Samples MINITAB Book Chapter 4 - QMS Global LLC
Lean Six Sigma: Training/Certification Books and ResourcesSamples from: MINITAB BOOKQuality and Six Sigma Tools using MINITAB Statistical Software: Acomplete Guide to Six Sigma DMAIC Tools using MINITAB Prof. Amar Sahay, Ph.D.One of the major objectives of this text is to teach quality, data analysis andstatistical tools used in the Six Sigma DMAIC (Define, Measure, Analyze, Improve,and Control) process. The chapters in this book provide concepts, understanding,and computer applications of Six Sigma DMAIC tools. The statistical tools used inthe DMAIC process are discussed with step‐wise MINITAB computer applications.The following are samples from the book randomly selected from differentchapters:CHAPTER 4: Quality Tools: The Basic Tools and Seven New Tools of Quality[Pareto Charts, Cause-and-effect Diagrams, Multi-vari Charts,Process maps, Check sheets, Run charts, control charts, TreeDiagrams, Prioritization matrix, Activity Network Diagramsand others)]Note: The graphical tools described in this chapter are not all available inMINITAB. The tools available in MINITAB are indicated after their names.Chapter HighlightsThis chapter deals with the quality tools widely used in Six Sigma and quality improvementprograms. The chapter includes the seven basic tools of quality, the seven new tools ofquality, and another set of useful tools in Lean Six Sigma that we refer to –“beyond the basicand new tools of quality.” The objective of this chapter is to enable you to master these toolsof quality and use these tools in detecting and solving quality problems in Six Sigma projects.You will find these tools to be extremely useful in different phases of Six Sigma. They are easyto learn and very useful in drawing meaningful conclusions from data. In this chapter, youwill learn the concepts, various applications, and computer instructions for these qualitytools of Six Sigma. This chapter will enable you to:1. Learn the seven graphical tools ‐ considered the basic tools of quality. These are:(i)Process Maps(ii)Check sheets(iii)Histograms(iv)Scatter Diagrams(v)Run Charts/Control Charts(vi)Cause‐and‐Effect (Ishikawa)/Fishbone Diagrams(vii)Pareto Charts/Pareto AnalysisPage 1 of 15
Lean Six Sigma: Training/Certification Books and Resources2.Construct the above charts using MINITAB3.Apply these quality tools in Six Sigma projects4. Learn the seven new tools of quality and their applications:5.6.7.(i)Affinity Diagram(ii)Interrelationship Digraph(iii)Tree Diagram(iv)Prioritizing Matrices(v)Matrix Diagram(vi)Process Decision Program Chart(vii)Activity Network DiagramLearn the construction and applications of some other quality tools including thestem‐and‐leaf and box plot.Learn a set of powerful tools beyond the basic and new tools of quality that includemulti‐vari charts, symmetry plots, and variations of scatter plots.Learn how to construct the symmetry plots, and multi‐vari charts using MINITAB.Chapter OutlineSeven Basic Tools of Quality1.2.3.4.5.6.7.Process MapsCheck SheetsHistograms(MINITAB)Using Histograms to Detect the Shift and the Variation in the ProcessEvaluating Process Capability Using HistogramScatter Plots (MINITAB)Run Chart / Control Charts(MINITAB)Constructing a Run ChartA Run Chart with Subgroup Size Greater than 1A Run Chart with Subgroup Size Greater than 1Run Chart Showing a Stable Process, a Shift, and a TrendCause‐and‐Effect Diagram or Fishbone Diagram(MINITAB)Cause‐and‐Effect Diagram (1)Cause‐and‐effect Diagram (2)Creating other Types of Cause‐and‐effect DiagramPareto Chart(MINITAB)A Simple Pareto ChartPareto Chart with Cumulative PercentagePareto Chart with Cumulative Percentage when Data are inOne ColumnPareto Chart by VariablePage 2 of 15
Lean Six Sigma: Training/Certification Books and ResourcesSome other Quality Tools:8.Stem‐and‐leaf Plot9.Box Plot(MINITAB)(MINITAB)The Seven New Tools for Quality Improvement(1)(2)(3)(4)(5)(6)(7)Affinity DiagramInterrelationship DigraphTree DiagramPrioritizing MatricesMatrix DiagramProcess Decision Program ChartActivity Network DiagramBeyond the New Tools of QualityAll the tools in this section are available in MINITAB.1.2.3.Bivariate Data: Measuring and Describing Two VariablesVariations of Scatter PlotsScatterplots with Histogram, Box‐plots and Dot plotsScatterplot with Fitted Line or CurveScatterplot Showing an Inverse Relationship between X and YScatterplot Showing a Nonlinear Relationship between X and YScatterplot Showing a Nonlinear (Cubic) Relationship between X and YMulti‐Vari Charts1. A Multi‐vari Chart for Two‐factor DesignMain Effects and Interaction Plots2. Another Multi‐vari Chart for a Two‐factor DesignBox Plots, Main Effects Plot, and Interaction Plot3. Mult‐vari chart for a Three‐factor DesignMulti‐Vari Chart, Box Plots, and Main Effects Plot4. Multi‐vari Chart for a Four‐factor DesignMulti‐Vari Chart, Box Plots, Main Effects and Interaction PlotsDetermine a Machine‐to‐Machine, Time‐to‐Time variationPart‐to‐Part Variation in a Production Run using Multi‐vari PlotsSymmetry PlotsChapter Summary and ApplicationsPage 3 of 15
Lean Six Sigma: Training/Certification Books and ResourcesSamples and Examples from this ChapterFigure 5.1: A Logical Sequence of Seven Basic Tools of QualityExample 5.1: A SIPOC Process Map of Online Order ProcessingFigure 5.5: Symbols and their Meaning in Process MappingPage 4 of 15
Lean Six Sigma: Training/Certification Books and ResourcesFigure 5.6 (a): A Current State Value Stream Map of a Production and Distribution SystemFigure 5.6 (a): A Current State Value Stream Map of a Production and Distribution SystemHISTOGRAMOpen the worksheet PROCESSHIST.MTWFrom the main menu, select Graph &HistogramClick on With Outline and Groups then click OKFor Graph Ring Dia: Run1Click on Scale then click the Reference Lines tab::type 4.95 5.0 5.05 (with a space between each value)Click OK in all dialog boxes.Page 5 of 15
Lean Six Sigma: Training/Certification Books and ResourcesHistogram of Ring Dia: Run 54.95Histogram of Ring Dia: Run 504.9654.9804.9955.0105.02505.0404.9324.950Ring Dia: Run 5 (e)Histogram of Ring Dia: Run 7204.9554.9684.9865.0045.0225.040Ring Dia: Run 6 (f)Histogram of Ring Dia: Run 985.005.025.045.065.0804.9525E 004.9707E 00Ring Dia: Run 7 (g)4.9889E 005.0072E 005.0254E 005.0437E 00Ring Dia: Run 8 (h)Histogram of Ring Dia: Run 5.0055.0185.0315.044Ring Dia: Run 9(i)Figure 5.9(e) The process has shifted to the left; products out of specification, Figure 5.9(f)Process shift to the left; more variation compared to (e), Figure 5.9(g) Process out of controland has large variation, Figure 5.9(h) Process within control but has large variation, Figure5.9 (i) Process stable and close to the target (desirable)SCATTER PLOTWITH BOX PLOTSOpen the worksheet SALES&AD.MTWSelect Graph & .In the Marginal Plots dialog box, select With Box PlotsIn the Marginal Plot–With Boxplots dialog box, select the following:Do not use the Histograms Labels tab.Click OK in all dialog boxesRepeat the steps in the above table to construct a scatter plot with dots plots of x andPage 6 of 15
Lean Six Sigma: Training/Certification Books and Resourcesy variables. The plots will be similar to Figures 5.16 and 5.17.Scatter Plot with Dotplots of X and Y Variables120120100100Profit ( )Profit ( )Scatter Plot with Box Plot of X and Y Variables80604080604050607080904010040Sales ( )506070Sales ( )8090100Figure 5.16: Scatterplot with Box Plots of x andFigure 5.17: Scatterplot with Dot Plots of x and yy VariablesVariablesTable 5.15RUN CHARTOpen the worksheet RUNCHART2.MTWFrom the main menu, select Stat &Quality Tools & .Under Data are arranged as click the circle next to Single column and::Click the Options tab and type a title for your plotClick OKA R un C ha r t S ho w i ng a T r e nd109Process 28765431510N u m b er o f r u n s ab o u t m ed ian :E x p ec ted n u m b er o f r u n s:Lo n g est r u n ab o u t m ed ian :A p p r o x P - V alu e fo r C lu ster in g :A p p r o x P - V alu e fo r M ix tu r es:1520251833.96970120.000040.99996303540Ob s e r v a t io n45N u m b er o f r u n s u p o r d o w n :E x p ec ted n u m b er o f r u n s:Lo n g est r u n u p o r d o w n :A p p r o x P - V alu e fo r T r en d s:A p p r o x P - V alu e fo r O sc illatio n :505560654343.6666740.421780.57822Example 5.18: Analyzing a Control Chart‐ Controlling the Shaft DiameterTable 5.20: Tests for Assignable CausesTest Results for Xbar Chart of n1, ., n5TEST 1. One point more than 3.00 standard deviations from center line.Test Failed at points: 14, 38, 39TEST 5. 2 out of 3 points more than 2 standard deviations from centerPage 7 of 15
Lean Six Sigma: Training/Certification Books and Resourcesline (on one side of CL).Test Failed at points: 37, 38, 39, 40TEST 6. 4 out of 5 points more than 1 standard deviation from centerline (on one side of CL).Test Failed at points: 14, 38, 39, 40* WARNING * If graph is updated with new data, the results above may nolonger be correct.Variab les Co n tro l Ch art w ith Ad d itio n al S am p les175.04Sample Mean1575.035X 75.0186175.0275.01LCL 75.0052811Sample RangeUC L 7 5 .0 3 1 9 559131721Sa m ple25293337UCL 0.048900.0480.036R 0.023120.0240.012LCL 00.00015913172125293337S a m pleFigure 5.31: Control Charts showing Out of Control ConditionsFigure 5.34: A Cause‐and‐Effect Diagram of Production Problems using MINITABM ajo r C au ses o f P ro du ctio n P ro blemM e a sure me ntM a te ria lC alibrationE quipm entGage problemW rong gagingObserver errorsL ack of trainingF atigueW ork conditionsD istractionsN oiseH eatD irtDustH um idityT em peratureEnvironme ntP e rsonne lP oor quality m aterialS upplier problemM any suppliersS upplier relationshipV variation inInternal flaw sExternal flawsQ uality checkC entralizedInadequate educationL ack of experienceIm proper workP oor w ork instructionsP oor toolsL ack of m otivationL ack of com m unicationP ersonal problem sH ealthS tress and fatigueH ydraulic problem sIm prove m ethodsP rev m aintenanceW ork design problemExessive downtim eT echnologyP oor m aintenanceN o autom ationAautom ationP oor skillsP oor toolingInstructionsT echnologyP rocess planingIncapable M achinesW ork m ethodsW orn out m achinesM e thodsM a c hine sPage 8 of 15P roble m
Lean Six Sigma: Training/Certification Books and ResourcesFigure 5.36: A Cause-and-Effect Diagram of Cost of Poor QualityCo sts o f Po o r Q u ality (CO PQ )Pre v e ntio nInte rnalIm p ro v e Qua lity e ngScra pIm pro v e M a nufa cturing e ngR e w o rkIm ro v ing de signR e p a irC o st o f qua lity pla nningR e te stC o st o f q ulity tra iningF a ilure a na ly sisSp e cia l e q uipm e nts to co ntro lDo w ntim eBuild ing sup plie r re la tio nsC o st o f y ie ld lo sse sVa ria b ility a na ly se sDo w ng ra ding pro ductsC o st o f sk ille d q ua lityCO PQC o st o f fie ld a ud itsC o st o f p ro duct a uditsC o st o f m a inta ining te st a ndC o st o f insp e ctio n a nd te stingC o st o f m a inta ining te stC o st o f m a inta ing m a te ria lsInsp e ctio n Supe rv iso rsA pprais alLo ss o f future busine ssLo ss o f m a rk e t sha reC usto m e rLo ss o f g o o dw illP a pe rw o rk p ro ce ssingC o rre ctiv e a ctio nSe ttle m e nt co stsLe ga l se rv ice s a ndC o st o f te stingR e ca llsC usto m e r co m pla insR e turne dW a rra nty cha rge sE x te rnalTable 5.23A SIMPLE PARETOOpen the worksheet PARETOCHART.MTWCHARTFrom the main menu, select Stat &Quality Tools & Pareto ChartDefect or attribute data in: select C1 or Failure CauseFrequencies in: C2 or CountIn the Combine remaining defects into one category after this::Check the box Do not chart cumulative percentageNext, type a title for your plot and click OK in all the boxesThe Pareto chart as shown in figures will be displayed in the graphicsPage 9 of 15
Lean Six Sigma: Training/Certification Books and Resources8070Count60Count50402010Causes of Failure0ssssssssnswrtreorororororlarrPasi eDnnintiwmuFhamcthaInreraInDacreceDecsuMMorear fancMSuICountPercentCum %10025080200601504010030Causes of srsnswsrt ecsuMacrrMrfeacoMSuInCountPercentCum %124.0100.084554033252117151227.8 18.2 13.2 10.9 8.3 7.05.6 5.04.027.8 46.0 59.3 70.2 78.5 85.4 91.1 96.0 100.0Figure 5.38: Pareto Chart of Defect Data withCumulative Points PlottedFigure 5.37: Pareto Chart of Defect Data with NoCumulative Points PlottedP a r e to C h a r t o f D e f e c t s i n M a c h i n e d P a r tsrsnrsror rosi oEE r rt ssrsthesraswroimenPElain i a i luDErmngFe d al F e Fgctregneniuciierasrrn r f ashwco-ueaacam n teraInDSuMIInDMrroS h if t D a yrsenS h if t M o rn in g1209060CountPercentPareto Chart of Defects in Machined PartsPareto Chart of Defects in Machined Parts90300S h if t N ig h t1209060300sssrsrse s ro r srto n rorwrrrr o il urrro ns iP a F laEEEEaedtlggFhnmaeinisineeniina g e rnt D emu s r awthimFccraaInDIncer re a s uDMfacoeurMInSTy p e s o f Fa ilu r ePage 10 of 15T y p e s o f F a ilu r eM a c h in in g E r r o r sI n c o r r e c t D im e n sio nM e a su r e m e n t E r r o r sD a m a g e d P a r tsI n te r n a l F la w sS u r fa c e F in ish E r r o r sI n - u se F a ilu r e sD r a w in g E r r o r s
Lean Six Sigma:STrraining/CCertificatition Bookks and RessourcesSummaary and Appplicationss of Basic ToolsTof QQualityTyppe ofChart//GraphProcess MapsMCheck sheeetsHistogrammDescription/ApplicattionNumber offVaariables PlotttedProcess mapping is floow chartingg a producttion orservicesproccess. The chhart provid es a modell of anoperation that facilitates communica tion about thhe .Check sheets are data gatheringgtoools. The purpose ofcheck sheetss is to Determining thee shape andd location oof datameassured on onne characteriistic. Also uused fordeteccting process problems including a shift inthe processpeitheer to the left oor right . Scatter DiagramsScatter diagramsbetweenbtwo ipontinued CoRun Charrt Onne variableplootted:Unnivariate dataaPagge 11 of 155
Lean Six Sigma:STrraining/CCertificatition Bookks and bone DiaggramsA cause‐annd‐Effect diaagram is a useful ttool inestablishing the relationsship Pareto ChhartTheT chart shhows (in desccending ordeer) the contrribution Onne variable .of the vital feew versus the trivial manny. .Stem‐andd‐leaf PlotA simple and useful way for summarizinng andpresentingpdata.dThe stemm‐and‐leaf p lot displays .Stem-and-leaf of Noo. of Defects (out of1000)N 65Leaf Unit 1.03 1 0248 2 0567817 3 004457788927 4 01244556669(13) 5 2344444556788925 6 023456668816 7 135669910 8 12236884 9 352 10 35Box‐plotPlot of five measures:mthee minimum, .Unnivariate dataaBoxplot of Box Plot7075808590All the aboveagraphs except thee Cause‐and‐ Effect diagraam are used to summariize ordescribee one charactteristic at a time,tand theerefore, descrribe Pagge 12 of 155
Lean Six Sigma: Training/Certification Books and Resources(1) Multi‐vari PlotThe multi‐vari plots of data in Table 5.40 are shown in Figures 5.67 and 5.68. Thedifference in appearance between the two plots is due to the order of selection of thetwo factors. When you select the command sequence Stat &Quality Tools &Multi‐Vari Chart, you must select the response variable and then factor 1 and factor 2. Forour example, the response variable is strength and the two factors are alloy type andthickness. If you select alloy type for factor 1 and thickness for factor 2, . Solid lines connect the means of factor 1 levels (at each level of factor 2).A dotted line connects the means of factor 2 levels.Both the plots above show that alloy type 2 and thickness 2 has the maximumstrength. .Multi-Vari Chart for Strength by Alloy Type - ThicknessMulti-Vari Chart for Strength by Thickness - Alloy TypeA lloyTy pe123740735735730730StrengthStrengthThick A lloy Type3Figure 5.68: A Multi‐Vari Chart for Strength byThickness and Alloy TypeFigure 5.67: A Multi‐Vari Chart for Strength byAlloy Type and ThicknessInteraction Plot (data means) for 0Alloy Type720AlloyType1237101234Figure 5.72: Interaction Plot of Strength by Thickness and Strength by Alloy TypePage 13 of 15
Lean Six Sigma:STrraining/CCertificatition Bookks and RessourcesSummaary of Seveen New Toools for QuualityThe seven new toolss for quality are a powerfful set of toools that have been successfullyused as decision makking tools for managing pprojects thatt involve teamm. Combinedd withthe basiic seven tools of quality (discussed(eaarlier in thiss chapter), thhese tools providesimple visualvtools to understaand differentt processes. These toolss are particuularlyuseful in solving unnstructured problems. TThe table beelow providees a summaary ofthese tools.AffinityADiaggramAffinity diaggram is a visuual tool that gathers large amounts .InnterrelationnshipDigraphDThe interrellationship diigraph is useed to identifyy the relationnshipsbetween diffferent issuess relating to a problem. .::.MatrixMDiagrramThe matrix diagram is a tool used to identify, analyze, andd ratenship amongg two or mmore variablees. It defines thethe relationrelationshipp::TreeTDiagrammThe tree diagram is ussed to breakk down broaad categoriess intodifferent levvels of detail. It starts:::Pagge 14 of 155
Lean Six Sigma:STrraining/CCertificatition Bookks and RessourcesPrioritizingPMatrixMA prioritizattion grid is uused to makee decisions involving muultiplecriteria and multiple alteernatives. Thhis tool priorritizes:::ProcessPDeciisionProgramPChaartThe Processs Decision Program CChart (PDPCC) is a toool forcontingencyy planning. TThis tool can be used to:::ActivityANetwworkDiagramDThe Activitty Network Diagram iss also knowwn as the PERT(Program Evvaluation annd Review Teechnique) nettwork, and CCPM ‐the Critical PathPMethodd (CPM):::Pagge 15 of 155
Lean Six Sigma: Training/Certification Books and Resources Page 1 of 15 Samples from: MINITAB BOOK Quality and Six Sigma Tools using MINITAB Statistical Software: A complete Guide to Six Sigma DMAIC Tools using MINITAB Prof. Amar Sahay, Ph.D. One of the major objec
title as IPS. It can be used with either Minitab Student Version 14, Minitab Version 14 or Minitab Version 13 running under Windows. The text is based on Minitab Student Version 14 and Minitab Version 14, but we have also indicated in the manual wherever there are differences
Sep 02, 2010 · created in Minitab 16 or in Minitab 15 cannot be read by previous releases of Minitab and cannot be read by Student Minitab. See page 3, point [4], for the work-around solution. In addition, Minitab can read and write Exc
The Minitab License Manager is a multi-user license management tool located online in the Minitab Customer Center. The Minitab License Manager guides license coordinators through the process of creating Minitab software license files. The Minitab License Manager is powered by FLEXnet Publisher from Macrovision, the
To start a Minitab session from the menu, select Start h All Programs h MINITAB 15 English h MINITAB 15 English To exit Minitab, select File h Exit from the menu. When you first enter Minitab, the screen will appear as in the figure with a toolbar, a Session window, and a Data window.
Minitab requires far less explication. 1.1.1 Minitab The first order of business is to obtain access to the program. For academic users, relatively inex-pensive copies of Minitab can be rented for six months or a year. Go to estore.onthehub.com or just search for the Minitab website. A key virtue of
“A Friendly Guide to Minitab” An introduction to Minitab; including basic Minitab functions, how to create sets of data, and how to create and edit graphs of different types “Minitab Step-By-Step” A guide to the following subjects: 1. Obtaining a Simple Random Sample 2. Frequ
Lean Six Sigma Master Black Belt, Financial Services *formerly Companion by Minitab Have We Met Before? Companion by Minitab has been upgraded to Minitab Engage . Minitab Engage enables organizations to collect ideas via a virtual suggestion bo
courts in their efforts to ensure equal justice and due process for all those who come before them. In December 2015, the Department convened a diverse group of stakeholders—judges, court administrators, lawmakers, prosecutors, defense attorneys, advocates, and impacted individuals—to discuss the assessment and enforcement of fines and fees in state and local courts. While the convening .
