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Johanan Collins

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  1. Hanedashi is a Japanese word that is translated to automatic ejection. A Hanedashi device is designed to automatically eject a part once the process on it is completed. In order to implement Hanedashi, the process should be reliable and stable. The operator would not need to inspect the finished product. The diagram below explains how a Hanedashi device reduces waste. In the above diagram, we can see that without Hanedashi, the operator is required to carry out 4 tasks, however, with Hanedashi this is reduced to 2 tasks. Chaku-Chaku Line. A chaku-chaku (load-load) line is Handdashi devices placed in a sequence. This enables a single operator to handle multiple machines thereby reducing waste, effort, Waste Reduction The wastes that are reduced are “Motion” and “Skills/ Under Utilization of Manpower”. Motion is reduced as - the operator only loads the part on the machine. The machine automatically ejects the part. - the operator does not have to walk to the back of the machine to remove the part, this reduces motion and movement. Skills/ Under Utilization of Manpower is reduced as the same operator will have more time to do other tasks. References https://www.isixsigma.com/dictionary/hanedashi/ https://www.velaction.com/hanedashi/ https://training.velaction.com/courses/structuring-standard-work for diagram above
  2. A/B Testing or Bucket Testing or Split-Run Testing. It is a simple randomized controlled experiment of two samples hypothesis testing for two alternatives namely A and B. It tests the user’s response to Product A against Product B to see which is more attractive to the end-user. The products are similar in every way except for one attribute such as color or size. Version A could be the current product that would form the control group whereas version B is the treatment group which is a modification of version A. A/B testing helps to obtain major improvements through minor changes and obtain high rewards by taking small risks. Use Cases. Some of the use cases of A/B testing could be in newsletters, email campaigns, digital marketing, internet advertisement, website design, etc. Variant Options could be with respect to layout, theme, color scheme, images, headings, subheadings, font, font size, pricing, offers, call to action design, etc. Examples A/B testing can be used to design the purchase funnel on an e-commerce website. The drop-off rates of the two designs of the purchase funnel can be tested to see if the difference in the drop-off rates is statistically significant. A/B testing was first used by Google in 2000 to assess the ideal number of results to display on its search engine page since the larger number of results displayed on its page increased the loading time. A/B testing was used in Microsoft to assess the different ways to display advertising headlines on their search engine, Microsoft Bing. This experiment led to a revenue increase of 12% for the company within four hours of its implementation, without affecting the other user’s experience metrics. Email Marketing/Social Media Marketing with variations of “Offer ends soon” Vs “Offer ends by this weekend” Discount Rs.500 Vs 5% Discount Arial Font Vs Times New Romans Font Blue color Vs Red color To Determine the price point that offers the maximum total revenue. Political Campaigns. To determine what voters, want from a candidate. Testing of APIs by HTTP Routing. New features of APIs are tested through A/B Testing. In this case, a certain percentage of the end-users will get the new version through HTTP routing. This also ensures that in case of a bug, only a small percentage of users are affected. Segmentation and targeting. A/B testing can be used to determine the optimal variant for a particular segment of the market and specifically target that segment. References https://en.wikipedia.org/wiki/A/B_testing https://mailchimp.com/marketing-glossary/ab-tests/
  3. A Full Factorial Design does experiments for every possible unique combination of the Independent Variables and their impact on the dependent variable. It gives information on all the main effects and all the interactions. Screening DOE is also called Fractional Factorial DOE. It is used when there are a large number of possible independent variables and the researcher has a limit on the number of experiments that can be run. Screening DOE reduces the total runs on the number of experiments by removing those factors that are not statistically significant. This means that these factors will have a negligible effect on the output. The Plackett Burman Design is another type of screening DOE. Benefits of Screening DOE Saving of Time and Money. In the case of destructive testing, screening DOEs are helpful as it reduces the number of pieces of the experimental units scrapped. Fewer runs will require lesser time and resources. For example, an experiment with 10 factors would have 2^10 or 1024 unique runs. Out of these only, 56 will give the main and two-way interactions. The balance 968 will give the 3 way and higher interactions. Drawbacks of Screening DOE Loss of Resolution. In a Fractional Factorial design, some of the main effects are confounded or aliased with each other, this means they cannot be assessed separately. For example, in a Resolution III design, main effects are not aliased with other main effects but with other 2 factor interactions. In Resolution III design we will be able to estimate the combination of A+BC, B+AC, and C+AB. Resolution IV Versus Resolution III. In Resolution IV the main effect is aliased with 3-way interactions whereas in Resolution III the main effect is aliased with 2-way interactions. Since higher-order interactions are usually not significant a Resolution IV Design is preferable to a Resolution III Design. Comparison of Full Factorial Design Vs Screening The data below, having four factors namely Speed, Quality, Service, and Density has been assessed in a Full Factorial (16 Runs) and a Half Factorial (8 Runs) Resolution IV design on Minitab. The response variable is Sat which measures the Satisfaction Level. The data in the model is purely fictional and not experimental. The results of the above are displayed below In the Analysis of Variance, Coded Coefficients, Regression Equation we can see that the Full Factorial design has 15 degrees of freedom and the Half Factorial design has 7 degrees of freedom. We can see that the Full Factorial design gives four main effects, six 2-way interactions), four 3-way interactions, and one 4-way interaction. This adds up to the degrees of freedom (4 + 6 + 4 + 1 = 15). Whereas, we can see that the Half Factorial design gives four main effects, and three 2-way interactions (3). This adds up to the degrees of freedom (4 + 3 = 7). On observing the Alias Structure, we can see that in the Full Factorial design the main effects and the 2,3,4-way interactions are not confounded, however, in the Half Factorial design we can see that the Main Effects are confounded with the 3-way interactions and the 2-way interactions are confounded with other 2-way interactions. References https://www.isixsigma.com/dictionary/screening-doe/#:~:text=A%20screening%20DOE%2C%20also%20commonly%20referred%20to%20as,you%20to%20run%20a%20large%20number%20of%20experiments.
  4. A covariate is a confusing term in statistics. (References 1 & 2) For example, SPSS describes a continuous independent variable as a Covariate in its General Linear Models and as an Independent Variable in Regression. Minitab describes a continuous independent variable as a Covariate in its General Linear Model. In research, one is looking for relationships between explanatory variables and the response variable. Covariates are the variables that the researcher is not interested in but it affects the response variable. Example 1 Which training methodology out of the three methodologies available is most effective in improving exam scores for the ICSE Exam? The Explanatory Variable is the training methodologies and the exam score is the response variable. Covariates, in this case, could be the current grade of the students, education level of parents, the income of parents, or studying abilities of the students within the three groups of the training methodologies. The variability on account of these covariates needs to be taken into consideration in order to see the correct relationship between the training methodology and the exam score. For example, in this case, we could use the current grade of the students as a covariate since the current grade would most likely be highly correlated with the exam score. Example 2. What is the relationship between the Square Foot Area of a house and its price? The Explanatory Variable is the Square Foot Area of the house and the price is the response variable. Covariates, in this case, could be the age of the house, the location of the house, or even the distance from the bus stop. The variability on account of these covariates needs to be taken into consideration in order to see the correct relationship between the Square Foot Area of the house and the price. For example, in this case, we could use the age of the house as a covariate since older houses are likely to be cheaper. The most common settings for Covariates are ANOVA and regression. ANOVA. Analysis of Variance is used to find if there is any statistical difference between three or more independent groups. However, in Example 1 above, we use the current grade as a covariate and would perform an ANCOVA (Analysis of Covariance). In this case, the students’ current grade, a continuous variable, is included as a covariate Regression. In regression, we are attempting to quantify a relationship between one or more independent explanatory variables and the response variable. We run a Multiple Linear Regression by including Square Footage (Variable of Interest) and House Age (the covariate) as an explanatory variable and House Price as the response variable. The regression coefficient of the Square Footage would give the change in House Price per unit change in Square Footage after taking into account the House Age. Thus, by adding House Age in the regression model in Example 2, the noise (variation on account of the covariate) is reduced. References 1. https://www.theanalysisfactor.com/confusing-statistical-terms-5-covariate/ 2. https://www.theanalysisfactor.com/series-on-confusing-statistical-terms/ 3. https://www.statology.org/covariate/
  5. Parameter Diagram In its simplicity, the Parameter Diagram can be considered a schematic representation of the signal, noise, control factors, and response variable. Juran defines Parameter Diagrams in his book on Quality, viz. Quality Planning and Analysis. He states that performance is one of the most basic features of any product and equates performance to the output of a product/service/system. For example, in a TV, it could be colour density, in an electric car it could be range, etc. The output is a factor of various engineering principles that are used to combine materials, components, parts, assemblies, etc. Each of these inputs has a range of parameters, which the design team needs to establish. Setting the correct value for each parameter would then produce the desired output. The Parameter Diagram relates the inputs which may come from the system or customer to the desired output. The parameter diagram also takes into consideration external influences that are non-controllable. The Parameter Diagram can be used as a visual tool for brainstorming and documenting various factors such as control factors, noise factors, input signals, error states, and ideal responses. Use Cases of P-Diagram - It can be used as a very effective Brainstorming Tool. - It is helpful in the preparation of an FMEA, as each input could be analyzed for the failure modes and the effects can be analyzed and RPN Number calculated. - In complex systems where there is an interaction between numerous subsystems, design and engineering parameters, and operating conditions, the Parameter diagram helps the team to visually see each element. - It can also be used for Component FMEA when the visual representation of inputs, ideal response, noise factors, and control factors is helpful. - It can also be used in New Product Development, in combination with the Design of Experiments. An Indicative Diagram of a Parameter Diagram is below:- Definitions of Elements of P Diagram - Input Signals. These are generally the energy sources required by the system. Variations in these inputs can cause a change in the output. - Control Factors. These are the parameters that the design team can control or change. - Error States. These are the loss of energy or undesirable output - Noise Factors. These are factors that influence the output but are not under the direct control of the design team. These include fair wear and tear of the equipment, normal degradation of materials, tiredness of operator, etc. A robust design protects the system against such noise factors. - Ideal Response. This is the desired functional output of the system. Parameter Diagram, New Product Development, and Design of Experiments DMADV. New Product Development generally follows the DMADV (Define, Measure, Analise, Design, Verify) methodology. In the Define phase, the process and its design goals are defined. In the Measure phase, the CTQ is identified and measured. In the Analyse phase data is used to analyze the best possible design. In the Design Phase, the prototype is designed and finally, in the Verify phase, the outputs are verified in real conditions. The DMADV methodology is used in New Product Development or when further improvement of the existing product is not a commercially or technologically viable solution. In the first case, no data would be available for analysis, and in the second case, the data from the previous product could possibly be used for analysis. Design of Experiments. Experimental design is a critically important tool in scientific and engineering for improving the product realization process. Critical components of these activities are new manufacturing process design and development, and process management. The application in DoE helps in increasing process yield, reduced variability, development time, and cost. Applications of DoE include - Evaluation and comparison of basic design configurations - Evaluation of material alternatives - Selection of design parameters so that the product will work under a wide variety of field conditions, that is so that the product is robust - Determination of key product design parameters that impact product performance - Formulation of New Products Parameter Diagram. After representing the system schematically in a Parameter Diagram, the Design of Experiments can be used with the input signals, control factors and error states, ideal response can be optimized based on the inputs. References https://www.weibull.com/hotwire/issue182/fmeacorner182.htm https://kanbanize.com/lean-management/six-sigma/dmadv Design and Analysis of Experiments, Eight Edition, Douglas C. Montgomery, Wiley
  6. Definitions of Reliability Manufacturing & Service - Change of Quality over time. - The ability of a product, service, or system to maintain the original level of quality over time and under different conditions. - The probability that is inherent in a system, service, or product that ensures it effectively carries out it’s designed function over a specified time, in a defined environment without failure. Research - Reliability is the consistency of a research study or measuring test. https://www.simplypsychology.org/reliability.html). - Reliability is the consistent replication of findings from research. A high correlation coefficient indicates high reliability. Psychometrics/Statistics - The overall consistency of a measure. A highly reliable measure repeatedly produces similar results under similar conditions. - "It is the characteristic of a set of test scores that relates to the amount of random error from the measurement process that might be embedded in the scores” https://en.wikipedia.org/wiki/Reliability_(statistics) Components of Reliability Manufacturing & Service These are the likelihood of success, the designed function, performance within given specification limits, a time period, and the environment/conditions such as the temperature, speed, or pressure. ASQ defines these elements as the probability of success, durability, dependability, quality over time, and availability to perform the function. Psychometry/Statistics. The components of reliability are precision, reproducibility, and consistency. Measurements are influenced by factors that contribute to consistency and factors that contribute to inconsistency. The factors that contribute to consistency are the stable characteristic of the person or the attribute that is being measured whereas the factors that contribute to inconsistency are attributes of the person or circumstance that might alter the measurement. Examples of these are things such as health, tiredness, motivation, emotions, comprehension of the task, attention, distractions, instructions, and even luck. Four Main Types of Reliability Test-retest. This is conducting the same test over a period of time. Interrater Reliability. This is conducting the same test but by different individuals Parallel Forms Reliability. This is conducting alternate versions of tests that are designed to measure the same attribute. Internal Consistency Reliability. This is the correlation between multiple items of the test and the construct it is supposed to measure. Examples of Reliability Electric Scooter under a warranty of 24,000 Kms or 2 years whichever is earlier Television. Life time guarantee. Ecommerce website uptime is 99.997% Once data entry error per one million keystrokes References https://asq.org/quality-resources/reliability https://www.simplypsychology.org/reliability.html https://en.wikipedia.org/wiki/Reliability_(statistics) https://www.scribbr.com/methodology/types-of-reliability/
  7. Training Within Industry was a necessity during World War 2 from 1940 to 1945. The success of the war depended on the industry meeting the increased requirements during war. There was an increased need for trained and skilled manpower during the war when the manpower was required to fight the war and at the same time required to produce material. TWI provided a framework for improved methods of training and modern ways to meet the shortfall. During World war, about 1.6 Million workers were TWI trained in about 16,500 factories and plants. The program continued in Asia and Europe post the war to rebuild the countries. It is of note that Kaizen and the Toyota Production System was an offshoot of TWI. TWI was developed by experts from the Private industries. It consisted of four training programs of ten hours each. Due to the urgency, it used various experimental models, many of which were discarded. The successful programs were put together to form the TWI. The introductory sessions were the “Appreciation Sessions” that were used to gain management support. For the need of additional trainers, TWI had the “Trian the Trainer” sessions and “Institute Conductor’s Manual” for the master trainers. It also had a “Staff Only” program for staff development. The trainers used the 5 Needs of the Supervisor viz., knowledge of work and responsibility, skill in instruction, improving methods, and leading. The four training programs of ten hours are Job Instruction, Job Methods, Job Relations, and Program Development. Job Instruction (JI). JI trained experienced staff to train inexperienced staff more quickly. It consisted of breaking down the task into well-defined steps, with the procedure and key points, demonstrating it to the students, and observing the students perform the task. Hospitals, farms, and offices used a variation of the program. Job Methods (JM). Workers evaluate their own jobs and look for areas of improvement. The course teaches job breakdown and reasoning skills to determine if there is a need to eliminate, combine, rearrange, or simplify the step. Job Relations (JR). This course teaches supervisors to treat the workers as individuals, hence human relationships on the job are emphasized. Programme Development (PD). This course is for those responsible for the training function in order to assist those on the line to solve problems during production by training. References https://en.wikipedia.org/wiki/Training_Within_Industry
  8. A Measles chart is also called a defect map or a defect location check sheet. It provides a visual image of the data collected rather than just collecting the count of the number of defects. In addition to the count and rate of defect, it shows the location of the defect. A drawing of the item is used to plot the place where the defect is occurring. The location of clusters of the defect could throw a better light on the nature of the defects, root cause identification, and its solution. Measles charts can throw light on the problem either by highlighting the areas where the maximum clusters of the problem occur as in the case of the 1845 Cholera Epidemic or by highlighting the areas where minimum/nil clusters of the problems occur as in the case of the Bomber Aircraft in World War 2. Examples Cholera Epidemic. The cholera epidemic hit Soho, London in 1854. Dr. John Snow, the father of epidemiology, plotted the location of deaths caused by the epidemic and the location of the pumps. His analysis led to the identification of the source as a contaminated public water pump. The removal of the handle of the pump stopped the epidemic. Survivability Bias World War 2 Survivability Bias draws attention to the survivors while evaluating a problem. Mathematician Albert Wald of the Statistical Research Group, United States did studies on neglected data and came to a conclusion that during World War 2, the retuning combat bombers needed to be strengthened in the areas where the bullet holes were minimum since the places with maximum bullet holes were not causing the aircraft to crash. A Measles chart of the returning aircraft gave an indication of the areas that showed the strongest part of the aircraft (a cluster of holes) and the most vulnerable parts of the aircraft having areas with no holes. The Measles clusters indicated the parts that were strong and needed the least additional protection. Defects in Cars The average number of defects that occur in the body of a car is 67. However, a Measles chart as indicated below show the locations that are more prone to defects. References. https://www.sixsigmadaily.com/measles-charts/ https://worldwarwings.com/the-statistics-that-kept-countless-allied-fighter-planes-in-the-sky/ https://www.r-bloggers.com/2013/03/john-snows-cholera-data-in-more-formats/ https://infodreamgroup.com/blog-defect-map-defect-location-advanced-attribute-spc/
  9. Burn-in Testing is the testing of the components of a system before it is put into service or before its assembly into the system. It is done to establish the load capacity of a component by forcing it into failure under supervised test conditions. The plot of the Failure rate against time takes a shape of a Bathtub curve. This shows that the failure rate is high early in the product life cycle. The burn-in testing is done in a stressful and accelerated environment in order to determine the failure rate during this early stage of the product life cycle when the failure rate is high. The failed components would be improved upon and replaced thus preventing premature failure of the system. Since the Burn-in testing generally destroys the components, a trade-off needs to be made to ensure a high yield. Cost Implications. Burn-in testing is not done for all components. It will generally depend upon the cost of the test, the cost of the component since it is damaged during the test, the cost of failure, the cost of warranty claims, and the cost of goodwill lost. Advantages of Burn-in Testing Higher reliability of the product. Proactive prevention such as planned preventive maintenance. Fewer customer returns leading to fewer service and call centers. Better estimated lifespan of the product Examples of Burn-in Testing Electronic Components testing is done at high voltage, current or temperature. Audio Equipment is tested by leaving it on for a large number of days. Stress testing of ropes, wires, and jigs is done to assess the safe working load. References https://en.wikipedia.org/wiki/Burn-in https://www.techopedia.com/definition/2161/burn-in-testing#:~:text=Burn-in%20testing%20is%20the%20process%20of%20increasing%20the,be%20replaced%20before%20the%20device%20reaches%20the%20consumer.
  10. P-Value. Under the assumption that the Null Hypothesis is true, the P-Value is the probability of getting test results at least as extreme as the results actually observed. Hence a P-Value of 0.049 indicates that the likelihood of obtaining a value as extreme as the test result is 4.9% whereas a P-Value of 0.02 indicates that the likelihood of obtaining a value as extreme as the test result is 2%. Hence, we can conclude, the smaller the P-Value, the smaller is the likelihood of the outcome to be at least as extreme the actual results obtained. Statistical Significance: Statistical Significance (Alpha) is the probability of rejecting the Ho, given that it is true. When p <= Alpha, the results are statistically significant. Type 1 and Type 2 Errors. Type 1 Error is the rejection of a null hypothesis that is true. It is called a false positive. The probability of Type 1 error is Alpha. Type 2 Error is not rejecting the null hypothesis is false. It is called a false negative. The probability of Type 2 error is Beta where the Power of the Test is 1 - Beta In False positive/negative, the word false means that the conclusion drawn is false. Type 1 and Type 2 are complementary. If you decrease one, the other will increase. Example. Case 1. Convicting an innocent defendant is a type 1 error, whereas acquitting a criminal is a type 2 error. Case 2. Test results says you have corona virus but you don’t is type 1 error, whereas test results indicating that you don’t have the virus and you have the virus is type 2 error In Case 1, we will want a low significance level, however in Case 2 we will want a high significance level. Selection of Statistical Significance. The Statistical Significance is chosen before the collection of data. In Case 1, we will want a low significance level, however in Case 2 we will want a high significance level. In Academic Settings once the Statistical Significance (Alpha) is determined, and the p-value calculated and compared to the Alpha, the Null Hypothesis is either rejected or we fail to reject the null hypothesis. The absolute difference between the p-value and α is inconsequential. Having said that, (as against Scientific or Academic research), in a Managerial setting, say to accept a consignment based on the p value, the manager may do the following in case the p value is close to Alpha (0.048) (a) accept the consignment with caution or (b) take another sample to confirm the findings or (c) accept the consignment at a reduced price and sell it on a discount or (d) have an alternative use for the consignment. However, in case the reduced quality may have an adverse effect on the reputation of the firm, the Manager would then reject the consignment. References https://en.wikipedia.org/wiki/Type_I_and_type_II_errors https://en.wikipedia.org/wiki/P-value
  11. Gen-ba or Gemba means Real Place. It means going to the actual place where the problem has occurred. An interesting article about the difference between Gemba and MBWA (Management by Walking Around) is on the Benchmark Six Sigma Forum. (Link in Reference 1) Gen-butsu means Real Part. Go to the real place and observe the real part and the real process. Gen-jitsu means Real Facts. It means collecting the real facts by going to the real place and observing the real part and the real process. This can be compared to the standard or ideal condition. The 4M data, i.e., Man, Machine, Material and Method may be collected. 3G Principles. Genba, Gebbutsu, and Genjitsu form the 3G Principles. 5G Principles. Genri and Gensoku are added to the 3G Principles Genri means Principles. It means verifying the related theory and/or principles. This helps in Root Cause Analysis Gensoku means Fundamental Rules. It means checking the Standards, Standard Operating Procedures, parameters, the level of training, motivation, etc. Example. Optimizing Crew Transportation of an Airline at a Metro City. ABC Airlines operates International and Domestic flights for their Pilots and Cabin crew from XYZ city. A transport delay generally leads to a flight delay causing both tangible and intangible loss for the airline. The transportation operations are contracted out to a vendor to carry out the operations. Problem. Increase in Flights being delayed on account of transport. Vendor asking for an increase in the number of cars for the operation. Application of 5G Principle Genba. This involved a visit to the airport and observing the operations both secretively, from a distance, and from within the parking lot. Genbutsu. Here it was observing the real process both for travel from home to airport and vice versa. Genjitsu. The real facts were collected some of these were, the geolocation of the addresses of all crew to calculate time and distance, flight schedule throughout the day, no of cars actually deployed with their registration numbers, odometer reading of all cars, number of crew in each car per trip, the spatial distance between crew being clubbed together in each trip, flight time – airport droptime on pickup , waiting time on drop, GPS feed, number of vendor supervisors deployed, non-productive trips (one way empty), breakdowns, preventive maintenance, the interaction between vendor supervisor, airline supervisor and crew, etc. Genri. The next step was to verify the related theory/principles. Timeline. A timeline of the entire operations was drawn out in Excel and peak loads and lean periods were calculated. The operations were balanced by combining the domestic and international operations into one contract. Further peak loads were handled through the hiring of Meru/Ola/Uber Cabs available at the airport. Geolocation. Geolocations of all crew members were plotted on the map and theoretical distances were calculated. These were compared with the actual odometer readings for corroboration of the facts. Infor Optimization Software, which is designed on various transportation and supply chain optimization theories such as traveling salesman etc., was deployed for optimizing the operations. Actual Odometer Readings. Actual daily odometer readings for each day of operations obtained from the cars, compared with the GPS readings. Average readings and standard deviations were calculated and the area under the normal curve was used to calculate probabilities of delay. Non-Productive Trips. Details of non-productive trips were studied and fed into the software which reduced the number of trips. Stakeholder Analysis. The stakeholders were the management (reduction in cost), crew (improved quality of service), vendor (increase in profit), Unions (political reasons), etc. Gensoku. The last step was to establish the Fundamental Rules. The number of cars for the operations was theoretically calculated and corroborated with the actual cars on the ground. Service Level Agreements, taking into consideration inputs from all stakeholders, were included as part of the contract. Airline Supervisors were given authority to hire Meru/Ola/Uber cabs on an as-required basis. The SLAs included the number of cars to be deployed during various time periods (peak and lean time periods) of the operations, waiting times (waiting times were increased in lean periods), number of crew to be clubbed in each cab (this was increased during peak operations), clear accountability and distribution of responsibilities between vendor and airline supervisor. Final Outcome. The above operations led to a reduction in the number of cars being deployed, nil transport delay on account of transport, increased satisfaction by the crew, clear accountability between vendor and airlines supervisor. The same model with a few modifications was applied in other Metros. The above example has been written after a detailed discussion with the person in charge of optimizing the transport optimization. References https://www.benchmarksixsigma.com/forum/topic/35238-gemba/#comment-46468 https://www.nikunjbhoraniya.com/2022/01/5-gen-methodology.html http://www.sixsigmatrainingfree.com/six-sigma-blog/gemba-gembutsu-genjitsu
  12. Overall Equipment Effectiveness / Overall Equipment Efficiency OEE measures the utilization of a machine. It is a ratio of the parts produced vs the theoretical capacity. Causes of OEE · Availability. Availability Losses can be due to planned maintenance, unplanned repairs, breakdowns, material shortage, changeovers, lack of transport for finished goods, absence of operator, etc. · Performance. Speed Losses are reduced rate of production due to wear and tear, poor maintenance, idling, lack of training leading to incorrect operation, wrong settings, etc. · Yield. Quality Losses are losses due to defects. These wastages can be in the form of scrap, rework, and start-up losses. Example. · Theoretical OEE – 100 parts per hour · Availability Losses – 5 parts per hour · Speed Losses – 10 parts per hour · Quality Losses – 15 parts per hour · Good parts produced – 70 · OEE – 70% TAKT Time Takt is a musical term. In German it means beat. It is the rhythm/rate at which production needs to be paced in order to meet customer demand. It is measured in Time/Unit. It helps in planning the resources such as employees, machines, raw material, transport, storage, etc with respect to the required production. Customers, transporters, employees, etc., can be given an accurate estimate of when to expect the finished goods. The Takt time changes as the business grow, hence necessary action such as increasing capacity will need to be taken to stay ahead of demand. Takt Time = Total Available Production Time/Customer Demand Example Total Available Production Time/day = 480 Minutes Cycle Time Cycle Time is the time spent on a specific task for one unit. Time/Unit Example 1. Unbalanced Line Cycle Time. · Cycle Time Task A = 30 sec/part, · Cycle Time Task B = 60 sec/par - Bottleneck, · Cycle Time Task C = 15 sec/part, · Cycle Time Task D 15 sec/part · Throughput without OEE = 60 parts/hour · Target Cycle Time = 60 Sec x 0.8 OEE = 48 Sec · Throughput with OEE (80%) = 3600/48 = 75 Parts Per Hour Example 2. Balanced Line Cycle Time. · Cycle Time Task A = 30 sec/part, · Cycle Time Task B1 = 30 sec/part, · Cycle Time Task B2 = 30 sec/part, · Cycle Time Task CD = 30 sec/part · Throughput without OEE= 120 parts/hour · Target Cycle Time = 30 Sec x 0.8 OEE = 24 Sec · Throughput with OEE (80%) = 3600/24 = 150 Parts Per Hour The target cycle time for a process is Takt Time multiplied by the OEE If the Target Cycle Time for a process is optimized without taking into consideration the reduced production due to OEE losses, it is likely that the customer demand is not going to be met. For the customer demand to be met taking into consideration OEE losses the · Average Output >= Average Customer Demand or · Target Cycle Time <= Takt Time x OEE This is illustrated in the examples above References https://www.benchmarksixsigma.com/forum/topic/36096-overall-equipment-effectiveness-oee/#comment-50835 https://www.allaboutlean.com/oee-definition/ https://www.allaboutlean.com/line-balancing-3/
  13. Weighted Shortest Job First Prioritization Framework The WSJF framework is used to maximize ROI. It needs clear objectives before starting since the Return on Investment is linked to the priority assigned to a task. It predicts the value that the project will deliver before undertaking it. It is suitable to prioritize a very large range of features such as marketing, content marketing, bugs, type of product, business/technical risks, value to customers, etc. In simple mathematical terms, WSJF can be defined as the Cost of Delay divided by the Duration. The components of Cost of Delay as determined by the developer of the framework (SAFe) are:- · User/Business Value · Time Criticality · Risk reduction/opportunity enablement User/Business Value. Rank the tasks by relative importance to users and their potential impact on revenue. Questions asked at this stage are, what is the value to the business, what is the impact to revenue, what is the relative value to the end-user, and how important is it to the user, what are the negative impacts caused by delay, what are the users preference to this solution over others? The ranking was done by SAFe in a Fibonacci series of 1,2,3,5,8,13… Time Criticality. Ranks the tasks by urgency. Estimate the decay in value over time or the number of customers lost over time. Questions asked are, is there a fixed deadline, will the value decay over time, will users wait, will users move to another solution, how urgent is it for the business or product? The measurement was done by SAFe in a Fibonacci series of 1,2,3,5,8,13… Risk Reduction/Opportunity Enablement. Looks at long-term benefits against revenue, further improvements that will increase the number of potential customers. Helps to analyze legal/technical risks early in the project. Questions asked are, will this increase future business opportunities, is it important to eliminate future risks, is the risk of future delivery reduced, will the information received give value? The measurement was done by SAFe in a Fibonacci series of 1,2,3,5,8,13… Duration/Size of Job. Duration ranks the job by the complexity of realization. The greater the complexity, the greater is the measurement. This would include factors such as costs of manhours, etc. Duration is also called feature points, story points, relative size, or effort. Since it is in the denominator, a smaller number is better. Questions asked are what are the dependencies that add risks and increase the time, how big or complex is the implementation, what will be the time to implement? The measurement was done by SAFe in a Fibonacci series of 1,2,3,5,8,13… Drawbacks All criteria are treated equally. What if you want to give a greater weightage to business value? You will have to add weights to the criteria. It is based on relativity. It is difficult to measure duration and other criteria. Mitigation Consistency. Use the same score scale for all tasks to ensure consistency Expert Opinion. Experts (developers) will be more accurate in the estimation of development time. Managers will be more accurate in estimating business value. Collaboration between managers and experts needs to be done for more accurate estimation. Common Sense. Prioritization techniques help you to decide and not decide for you. Various other intangible factors need to be taken into consideration. Use Cases. It is commonly used to maximize economic benefits in business problems. Use cases are to prioritize projects, features, ideas, hypotheses, and user stories. RICE Scoring – Reach, Impact, Confidence, Effort The Rice scoring system is a prioritization framework that uses four factors viz, Reach Impact, Confidence and Effort to arrive at a decision. Being a quantitative prioritization technique, it relies more on data and removes the subjective and feeling aspects of decision-making. Further details of Rice and details of the Kano Model (Delighter, Satisfactory, Neutral, Dis-satisfied), MoSCoW Method: (Must have, Should have, Could have, Will have), Product Tree, Benefit Vs Effort can be read from the Benchmark Six Sigma Forum link here https://www.benchmarksixsigma.com/forum/topic/39068-rice-scoring/#comment-57229 Details of other Prioritization Matrix such as Eisenhower Matrix, 2x2 Matrix, Weighted Decision, VRDT, HEART, ICE, AARR, REAN are in the link in the references below. Some of them are explained below. VRTD Framework (SEO Content Prioritization) [Volume, Relevance, Difficulty, Time] There are four criteria for content prioritization i.e., volume, relevance, difficulty, and time Volume. This is the potential traffic to the website. The number of people who search for a keyword. It can be scored as 0 for less than <250, 1 for volume between 250 and 500, 2 for volume between 500 and 1000), and 3 for above 1000. These numbers are based on the average volume in your domain. Relevance. Traffic should be targeted and lead to conversions. How the keyword is relevant to the conversion to a customer. It can be scored as 0 for not relevant to 3 for highly relevant. Difficulty. Difficult keywords are difficult to rank in an SEO. The difficult score can range from 0 for easy to 3 for very difficult. Time is the time required to create content and can be scored as 0 for less than a day to 3 for above 10 days. The Final Score for the keywords is calculated as below Score = (Volume Score * 1) + (Relevance Score * 1) – (Difficulty*-1) – (Time Score*-1) HEART Framework [Happiness, Engagement, Adoption, Retention, and Task Success] The HEART Framework along with the Goals-Signals-Metrics is developed by Google to measure and improve User Experience. The HEART Framework uses categories to define user-centered metrics. ICE [Impact, Confidence, Ease of implementation] Prioritization The ICE framework is used to prioritize projects, marketing initiatives, features, user stories, hypotheses, etc in a rapid manner with limited resources. It takes into account both the value of the product feature and the efforts required. Score = (Impact + Confidence + Ease) / 3 Drawbacks. It is subjective. To circumvent the subjectiveness, the average score of the team can be taken. AARRR Framework [Acquisition, Activation, Retention, Referral, Revenue] The AARRR framework is a metric to understand user behavior. It is used for goal setting and customer journey optimization. Acquisition deals with the market channels used, Activation on the initial action that the user should take, Retention deals with repeat customers, Referral looks at the word-of-mouth aspect, and finally, Revenue deals with monetization. Importance of AARRR. Analyzing and understanding users’ behavior helps in targeting metrics that make a difference in the bottom line. It keeps the team focussed on what is important. REAN Framework [Reach, Engagement, Activation, and Nurture] Used to map and analyze goal setting, marketing effectiveness, and develop KPIs. Reach deals with brand awareness, Engage deals with audience interaction with the brand, Activation deals with conversion metrics, and Nurture deals with the effectiveness of the re-marketing efforts. RACE Planning Framework [Reach, Act, Convert, and Engage.] It is used for mapping and managing engagement activities. Reach deals with the volume of the website traffic, Act deals with conversions, time on site, likes, shares, etc., Convert deals with conversation rate optimization, retargeting, etc., and Engage deals with developing long term customers relationships. References https://www.benchmarksixsigma.com/forum/topic/39068-rice-scoring/#comment-57229 https://hello.ducalis.io/prioritization-frameworks/all-prioritization-templates
  14. Advanced Product Quality Planning APQP is a structured tool for the design, development of the product/process in order to meet the customer’s expectations and requirements. The first Advanced Quality Planning handbook for suppliers was published by Ford Motors in the early 1980s. The success of this handbook led to the North American Automotive OEMs collectively bringing out the APQP process in 1994. This was then updated in 2008. The intention of APQP was to aggregate the common planning activities of all OEMs. IATF 16949:2016 Standard and Objectives. It is part of the five tools of the IATF 16949:2016 Standard. The other tools of the standard are MSA (Measurement System Analysis), FMEA (Failure Mode and Effect Analysis), SPC (Statistical Process Control), and PPAP (Production Part Approval Process). The objectives of APQP focus on communication, timely completion, minimal quality complaints, quality assurance, and customer requirements and expectations with a focus on risk mitigation associated with a change in the development of new products or processes. APQP uses cross-functional teams to understand the voice of the customer and translate it into clear technical specifications and characteristics. APQP - Phases APQP has five phases. They are plan and define program, product design and development, process design and development, product and process validation and the final phase is feedback, assessment, and corrective action. In “plan and define program” the customer’s needs and expectations are clearly understood. In “product design and development”, design features are developed. DFMEA (Design Failure Mode and Effects Analysis) and DFMA (Design for Manufacturability and Assembly is included). In “process design and development”, effective management systems to assure customer needs and expectations are built into the system. PFMEA (Process Failure Mode Effects Analysis) and control plans are part of this phase. In the “product and process validation” phase the manufacturing process is validated through a production trial run and production control plans are finalized. In the “feedback, assessment and corrective action” phase, continual improvement is undertaken in order to improve the customer satisfaction level. Benefits. The benefits of APQP are increased customer satisfaction and service performance. It helps in directing resources by identifying the vital few from the trivial many, on-time delivery of the quality product at a lower cost, reduction in variability, changes identified early in the development and avoiding changes after launch, mitigating risk, etc. When to use APQP? APQP involves the entire supply chain. It helps in communication between the supply chain, the organization, and the customer. The customer’s expectations are translated and understood throughout the entire supply chain. APQP hence brings the entire supply chain on one page with regard to the customers’ needs, and expectations. Use Cases. The use cases of APQP are below: - · New Product Introduction. APQP uses risk-based tools that focus on the entire range of aspects of the product and process such as design, quality control, service, packaging, continuous improvement, etc. APQP focuses on risk as a substitute for failure. · Product or Process Change (post-release). The change is done independently of the product development. The problems created by the change and its associated risks are prevented by using this approach. · Develop requirements from Voice of the Customer (VOC) and Quality Function Deployment (QFD). · Develop Product Quality plans, test plans, project timelines. · Linking DFMEA to PFMEA · Conduct Performance stability and capability studies in tandem with Statistical Process Control. Design for Six Sigma DFSS is a proven proactive approach to design used for translating the customers' and business needs into a well-designed product or service. It is used in process design and not process improvement for which the DMAIC methodology is used. DFSS incorporates the efficiencies of the six sigma methodologies in the new design. The DFSS team is cross-function to include all aspects of the product or service. The goal is to minimize the defects and variations at their root. DFSS not only reduces the time to market by between 25 to 40% but also ensures a high-quality product that meets customers' expectations. When to use DFSS? DFSS is used in the design of a totally new product or service. It is generally used when you replace a product instead of improving a product. This happens when the existing product or service is beyond improvement to meet the customers’ expectations. It is not used for incremental change to a process or product design. When designing a new product the DFSS methodology is used to prevent quality issues. It is used to optimize the design, shorten the time to market, meet the end users’ actual expectations, to provide a product or service at a very high-quality level for the first time. As in APAQ, it uses a Cross-Functional Team that focuses on what is Critical to Quality and the customers' requirements. The steps that DFSS could follow depend on various factors. DFSS could follow the DMADV, IDOV, or the DCCDI steps. In DMADV, the first three phases are similar to the DMAIC. In the Design phase of the DMADV, the Design of Experiments, Failure Mode and Effect Analysis, etc are undertaken. In the Verify phase of DMADV, Process FMEA is performed to evaluate the risk. Prototypes or pilots are undertaken and a Control Plan is developed. DFSS could also use DMADOV, which uses Optimization between the Design and Verify phases. Another variation to DFSS is Define Customer and Concept, Design, Implement (DCCDI) or the Identify, Design, Optimize, Verify (IDOV) APQP Vs DFSS · APQP is the product development process used as default to support supplier engagement. It is used to collaborate with suppliers. · DFSS is focused on high-value requirements or specifications that are different from past products. · APQP and DFSS share development tools and goals. · APQP is broader in scope than DFSS · APQP scales to the perceived risk that each supplier, design, or process contributes towards the success of a program. References https://en.wikipedia.org/wiki/Design_for_Six_Sigma DFSS and Advanced Product Quality Planning (APQP) in ISO/TS16949", Asian Journal on Quality, Vol. 8 No. 3, pp. 173-187. https://doi.org/10.1108/15982688200700031 https://quality-one.com/dfss/ https://quality-one.com/apqp/#:~:text=DFSS%20is%20a%20highly%20focused%20effort%20reserved%20for,%28OEM%29%20is%20preparing%20a%20new%20end%20user%20product.
  15. What comes to your mind when you think about robots or bots? Some human-looking machine that does physical tasks! R2-D2 or C-3PO from Star Wars! However, with the increasing complexity and connectivity of the enterprise, automation of tasks done by humans on a computer interface is increasingly being automated. These are called Bots and offer the company a unique versatility by allowing it to scale based on the workload, budget, and other operational constraints. This change in the level of operations is done without any work stoppage or disruptions to the value chain. Besides scaling, and providing a better product/service, bots also give the company the capacity to work faster, with more precision, and leaner. Processes requiring repetitive and tedious action, require different levels of automation with regard to processes requiring a high level of cognition. Bots can be attended and/or unattended. Attended and unattended bots can be deployed at the same time to create a synergized, unified integrated platform. Bots can be thought of as different musicians/sections in an orchestra with each musician playing their part to create a beautiful harmony. Unattended RPAs Unattended Automation requires nil to very little human intervention. They are self-triggered and the tasks are endlessly completed in a batch process. That is to say that these bots can work round the clock throughout the year. If required, these bots can be monitored and controlled remotely via different platforms or interfaces. They can be analyzed, viewed, scheduled, and modified in real-time. This gives the employee a means to interact and collaborate with the bots and breakdown the communication and functional silos in the organization. Use Case Unattended Bots. These types of bots are generally used in back-office scenarios where a large volume of data is collected, sorted, analyzed, and distributed in the enterprise. Claim processing in Insurance companies are suitable candidates. Examples of unattended automation scenarios are below: - · Exception Based – Fully Automated RPAs · Human Prepared Processing · Validation through Human in the Loop Exception Based – Fully Automated RPAs Example. Health Insurance Companies are required to process large volumes of claims and invoices. The data is generally stored in a mix of multiple legacy and modern systems. APIs are not available for the integration of these multiple systems. Data has to be verified, updated, and moved between these systems A fully automated bot can be created to verify, move, update the data across all these systems. Based on the Service Level Agreements, the optimum number of bots can be deployed to process these invoices and claims. Human Prepared Processing These are processes that require human intervention to start the process, however can be automated once the process is started. This combines human creativity with software efficiency. Example. Mortgage Companies process a very large volume of mortgages. The Mortgage process involves human logic that is necessary to start the process, however, the rest of the process is repetitive and can be automated. The human logic designates when the appraisal is ordered, the required additions, and the appraisal firm. Validation through Human in the Loop In some cases, some processes require human intermittent intervention. Automation can be built into the process to seek human intervention when a problem arises. Example. The Accounts Payable Departments repeatedly process different types of not-standard invoices in different formats and forms. Machine Learning and Optical Character Recognition can be used to read these invoices. However, in case the unattended bot is unable to recognize the data, a human being would be called upon to intervene in the process and then hand over the process back to the unattended bot. Attended RPAs Attended bots require human intervention. These bots are at the employee workstation level and triggered by specific commands, actions, or events that the employee engages within the workflow. Since it generally involves switching between multiple interfaces, screens during the employee workflow, these bots are designed to be user-friendly and agile. Attended bots are generally restricted to a specific workstation, section, or department making the automation generally restricted to the employee engaging in the workflow at that moment Use Case Attended RPAs. These bots are generally used in customer-facing tasks. Call Centres are an ideal place for the use of attended RPAs. Call Centre operators need to switch between different screens and interfaces while addressing a customer issue. The unattended bots generally take care of the tasks involved in entering/retrieving the data so that the operator can spend more time interacting with the customer. Examples of attended automation scenarios are below: - · Attended, Interval: Robot takeover · Attended, in tandem: Working alongside the robot Attended, Interval: Robot takeover In Financial services companies, the process requires robot intervention at various stages to handle monotonous and repetitive tasks. The human can hand over control to the robot by some shortcut key to hand over this part of the process to the robot. In this model, there are a number of switches between the human and robot in order to complete the task. Attended, in tandem: Working alongside the robot This model is used when humans need to move between a conversation (Call centre) and repetitive tasks. This calls for humans and robots working alongside each other. In this case, the agent continues to focus on the customer, while the robot does the routine and mundane tasks References https://www.uipath.com/blog/rpa/unattended-attended-automation https://www.uipath.com/blog/automation/rpa-use-cases-part-one-unattended-robots https://www.uipath.com/blog/automation/rpa-use-cases-for-attended-robots-automation
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