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QBASE

Engineering

Practical D.O.E Using Shainin's Methods

Overview

The secret weapon of Japanese quality is the widespread use of Design of Experiments (DOE). DOE discovers key variables in product and process design and drastically reduces variation they cause. Also, DOE opens up tolerances on the lesser variables so as to reduce cost. In early 1970, there was a dramatic rise in the use of DOE in Japan. Hundreds of Japanese companies conduct thousands of design of experiments each year to make the product and process design " more robust". This three-day training seminar explores the techniques pioneered by Dorian Shainin, who through his contribution to reliability perfection developed DOE tools that can diagnose and greatly reduce variation, leading to beyond zero defect, beyond the milestone of Cpk=2.00, or to near zero variability. These tools are 1) Simple and easy to use -understood by engineers and line worker alike. The mathematics involved is relatively simple. 2) Logical - based on common sense; 3) Practical - easy to implement in production, design, with suppliers ; 4) Universal in scope - applicable in wide range of industries, big or small, process intensive as well as assembly intensive 5) Statistically powerful - in term of accuracy, no violation of statistical principles 6) Excellent in term of results. This training focuses on design of experiment techniques - the principal weapons to go beyond zero defects and 100% yield to the ultimate zero variation. The seven weapons are: 1) multivari charts 2) component search 3) paired comparisons 4)variable search 5) full factorials, 6) Bvs.C and 7) scatter plots. And 8)Response Surface Method. Each technique is explained in easy, non-mathematical and non-theoretical manners, with case studies and practice exercises to guide participants in implementing each method with immediate results. Real-life, experimental matrices are also developed during training, which enable participants to implement these tools within their own working environment methods. QBASE supplies a DOE workbook that enables immediate implementation of these techniques.

© QBASE Engineering Sdn Bhd

( Practical D.O.E. Using Shainin's Methods )

QBASE

Engineering

Course Objectives

·To deliver in simple, non-mathematical terms a variety of easy but statistically powerful, techniques that can be learned by all levels in a company. The emphasis will be on practical and doable method ; and ; · To show how it is possible to progress from the current unacceptably high defect rate to zero defects, and from zero defects to near zero variation, through the use of simple design of experiments, and to achieve this objective coupled with substantially reduced cost. At the conclusion of this training the participants will have the necessary knowledge to be able to: ·Explain how the Shainin's tools can be applied to manufacturing process and/or assembly processes. ·Explain the problem solving process steps and how each of the Shainin's tools is mapped to each of the step, and be able to select the most appropriate tool that suits the objective of the step. ·Explain the statistical validity of each tool, its strength and weaknesses, it applicability, and most important of all how each of them problems existed in the process . · apply the tools to troubleshoot and optimize a problematic process. ·Adapt and adopt some of these problem solving tools by incorporating into organization-wide problem solving process initiatives. At the conclusion of this training the participants will have the necessary skills to be able to:

·Assess situation, design, plan and execute simple experiments to trouble shoot process problems, parts/component problems, assembly related problems, resolve product performance problems and etc. ·Interpret the result and/or outcome the analysis using these tools so that the permanent action can be implemented. ·apply the Shainin's tools to troubleshoot the process, process improvement, to identify cause and effect relationships, identify important components and/or factors, process optimization, identify special casue variation existed in a process. ·Select and apply combination of the following tools based on situation at hand. 1) Multivari charts 2) Component search 3) paired comparisons 4) Variable search 5) Full factorials 6) B vs.C and 7) Scatter plots and Regression 8) Response Surface Method.

© QBASE Engineering Sdn Bhd

( Practical D.O.E. Using Shainin's Methods )

QBASE

Engineering

Target Audience

· · · · · Process and Product Engineers & Managers Quality Engineer & Managers Technical Specialists QA/QC professionals Design Engineers

Methodology

·Classroom lecture on concepts, methodologies and techniques ·Workshop and simulation excercises ·Case studies , case discussion and best practices ·Learning from actual examples

Prerequisite

·Scientific Calculators

Course Duration

·Three (3) days 9:00 ­ 5:00 pm

Delivery

· English and / or Bahasa Malaysia

Fees per Session

· 3 days at RM 1,800 per pax. · Contact QBASE for special Discounts and Terms and Conditions ·* Contact QBASE for in-house training fee

Applicability ·Manufacturing process (component/ items) ·Assembly Process (sub-assemblies, Final Assembly) ·Product Development ( prototype trouble shooting, problem identification etc) ·Failure Analysis ( warranty analysis, customer returned.. Etc)

© QBASE Engineering Sdn Bhd

( Practical D.O.E. Using Shainin's Methods )

QBASE

Engineering

Course Outlines Introduction · Economic Imperative of quality · Traditional Statistical Process Control · Elementary SPC Tools ( 7 QC Tools) · Measurement of Process Capability

·Shainin Diagnostic Tools

· Factor Screening Tools · Multi-vari charts · Component search · Paired Comparison · Variable Search · Factor optimization tools · Full Factorial experiments · B vs. C · Scatter plots and linear · regression · Fractional Factorial Experiments · "Holding the Gain" tool and Technique · Poka-yoke · Standardization · Positrol

Variation - An industrial epidemic · Concept of variation · Many sources and causes of variation · Deming's view of a system · Four state of a process · Concept of Loss Functions

·The True Role of SPC - The "big picture" · The Management of Change ·Standardization ·Control Plans ·Class Projects · Designing a real-life experimental matrix.

Design of Experiment (DOE) · Three Approaches · Classical Method · Taguchi Technique · Shainin Technique · Comparison DOE Preliminary. · Green Y · Red X · Pink X · Non Important factors/parts

· Case studies and Workshop · Using the Workbook · Project Discussion · Next Step

© QBASE Engineering Sdn Bhd

( Practical D.O.E. Using Shainin's Methods )

QBASE

Engineering

Course Agenda Day 1

9:00 ­ 10:00 Introduction

Day 2

· Economic Imperative of quality · Traditional Statistical Process Control · Elementary SPC Tools ( 7 QC Tools) · Measurement of Process Capability 10:00- 10:15 Morning Break 10:15 - 1:00 Variation - An industrial epidemic · Concept of variation · Many sources and causes of variation · Deming's view of a system · Four state of a process · Concept of Loss Functions

1:00 -2:00 2:00 - 3:00 Lunch Break

·Shainin's Diagnostic Tools

· Factor Screening Tools · Multi-vari charts · Component search workshop and case studies

Morning Break

·Shainin's Diagnostic Tools (cont..)

· Factor Screening Tools · Paired Comparison · Variable Search · Workshop and case studies

Design of Experiment (DOE) · Three Approaches · Classical Method · Taguchi Technique · Shainin Technique · Comparison DOE Preliminary. · Green Y · Red X · Pink X · Non Important factors/parts

· Shainin's Diagnostic Tools · Factor optimization tools · Full Factorial experiments · B vs. C · Workshop and case studies

Afternoon Break

Lunch Break

3:00 - 3:15 3:25 -5:00

Afternoon Break

·Shainin's Diagnostic Tools (cont..)

· Factor optimization tools · Scatter plots and linear · regression · workshop and Case Studies

© QBASE Engineering Sdn Bhd

( Practical D.O.E. Using Shainin's Methods )

QBASE

Engineering

Course Agenda Day 3 9:00 ­ 10:00

·Shainin's Diagnostic Tools

Review of day1 and day 2

· Fractional Factorial Experiments · Workshop and Case Studies

10:00- 10:15 10:15 - 1:00

Morning Break

·Shainin's Diagnostic Tools

· "Holding the Gain" tool and Technique · Poka-yoke · Standardization · Positrol · Workshop and Case studies

1:00 -2:00 2:00 - 3:00

·The True Role of SPC - The "big picture" · The Management of Change ·Standardization ·Control Plans Class Projects · Designing a real-life experimental matrix.

Lunch Break

3:00 - 3:15 3:25 -5:00

Afternoon Break · Case studies and Workshop · Using the Workbook · Project Discussion · Next Step

© QBASE Engineering Sdn Bhd

( Practical D.O.E. Using Shainin's Methods )

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