Cpk Calculations In Excel Free Software

Process Maps Flowcharts. Description Process Maps are detailed flow diagram of the process using color coded symbols that drill further into the high level map generated on the SIPOC. The purpose is to visually represent the process as it is in reality. Complete the current state map by walking GEMBA walk and experiencing the process. This is a valuable learning experience, the team will quickly gain insight about the actual flow. Dont sit in a room and think it through yourself or with the team. I Six Sigma Six Sigma Quality Resources for Achieving Six Sigma Results via free articles, tools and resources. Easy to use software for Statistical Analysis, Six Sigma, and QUality Control Quantum XL. Free Statistical Software This page contains links to free software packages that you can download and install on your computer for standalone offline, nonInternet. Patience, time, asking questions are all part of the completing this map. Create a current state and a future state. Your team may want a future state with a short term target such as 9. Objective To capture all the complexity and improvement opportunities by analyzing each step in detail. Seek out the 7 Wastes and enhance current value added activities. Levels of a Process Map. Look for Automation Opportunities. Material Handling. Duplication. Redundancy. Decisions. Delays. Rework Loops. Non Value Added Steps vs. Value Added Steps. These represent opportunity for waste elimination. Proceed with the goal to eliminate waste before settling for waste reduction. Throughout the entire process map, look for the 7 Wastes. So, before process mapping, educate the team on how to see waste. Take caution when considering automation to take over manual processes. People are adaptable and much more flexible. Automation is fixed, constant, and often difficult to fix and maintain. In a JIT environment the decision to automate is advised with caution. This map is considered a living document. This template for Excel calculates Cp, Cpk, Pp, and Ppk for up to 8 characteristics and 100 measurements when you just drop in your data. Start your trial. Maker of the worlds leading risk and decision analysis software, RISK the DecisionTools Suite. Digital Torque Gauges Models. Torque testers are used as quality control devices to test or calibrate torque controlled tools. This includes electronic torque. RASLIC. If you do not use the GPL, the following license terms apply RasMol License Even though the authors of the various documents and software found here have. It is meant to be reviewed and updated on a continuous basis. The more detail it contains, the better understanding you and the team will have of the true process and opportunities. Peanut Butter Jelly Process Map Example. A good process map gets the process from the 5. The development of the map is a team effort and it will educate everyone on the reality of the process and most often how little of the total process is value added. Typically, there are obvious improvements that will be become evident while the mapping is being done. It will not be perfect the first time through, add more detail as it evolves. It is important to remain with the Start and Finish boundaries set forth by the SIPOC in the DEFINE phase. The team needs to begin identifying the value added steps versus the non value added steps and time. This realization is clearer during Value Stream Mapping VSM that adds more quantification to the steps. Creating a future state or ideal state while being realistic yet not too limited will make it clear to the team that everything getting in the way is opportunity to improve. Laws, regulations, customer standards, past paradigms all need to be challenged because they change over time. Creating a process map on a computer is common and many software programs exist that have symbols created. However, the first drafts are often very complex and frequently revised. Create the real flow on paper and post it publicly for others to offer input and critique. It is very important to catch the rework loops, communication issues, decision delays, stops, starts, pick ups, drop offs, and other waste so the team fully understands the opportunities. These hidden factory what if and sometimes paths are important for everyone to document and understand. This knowledge will create better subjective decisions when assigning weights to the inputs using the subjective root cause analysis tools in the Measure phase. Rework Loops. Rework loops are where defects and wasted time are occurring. The team should focus on preventing them, reducing their severity, and detecting them if they can not be eliminated. Some product or process may actually go through the rework path multiple times and the map does not illustrate this unless specially noted and discussed. The picture below shows two Rework Loops. Rework loops have varying severity. The process map does not show the amount or cost of pieces scrapped or the amount or cost of pieces reworked. Use the yield calculations to get this data. Often a Rolled Throughput Yield RTY is calculated to help quantify the scrap and rework through these loops and this does not always mean the lowest RTY is the worst financially or to the customer. If one type of rework is more expensive or higher risk to the customer such as a delayed delivery, then it may be a higher priority to improve. This is all going to shake out in the subjective root cause analysis tools and the inputs get funneled out to the most important, key process input variables KPIVs. Insurance companies will often use flowcharts to identify hazards or perils that could result in exposure. Flowcharts should also be used by the team to evaluate ideas to reduce these exposures, similar to reducing the severity, occurrence, and detection of an input within a FMEA. Risk managers often use them along with questionnaires for employees, inspections, and statistical analysis of previous losses to establish premiums for the company. Have an internal Risk Manager sit on your team from your company may be another way to capture financial savings. Through a careful and detailed inspection process the best overall risk assessment can be done. Process Maps can provide a lot of information in an easy to read format. They will be looking for potential problems that are a combination of hazards, perils, and exposures. For example A Six Sigma team may be working to reduce the number of Recordable Injuries and Lost Time Injuries. Some improvements that may be implemented are alarm systems, sprinklers in new areas, facility wide intercoms, and others that may also qualify your company for reduced property insurance premiums. Create a Process Map in Excel. Value Added vs. Non Value Added. Theoretically, the perfect state of a value stream or flowchart is to have 1. What does this meanValue Added Physical change in the product. Customer is willing to pay for the step or service. First time yield is 1. There is some debate about compliance steps. Certain steps are done to meet compliance criteria such testing and documentation. There is usually opportunity to streamline this regulatory or business mandated processes. The team should review these and not simply accept that they are requirements. Challenge the process and rule, ensure that the rules have not changed and get evidence of the rule to validate. Perhaps, the current method has waste or even the requirement is not being met. Non Value Added Set ups. Preparation. Meetings. Any of the 7 Wastes. Inspections that are not business or regulatory requirements. Not necessary to add value to the product or service. Customer is not willing to pay for the step. Process Mapping Download. This module provides lessons on how to use different types of process mapping tools to breakdown and understand your business processes. It also gives an insight of how the outputs from this tool can become critical inputs for the more advanced tools you may use through your DMAIC journey. Click here to purchase the Process Mapping module and others that are available. Flowchart Symbols. Different sources will use suggest different colors denotations for symbols. The color will help to identify specific steps when looking at very detailed maps. It is important that your teams uses a consistent color scheme. There are hundreds of symbols, some of the most common are shown. Statistical Process Control SPC Tutorial. Introduction and Background. More. Steam Hint As a pre requisite to improve your understanding of the following content, we recommend that you review the Histogram module and its discussion of frequency distributions. The concepts of Statistical Process Control SPC were initially developed by Dr. Walter Shewhart of Bell Laboratories in the 1. Dr. W. Edwards Deming, who introduced SPC to Japanese industry after WWII. After early successful adoption by Japanese firms, Statistical Process Control has now been incorporated by organizations around the world as a primary tool to improve product quality by reducing process variation. Dr. Shewhart identified two sources of process variation Chance variation that is inherent in process, and stable over time, and Assignable, or Uncontrolled variation, which is unstable over time the result of specific events outside the system. Dr. Deming relabeled chance variation as Common Cause variation, and assignable variation as Special Cause variation. Based on experience with many types of process data, and supported by the laws of statistics and probability, Dr. Shewhart devised control charts used to plot data over time and identify both Common Cause variation and Special Cause variation. This tutorial provides a brief conceptual background to the practice of SPC, as well as the necessary formulas and techniques to apply it. Process Variability. If you have reviewed the discussion of frequency distributions in the Histogram module, you will recall that many histograms will approximate a Normal Distribution, as shown below please note that control charts do not require normally distributed data in order to work they will work with any process distribution we use a normal distribution in this example for ease of representation In order to work with any distribution, it is important to have a measure of the data dispersion, or spread. This can be expressed by the range highest less lowest, but is better captured by the standard deviation sigma. The standard deviation can be easily calculated from a group of numbers using many calculators, or a spreadsheet or statistics program. Example. Why Is Dispersion So Important Often we focus on average values, but understanding dispersion is critical to the management of industrial processes. Consider two examples If you put one foot in a bucket of ice water 3. F and one foot in a bucket of scalding water 1. F, on average youll feel fine 8. F, but you wont actually be very comfortable If you are asked to walk through a river and are told that the average water depth is 3 feet you might want more information. If you are then told that the range is from zero to 1. More. Steam Hint Analysis of averages should always be accompanied by analysis of the variabilityControl Limits. Statistical tables have been developed for various types of distributions that quantify the area under the curve for a given number of standard deviations from the mean the normal distribution is shown in this example. These can be used as probability tables to calculate the odds that a given value measurement is part of the same group of data used to construct the histogram. Shewhart found that control limits placed at three standard deviations from the mean in either direction provide an economical tradeoff between the risk of reacting to a false signal and the risk of not reacting to a true signal regardless the shape of the underlying process distribution. If the process has a normal distribution, 9. Stated another way, there is only a 1 9. Therefore, a measurement value beyond 3 standard deviations indicates that the process has either shifted or become unstable more variability. The illustration below shows a normal curve for a distribution with a mean of 6. Values, or measurements, less than 6. These laws of probability are the foundation of the control chart. Now, consider that the distribution is turned sideways, and the lines denoting the mean and 3 standard deviations are extended. This construction forms the basis of the Control chart. Time series data plotted on this chart can be compared to the lines, which now become control limits for the process. Comparing the plot points to the control limits allows a simple probability assessment. We know from our previous discussion that a point plotted above the upper control limit has a very low probability of coming from the same population that was used to construct the chart this indicates that there is a Special Cause a source of variation beyond the normal chance variation of the process. Implementing Statistical Process Control. Deploying Statistical Process Control is a process in itself, requiring organizational commitment across functional boundaries. The flow chart below outlines the major components of an effective SPC effort. The process steps are numbered for reference. Determine Measurement Method. Statistical Process Control is based on the analysis of data, so the first step is to decide what data to collect. There are two categories of control chart distinguished by the type of data used Variable or Attribute. Variable data comes from measurements on a continuous scale, such as temperature, time, distance, weight. Attribute data is based on upon discrete distinctions such as goodbad, percentage defective, or number defective per hundred. More. Steam Hint Use variable data whenever possible because it imparts a higher quality of information it does not rely on sometimes arbitrary distinctions between good and bad. Qualify the Measurement System. A critical but often overlooked step in the process is to qualify the measurement system. No measurement system is without measurement error. If that error exceeds an acceptable level, the data cannot be acted upon reliably. For example a Midwest building products manufacturer found that many important measurements of its most critical processes had error in excess of 2. Using this erroneous data, the process was often adjusted in the wrong direction adding to instability rather than reducing variability. See the Measurement Systems Analysis section of the Toolbox for additional help with this subject. Initiate Data Collection and SPC Charting. Develop a sampling plan to collect data subgroups in a random fashion at a determined frequency. Be sure to train the data collectors in proper measurement and charting techniques. Establish subgroups following a rational subgrouping strategy so that process variation is captured BETWEEN subgroups rather than WITHIN subgroups. If process variation e. The type of chart used will be dependent upon the type of data collected as well as the subgroup size, as shown by the table below. A bar, or line, above a letter denotes the average value for that subgroup. Likewise, a double bar denotes an average of averages. Consider the example of two subgroups, each with 5 observations. The first subgroups values are 3,4,5,4,4 yielding a subgroup average of 4 x1. The second subgroup has the following values 5,4,5,6,5 yielding an average of 5 x2. The average of the two subgroup averages is 4 52 4. X double bar x, because it is the average of the averages. You can see examples of charts in Section 9 on Control Limits. Develop and Document Reaction Plan. Each process charted should have a defined reaction plan to guide the actions to those using the chart in the event of an out of control or out of specification condition.

My customer wants to know my process capability, Cpk. My boss needs the. Buy SPC for Excel Download Free Trial. Pp, Ppk, Ppu, Ppl; Calculated Sigma; PPM USL; PPM.

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