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STATS Manufacturing Project - Lovell Levelers, Inc.

Description

solution. -


Question

Instructions

 

You need to understand how to send your assignments (deliverables) to your instructor. The tabs (bottom of each sheet) in this document contain all of the deliverables expected of you.

 

If you need help along the way, look for these special cells that have a red indicator Read me

 

in the corner. It looks like the "Read me" box to the right:

 

Simply slide your cursor over the red-cornered cell and you will get more information.

 

The format for all of the deliverables is the same:

 

The \'assignment objective\' is in black font.

 

The next segment is in green font. These are your instructions for that assignment.

 

The blue font is the data (where applicable) for completing each the assignment.

 

 

Software

 

We are using Excel software for the projects. You may use other software to complete your projects, but please \'report\' your answers in the Excel format described below.

 

You may complete your assignments with any version of Excel software.

 

All assignments can easily be completed with a basic copy of Excel.

 

There is also an Add-In feature which is available for Excel that can be helpful, although it is not required. The Add-In feature comes free with each Excel package, although it may not be currently loaded into your copy.

 

Following are the simple instruction for loading the Excel Add-ins for both Excel 2003 and Excel 2007. (Slide your cursor over the red-cornered cells to read)

 

 

Excel 2003

 

 

Excel 2007

 

 

Excel Novice - Please read

 

 

Project Timeline

 

Deliverables include:

 

Project charter (target week 3 or sooner)

 

Baseline sigma (week 4 or sooner)

 

Histogram (week 5 or sooner)

 

Expected variation (week 6 or sooner)

 

t test ( week 7 or sooner)

 

Chi square (week 9 or sooner)

 

ANOVA (week 11 or sooner)

 

DOE (week 12 or sooner)

 

Scatter diagram (week 13 or sooner)

 

Control chart (XmR) (14 or sooner)

 

Pp Ppk (week 15 or sooner )

 

 

How to submit an Assignment

 

In response to customers like you, we have added a peach-colored box for each deliverable. We have done this to make it clear (and consistent) the areas of the project that will be reviewed to your instructor.

 

Project:

 

Deliverable:

 

Student last name:

 

 

Manufacturing Project

 

Improve phase - gen. sol.

 

Johnson

 

 

What is the control chart telling you?

 

There is a point out of control at

 

subgroup #15. I would try to figure

 

out why that happened. We would

 

also recalculate the control limits

 

because there is evidence the

 

process has changed.

 

 

of

 

Example ble

 

a

 

r

 

a delive

 

 

What is the average of subgroup 1?

 

What is the average of subgroup 2?

 

What is the average of subgroup 3?

 

What is the average of subgroup 4?

 

What is the average of subgroup 5?

 

What is the average of subgroup 6?

 

What is the average of subgroup 7?

 

What is the average of subgroup 8?

 

 

22

 

34

 

23

 

22

 

25

 

23

 

29

 

27

 

 

Read this!

 

To send each assignment to your instructor:

 

Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the

 

peach-colored box, then while holding down on that button, drag to

 

the LOWER-RIGHT corner of the box. This will highlight the entire

 

peach-colored box. Release the mouse button. Do a CTRL-C. This will

 

copy what has been highlighted.

 

Go to your Villanova website and follow this sequence:

 

1. COMMUNICATE

 

2. CLASS ROSTER

 

3. Click on your instructor\'s email envelope icon

 

4. Type "Check My Work - Specific assignment" in the SUBJECT box.

 

5. Click once inside of the message box

 

6. Do a CTRL-V. This will paste your deliverable into this box.

 

Don\'t be concerned if after you paste it, the appearance of the text is out of

 

alignment. It will straighten out after you hit SEND.

 

7. SEND Check your SENT ITEMS folder afterward to see how it straightened out.

 

Please \'hand-in\' your assignments throughout the course.

 

DO NOT SAVE THEM FOR THE END.

 

Procrastinators: The deadline for completing all project deliverables

 

is 7 days prior to the end of the course.

 

 

Read this!

 

 

This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your Excel software.

 

If you see Data Analysis already listed under the Tools tab, you are set. If you do not see Data Analysis

 

follow the instructions in the Green tab.

 

Excel 2003 instructions

 

 

Excel 2003 or earlier versions of Excel example

 

 

This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your 2007 Excel software.

 

If you see Data Analysis already listed under the DATA tab, you are set. If you do not see Data Analysis

 

follow the instructions in the Green tab.

 

Excel 2007 instructions

 

 

Excel 2007 example

 

 

Manufacturing Project

 

Lovell Levelers, Inc. is a major provider of specialized parts

 

for the automotive industry. LLIs biggest customer, Specific Motors

 

was not a delighted customer this month. In fact, last

 

Monday, the executive vice president of Specific Motors headquarters,

 

Phyllis Kendall was diverted from a return trip from Singapore

 

to drop in unexpectedly at the LLI plant. There was nothing

 

routine about this visit. She made it explicitly clear that

 

Specific Motors was disappointed with the level of quality relative

 

to the leveler plates. In particular, she was disappointed with the

 

current average of rejects at the rate of 1,350 defects per million

 

opportunities (DPMO), and at LLI\'s cost of poor quality of just over $256,000

 

per quarter. She said the industry standard is <50 DPMO and

 

if we do not get the level of quality to the industry standard (as a

 

minimum) within the next six months, LLI should not expect

 

to keep the business next year.

 

The student will be a Black Belt working for LLI. The specifics about their company:

 

CEO

 

Bill Lovell

 

GM

 

Mary Nichols

 

Sponsor

 

John Hopps

 

Finance

 

Cindy Jenkins

 

Process owner

 

Leroy Miller

 

Master BB

 

Dennis Kens

 

Manufacturing

 

Mitch Freese

 

Design Engineer

 

Al Nelson

 

Quality

 

Debbie Judson

 

The deadline for completing all project deliverables is 7 days prior to the end of the course

 

 

Objective:

 

The Black Belt team did a pareto analysis of the data and determined that three factors were causing

 

over 95% of the problem with the leveler plates. Those factors are,

 

the length of the plates, the width of the plates, and the thickness of the plates.

 

You need to know if the data from these three \'product parameters\' are normally distributed.

 

 

Instructions for you:

 

1. Construct three (3) histograms for the three data sets.

 

2. Interpret each of the histograms to determine whether the variables are random or normally

 

distributed.

 

 

Data:

 

Length

 

10.67

 

10.74

 

10.68

 

10.72

 

10.66

 

10.69

 

10.70

 

10.72

 

10.69

 

10.68

 

10.72

 

10.70

 

10.70

 

10.73

 

10.75

 

10.73

 

10.69

 

10.68

 

10.70

 

10.77

 

10.72

 

10.69

 

10.66

 

10.69

 

10.63

 

10.68

 

10.73

 

10.74

 

10.65

 

10.69

 

10.70

 

10.72

 

10.75

 

10.71

 

10.72

 

Upper Spec

 

Lower Spec

 

Target

 

 

Width

 

 

11

 

10.5

 

10.75

 

 

7.66

 

7.45

 

7.55

 

 

7.51

 

7.57

 

7.55

 

7.53

 

7.53

 

7.56

 

7.52

 

7.58

 

7.55

 

7.53

 

7.56

 

7.58

 

7.55

 

7.55

 

7.54

 

7.57

 

7.54

 

7.55

 

7.55

 

7.56

 

7.54

 

7.56

 

7.56

 

7.55

 

7.54

 

7.55

 

7.56

 

7.57

 

7.54

 

7.55

 

7.54

 

7.55

 

7.53

 

7.54

 

7.55

 

 

Thickness

 

0.551

 

0.546

 

0.546

 

0.554

 

0.546

 

0.542

 

0.545

 

0.538

 

0.552

 

0.547

 

0.546

 

0.545

 

0.546

 

0.548

 

0.546

 

0.543

 

0.548

 

0.545

 

0.553

 

0.539

 

0.549

 

0.541

 

0.543

 

0.545

 

0.549

 

0.546

 

0.545

 

0.540

 

0.541

 

0.545

 

0.547

 

0.543

 

0.545

 

0.546

 

0.547

 

 

Histograms in Excel 2003

 

Histograms in Excel 2007

 

More on Bin Ranges

 

 

0.56

 

0.54

 

0.55

 

 

How to submit an Assignment

 

Target Assignment Date - Submit in Week 5 or earlier

 

YOU DO NOT NEED TO SEND THE ACTUAL HISTOGRAMS

 

Project:

 

Manufacturing

 

Deliverable:

 

Histogram

 

Student last name:

 

Merriweather

 

Is \'length\' normally distributed?

 

Is \'width\' normally distributed?

 

Is \'thickness\' normally distributed?

 

 

Yes

 

Yes

 

No

 

 

YOU DO NOT NEED TO SEND THE ACTUAL HISTOGRAMS

 

To send each assignment to your instructor:

 

Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the

 

peach-colored box, then while holding down on that button, drag to

 

the LOWER-RIGHT corner of the box. This will highlight the entire

 

peach-colored box. Release the mouse button. Do a CTRL-C. This will

 

copy what has been highlighted.

 

Go to your Villanova website and follow this sequence:

 

1. COMMUNICATE

 

2. CLASS ROSTER

 

3. Click on your instructor\'s email envelope icon

 

4. Type "Check My Work - HISTOGRAM" in the SUBJECT box.

 

5. Click once inside of the message box

 

6. Do a CTRL-V. This will paste your deliverable into this box.

 

Don\'t be concerned if after you paste it, the appearance of the text is out of

 

alignment. It will straighten out after you hit SEND.

 

7. SEND Check your SENT ITEMS folder afterward to see how it straightened out.

 

Please \'hand-in\' your assignments throughout the course.

 

DO NOT SAVE THEM FOR THE END.

 

Procrastinators: The deadline for completing all project deliverables

 

is 7 days prior to the end of the course.

 

 

Objective:

 

Although many things have been learned to this point and we have made progress, but we are not quite there.

 

Earlier in the project the team determined that thickness was the main problem relating to the high level

 

defects in the leveler plates. The analysis has been completed. Now, we want to IMPROVE the process.

 

You recommend using a design of experiments approach to hopefully realize a breakthrough improvement.

 

The team brainstorms a long list of possible reasons why the thickness is not capable. From that list, the

 

team has reduced it down to five factors they want to include in an experiment. They suspect

 

interactions, so they conclude a full factorial will be required. They refer to the resolution matrix (found in your

 

reading materials and in the Fractional Factorial Designs Lecture) and they find they can

 

learn about the effects of those five factors in 32 experiments.

 

The factors for the experiment were Depth, Temp, Pressure, R.P.M. and Time.

 

 

Instructions for you:

 

From the factorial experiment (below) calculate the interactions to determine confounding.

 

1. Fill in the interaction columns. (shaded in peach color) You will need to do

 

this to answer #1 in the peach-colored area below.

 

2. Is the design below a resolution III, IV, V or Full Factorial (no resolution)?

 

3. The design below is a design that an consultant is recommending. Unfortunately, you learn some bad news.

 

Your management has set your budget only allowing for 8 runs because the trials cost $600 a piece.

 

The team has determined it cannot live with main factors being confounded with other main factors or with

 

two-factor interactions.

 

What would you recommend? Big Hint: One of the factors MAY

 

be dropped from the study - for economic reasons. (please provide

 

your answer in the peach-colored area below) You do not have to determine which factor to drop.

 

4. Using the resolution matrix found in your online textbook,

 

what resolution would your recommendation be?

 

5. Based on your new recommendation, what are you giving up? Explain (briefly in the peach area)

 

 

"I\'m lost"

 

 

Data:

 

Factor

 

Depth

 

Temp

 

Pressure

 

R.P.M.

 

Time

 

 

(-)

 

85

 

140

 

850

 

4400

 

30

 

 

(+)

 

150

 

155

 

2500

 

4800

 

45

 

I try to enter + or - and it does not work.

 

 

Trial

 

1

 

2

 

3

 

4

 

5

 

6

 

7

 

8

 

9

 

10

 

11

 

12

 

13

 

14

 

15

 

16

 

17

 

18

 

19

 

20

 

21

 

22

 

23

 

24

 

25

 

26

 

27

 

28

 

29

 

30

 

31

 

32

 

 

Factor Factor Factor Factor Factor A X B A X C A X D A X E B X C B X D B X E C X D C X E D X E

 

C

 

A

 

B

 

D

 

E

 

+

 

+

 

+

 

+

 

Entering +

 

+

 

or - does

 

+

 

+

 

not work

 

 

How to submit an Assignment

 

Target Assignment Date - Submit in Week 12 or earlier

 

YOU DO NOT NEED TO SUBMIT THE DESIGNED EXPERIMENT

 

Project:

 

Manufacturing

 

Deliverable:

 

DOE Design Choice

 

Student last name:

 

Merriweather

 

1. What is the sign (+ or -) for the AxC interaction for the 4th trial?

 

2. What is the resolution as shown above? (III, IV, or V, or Full):::

 

 

"I\'m lost"

 

III

 

 

3. What is your recommendation?

 

Your recommendation here

 

 

4. What would the new resolution be? (III, IV, or V) :::

 

5. What would you be giving up?

 

What confounding will you see?

 

 

V

 

 

Please describe what you would be giving up based

 

upon your recommendation.

 

 

YOU DO NOT NEED TO SUBMIT THE DESIGNED EXPERIMENT

 

To send each assignment to your instructor:

 

Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the

 

peach-colored box, then while holding down on that button, drag to

 

the LOWER-RIGHT corner of the box. This will highlight the entire

 

peach-colored box. Release the mouse button. Do a CTRL-C. This will

 

copy what has been highlighted.

 

Go to your Villanova website and follow this sequence:

 

1. COMMUNICATE

 

2. CLASS ROSTER

 

3. Click on your instructor\'s email envelope icon

 

4. Type "Check My Work - DOE" in the SUBJECT box.

 

5. Click once inside of the message box

 

6. Do a CTRL-V. This will paste your deliverable into this box.

 

Don\'t be concerned if after you paste it, the appearance of the text is out of

 

alignment. It will straighten out after you hit SEND.

 

7. SEND Check your SENT ITEMS folder afterward to see how it straightened out.

 

Please \'hand-in\' your assignments throughout the course.

 

DO NOT SAVE THEM FOR THE END.

 

Procrastinators: The deadline for completing all project deliverables

 

is 7 days prior to the end of the course.

 

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