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Variation Analysis Format

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abdul kuddus ansari
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6 views

Variation Analysis Format

Uploaded by

abdul kuddus ansari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
You are on page 1/ 4

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
USL Gage Bias and
Study dates and Uncertainity
Shift (%)
LSL
Any other details
Data Grouping and Sample details
Number of Groups (Number of time
blocks x number of streams)

Number of Samples in Each group (It is


preferable to collect 5 samples
continuously from the process so that
the inherent variations are captured

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


Average Range (R-bar) (Round off to one decimal more Samples D3 D4
than the data) 2 0 3.267
Upper Control Limit (UCL) = D4*R-bar (Round off to the 3 0 2.575
4 0 2.282
same decimal as data) 5 0 2.115
6 0 2.004
Lower Control Limit (LCL) = D3*R-bar
Is the Part to Part variation consistent Yes/No
If the Part to Part variation is not consistent, STOP, do not proceed further. Plan for DOE

Is the Range Chart plotted Yes/No

Are the Stratification levels more than 3 Yes/No


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 and Yes / No If yes write
one side of the Mean range causes (if
possible)

Rev: 1/Jan 2003 Page: 1/4


World Class Manufacturing Solutions

Variation Analysis

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 than Sample d2
data) 2 1.128
3 1.693
6 * Sigma (Round off to the same decimal as data) 4 2.059
5 2.326
6 2.534
Overall Average (Round off to one decimal more than data)
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

Rev: 1/Jan 2003 Page: 2/4


World Class Manufacturing Solutions

Variation Analysis

Based on the above analysis, can you conclude that the


histogram is Normal Yes/No
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

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


Projected Rejection % above USL (Based
6 * Sigma on the Normal table
Projected Rejection % below LSL (Based
USL on the Normal table)
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
6 * Sigma on the Normal table
Projected Rejection % below LSL (Based
USL 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 <=100%
6 Sigma <= 75% of Tolerance 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 100%
50% of tolerance tolerance inspection

Use Pre-control Use Average and Do DOE to reduce variation or to question 100% Inspection
chart for Range chart for the tolerance for that parameter
monitoring monitoring
Remove 100% inspection if done on
this parameter

Calculation of limits for Average if the decision taken is Average and Range monitoring

Rev: 1/Jan 2003 Page: 3/4


World Class Manufacturing Solutions

Variation Analysis

Sample A2
2 1.880
Average 3 1.023
4 0.729
UCL = Average + A2*R-bar 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: 4/4

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