very short time,
Without expensive inputs.
Slide 14 : Work pending Further application of DOE
will being this rejection
down to near zero.
Slide 15 : Do you have a process crying for improvement? Get in touch with
sigmaguru at gmail.comorVidyut Bapat at +91 94235 07631