QUALITY

SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

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SIPOC Template

SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

Hi Readers! Today here, we will be discussing on SIPOC template and examples of sipoc diagrams of manufacturing and service industries. As you know that SIPOC is one of the most useful diagrams which is generally used for a better understanding of the process. In both the manufacturing and service industries are commonly used the two types of process mapping diagrams are. I.e. [1] PFD- Process flow diagram and another [2] SIPOC diagram. If you would like to download the free SIPOC excel template then, click on the given below download link.  

Download the SIPOC template in excel format-SIPOC Excel format-DOWNLOAD Link

What is SIPOC Diagram?

The SIPOC diagram consists of 5 elements i.e. [1] Suppliers, [2] Inputs, [3] Processes, [4] Outputs, [5] Customers. The diagram is generally used for process mapping. It helps to understand the overview of the process in detail.

5 Steps to create a SIPOC Diagram:

Step-1:

Create a CFT team including the process owner of a particular process, which you are trying to draw.

Step-2:

Define the process, for example, let’s consider a process namely called Process-A and you are trying to draw an SIPOC diagram, so first of all you are supposed to list out the details activities of process-A in sequence with the help of the CFT team.

Step-3:

After listing out the details process sequence, find out the internal and external suppliers. Details are mentioned below example.

Step-4:

List out and identify the inputs, process, process output and then customers

Step-5:

 Draw the Diagram by entering the above points in the appropriate places.

SIPOC Template

[SIPOC Template / Format]

SIPOC Diagram vs PFD – process flow diagram:

Both the SIPOC diagram and process flow diagram are used to represent the process mapping but the difference between the two is the elements that are used to represent the process details. In SIPOC, we use the 4 elements like supplier, input, process, output, and customer but in PFD, we use flow chart symbols, like the terminator, process, flow line (arrow connector), decision, document, connector, data, preparation, off-page connector, etc.

SIPOC Diagram Example of Manufacturing & Service Industry:

Manufacturing Industry Example:

Suppose a company manufactures automobile parts through foundry technology and they have planned to prepare a SIPOC diagram of one of the processes called green sand mould preparation.

SupplierInputProcessOutputCustomer
Sand plantGreen sandFilling green sand into drag pattern cavityDrag mouldMould making dept.
Sand plantGreen sandFilling green sand into cope pattern cavityCope mouldMould making dept.
Mould making dept.Cope and drag mouldCore fittingMould with core fittedMould making dept.
Mould making deptMould with core fittedFitting of cope and drag mouldFinal mouldPouring dept.
SIPOC Template
Service Industry Example:

Let’s consider one of the service sectors of finance as an example bank, and we are going to draw a SIPOC diagram of an offline saving bank account opening process, which is given below;

SupplierInputProcessOutputCustomer
…..Application filled-up formOffline checking and verification of documents deposited by the customerVerified documentDocument verification document
Document verification dept.Verified documentAccount creationNew saving bank account numberAccount creation dept
Account creation deptNew saving accountPassbook issuingNew passbookMr. XYZ
FAQ:

What does sipoc stand for in Six Sigma?

Ans.: The SIPOC stands for Supplier, Input, Process, Output and Customer.

What is a SIPOC template?

The SIPOC template is a diagram which consists of suppliers, inputs, processes, outputs and customers. With the help of the SIPOC diagram, you can prepare the details process flow from start to end.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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Equipment Ranking Process | A B C Ranking of Machine with Manufacturing Example

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Equipment Ranking Process

Equipment Ranking Process | A B C Ranking of Machine with Manufacturing Example:

Hi readers! Today we are going to discuss on equipment ranking process, it is an important part of the maintenance process, where machines/equipment/ parts will be ranked and based on the rank category, and you can easily set up the maintenance principle. The organization will get benefits in terms of productivity, quality, cost, safety, etc., and also it will help you to select the type of maintenance applicable / applied on which machine.

Equipment Ranking Process:

Equipment Ranking Process

If first time, you are going to implement it in your organization then you have to formalize many more things like SOP, Check-sheet, list of equipment/ machine, machine /equipment ranking criteria, data, etc. so here, we will help you for easy implementation of this process.

Step by step process has been defined below to implement the machine /equipment ranking process in your manufacturing organization;

Step-1: Prepare the SOP, List of equipment, and equipment/machine ranking criteria procedure.

In the ranking criteria, you can consider the PQCDS means Production, Quality, Cost, delivery, and safety as weightage for factors in categorization, but some industry also considers other factors like Maintenance / Maintainability, Operability, etc.

All the above factors are not equally important and they vary from industry to industry based on the application, material used, quality, safety, etc. For example, equipment is being used for chemical handling, safety factors get a high weightage for rating calculation. And similarly, imported machines may come under high weightage on maintainability if spare parts are mostly imported procurement may take more time and the cost of repair could be high.

Step-2: Form a CF-Team, including Production, quality, maintenance, and safety personnel for best weightage consideration.

For example, let’s say we are having total of 16 machines, and according to their criticality w.r.t PQCDSM and consultation with CF-Team, finally, we have broadly done the weightage of factors of individual machines or similar types of machines.

Machine-1
P-Production100
Q-Quality100
C-Cost50
D-Delivery50
S-Safety20
M-Maintainability20
Total =340
[M/C-1 Data Table-1]

Machine-2

P-Production100
Q-Quality90
C-Cost50
D-Delivery40
S-Safety40
M-Maintainability40
Total =360
[M/C-2 Data Table-2]
Machine-16
Production-P100
Quality-Q80
Cost-C50
Delivery-D40
Safety-S40
Maintainability-M40
Total =350
[M/C-16 Data Table-3]

Similarly, you can do the weightage of factors of all machines or you can prepare the common criteria sheet for similar types of Machines.

Step-3: Prepare the final ranking criteria sheet.

For example, we have prepared the below-ranking criteria sheet for reference only, you can prepare according to your organization’s decision and machine’s factors, operations, etc. but here we have made the generic criteria rules is given below.

Let’s say “Quality” factors have 100 marks and we have divided them into four degrees of factors.

Mark=100806040
Always being required to work to a very fine tolerance or Equipment failure mode has a major effect on quality, the product produced out of Specification.Produce quality variations, some of the products may get rejected but the operator’s intervention requires less time to correct it.The Product can be reworked and used, meets the specification and drawing, machine is sufficiently accurate for required tolerance.No quality problems, no effect on quality, and no product defects.
[Ranking Criteria Matrix]
 Accordingly, you can prepare the ranking criteria matrix for Production, cost, safety, delivery, and maintainability, etc.

Let’s consider the machine-1, factors given in above i.e.

P-Production100
Q-Quality100
C-Cost50
D-Delivery50
S-Safety20
M-Maintainability20
Total =340

The total mark of the entire above factor (PQCDSM) is 340.  Based on the organization’s decision and degree of factors mark, an organization can decide the range for the category of machine, e.g.

Up to 130 marks ——-C Rank / Category

131 to 190 marks ——-B Rank / Category

191 to 340 marks ——- A Rank / Category

As you know that we have considered 16 machines, so our CF-team members have collected and gathered the machine history records, data and with the help of the ranking criteria matrix, they have evaluated the entire machine, and the same is mentioned below the table.
MachineRank / Category
M/C-1A
M/C-2B
Machine-3C
M/C-4C
M/C-5A
Machine-6B
M/C-7A
Machine-8B
M/C-9B
Machine-10B
M/C-11A
Machine-12B
M/C-13B
Machine-14A
M/C-15C
Machine-16C
[A B C Ranking Table]

According to the machine’s rank, you have to prepare the maintenance plan, e.g. our maintenance engineer has decided that M/C-1 will be covered under preventive and predictive maintenance twice a month and similarly M/C-8 will be covered under preventive maintenance twice a month. And M/C-16 may be covered under preventive maintenance once a month or only BM. So, in this way, you can prioritize the machine maintenance period w.r.t m/c or equipment category or ranking.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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Variation Calculation in Excel | Types of Variation | Manufacturing Example

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Variation Calculation in Excel

Variation Calculation by Excel | Types of Variation | Manufacturing Example:

Hi readers! Today we are going to calculate the different types of Variation with the help of Excel. Here we will learn the complete calculation of variation with industrial examples. All the calculations related to variation are done here with the help of the excel-2007 version, the positioning and terminology may be varied w.r.t other versions of Excel. But anyway variation calculation in excel-2007 version will give you a complete idea so you can easily apply the concept in any version of Excel as well.

This topic will help you to enhance your knowledge so that you can easily solve the problem related to variation calculation and the important things that, if you are working in the manufacturing industry and if you would like to know the data variation of process or product characteristics then by using of excel sheet easily you can calculate the variation of the data set.

Variation Calculation in Excel:

First of all, we are supposed to know that what is Variation. I mean to say that Variation is nothing but a way to show how the data is spread out, which means how the data are spread over a wide area.

Types of Variation:

There are so many ways to measures the variation but some common measures of variation used in statistics are;

  1. Range.
  2. Variance (Population, Sample).
  3. Standard Deviation (σ, s).
  4. Coefficient of Variation ((Population, Sample).
  5. Mean Absolute Deviation.
  6. Z-score
  7. Quartiles.
  8. 5-Number Summary

We will be calculating all the above measures of variation with the manufacturing example so that you can easily understand and implement the concept in your manufacturing process to know the variation of the data set.

Manufacturing Example to Calculate the Different Measures of Variation:

Let’s a company m/s PQR manufacturing the product “X”. A Quality Engineer Mr. P monitoring the process parameter as per the QA plan, but one day during the shop floor visit, the QA head observed that the process parameter of temperature reading was on the higher side, so he immediately called to process QA engineer and asked to calculate the different measurement of the variation of last period data set. Accordingly, the Process QA engineer had started the calculation, details are given below;

Data: Specification of Temperature: 1400±10°C

Time/ShiftTemperature in °C
8AM/A1402
8.30AM/A1405
9AM/A1401
9.30AM/A1400
10.0AM/A1405
10.30AM/A1403
11.0AM/A1406
11.30AM/A1401
12.00Noon/A1404
12.30AM/A1400
[Temperature reading table]

Here, we are going to calculate the first Range of all the above data sets.

Range = (Maximum Value – Minimum Value)

How to Calculate Range in Excel?

Step-1: Open the Excel Sheet

Step-2: Type the Data.

Variation Calculation in Excel

Step-3: Use the “MAX” function to find out the maximum value, see the below picture to learn more

Variation Calculation in Excel

The Maximum value, we found from the above data set is 1406°C and similarly calculated the minimum value as per the below process as.

Variation Calculation in Excel

Found, the minimum value is 1400°C.

Range = (Maximum Value – Minimum Value)

=1406-1400=6°C

VARIANCE:

variance calculation

Excel-2007 function of Variance for population = VARP(data range)

The Variance of the above population data is 4.41, enter the same data in your excel sheet and calculate & check whether you are getting the same value or not.

Standard Deviation (σ):

standard deviation

Standard Deviation (σ)excel-2007 function=STDEVP(Data range)

(σ) The standard Deviation of the above data set is 2.1, check whether you found the same value in your excel sheet or not using the above data set.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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How to Choose the Best Forecasting Method | Marketing & Sales Example

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How to Choose the Best Forecasting Method

How to Choose the Best Forecasting Method | Marketing & Sales Example:

Hi Readers! Here, today we will learn on How to Choose the Best Forecasting Method with sales and marketing examples and also simultaneously study the different types of forecast methods in excel and their interpretation. As we know sales volume may not be constant in every month it depends on several factors like market demand, supply quantity, buyer interest, season, festive time, price, product features, etc. but as a market sales person how can you easily predict the future sales volume w.r.t your past sales data. If you can do it easily then similarly you can prepare the manufacturing/service plan accordingly. It could give an approximate idea for business planning. So forecasting is one of the common methodologies used in several types of industries for predicting the future based on the results of previous data.

So, especially we will talk about a sales-related example here, and different types of forecasting methods or processes or types. After reading this article I think you can be understood and select or choose or decide the best forecast methods.

Example:

Suppose a company PQR Ltd has the following below sales quantity for the last 8 months and based on the past 8 months data the sales manager is going to forecast the sales volume of 9th month but after calculating of forecast quantity of 9th month he is confused to select method which will be best. But here we will help you to choose and select the best forecast method, just go through the below concept.   

MonthSales Quantity
Jan150000
Feb249000
Mar351000
Apr448000
May552000
Jun656000
Jul749500
Aug851300
Sep9??

[Table 1-Sales Quantity of past 8 months]

As you know that there are so many forecasting methods available but which one will give you the best forecast value for the 9th month, it is difficult to select at an initial time so we are going to calculate the forecast value by 3 to 4 methods and will calculate the error of each method to select the best one.

Method-1: 3-Months Moving Average Forecasting

MonthSales Quantity3-Months Moving Average Forecast
Jan150000NA
Feb249000NA
Mar351000NA
Apr44800050000
May55200049333
Jun65600050333
Jul74950052000
Aug85130052500
Sep9??52267

9th Month Value= (56000+49500+51300)/3 = 52266.66

Method-2: Exponential Smoothening Forecast (let’s say, factor, alpha=0.8)

MonthSales QuantityExponential Smoothening Forecast (factor, alpha=0.8)
Jan150000NA
Feb24900050000
Mar35100049200
Apr44800050640
May55200048528
Jun65600051306
Jul74950055061
Aug85130050612
Sep9??51162

9th Month Value= 0.8*51300+0.2*50612 = 41040+10122.4 = 51162.4

Method-3: Linear Regression.

MonthSales Quantity
Jan150000
Feb249000
Mar351000
Apr448000
May552000
Jun656000
Jul749500
Aug851300
Sep9??
How to Choose the Best Forecasting Method

After plotting the graph, we found the Linear regressing function is 364.2*X+49211 and by using the function we have to calculate the forecast value as given below;

MonthSales QuantityLinear Regression
Jan15000049575
Feb24900049939
Mar35100050304
Apr44800050668
May55200051032
Jun65600051396
Jul74950051760
Aug85130052125
Sep9??52489

9th Month Value= 364.2*9 + 49211 =3277.8+49211 = 52488.8

Method-4: Polynomial Regression.
MonthSales QuantityPolynomial Regression
Jan15000049016
Feb24900049859
Mar35100050542
Apr44800051066
May55200051430
Jun65600051635
Jul74950051680
Aug85130051565
Sep9??51291
How to Choose the Best Forecasting Method

9th Month Value= -79.76*9*9 + 1082*9 +48014 =-6460.56+9738+48014 =51291.44

Methods 1 to 4 in single Table:
MonthSales Quantity3-Months Moving Average ForecastExponential Smoothening Forecast (factor, alpha=0.8)Linear RegressionPolynomial Regression
Jan150000NANA4957549016
Feb249000NA500004993949859
Mar351000NA492005030450542
Apr44800050000506405066851066
May55200049333485285103251430
Jun65600050333513065139651635
Jul74950052000550615176051680
Aug85130052500506125212551565
Sep9??52267511625248951291
How to Choose the Best Forecasting Method?

Now, the most important thing is to select or choose or decide the best method from the above 4 types of forecasting methods. As you can see in the above table we have mentioned the forecast value of the possible period of all 4 types of methods but even after getting the forecast value it is difficult to select the best method, so to choose the best one, we are supposed to calculate the error of each method.

MAF-Error ESF-Error LR-Error PR-Error
MonthSales Quantity3-Months Moving Average ForecastErrorSquare ErrorErrorSquare ErrorErrorSquare ErrorErrorSquare Error
Jan150000NANA NA 425180455984967783.7
Feb249000NANA -1000.001000000-939882472.4-859737812.3
Mar351000NANA 1800.003240000696484973458209617.5
Apr44800050000-2000.004000000-2640.006969600-26687117157-30669399375
May552000493332666.6771111113472.0012054784968937024570324900
Jun656000503335666.67321111114694.4022037391460421194974436519056368
Jul74950052000-2500.006250000-5561.1230926056-22605109408-21804751354
Aug85130052500-1200.001440000687.78473035.8-825679965.2-26570415.93
Sep9??52267MSE10182444 1095726745733044439703
RMSE3190.993310.182138.5282107.06

According to the above RMSE of all four forecasting methods, we found that the Polynomial Regression method is the best method in this case. So we can consider the forecast sale quantity of 9th month is 51291.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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How to create forecast in excel | Illustration with Example

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How to create forecast in excel

How to create forecast in excel | Illustration with Example:

Hi Readers! Here we are going to learn today on how to create forecast in excel. We have already published an article on basic knowledge and the selection process for best forecasting methods. As we know that forecasting is one of the common methodologies used in various types of industries for predicting the future based on the results of previous data. Here we will give more focus on the creation or preparation of the forecasting method in excel (note that, given excel process may be different from excel to excel depending on excel’s version).

Suppose a bike showroom owner would like to do the purchasing plan considering the last 4 month’s selling quantity, store constrain, Market demand, festive season, etc.  But he could not finalize the quantity. So, here we are going to do the forecast method to finalize the value (this is only the reference method and forecast value, the actual value may vary depending on various factors). Through this example, we shall learn only on how to create forecasts in excel (Some common methods only). We are going to use the excel-2007 version, the process may vary from excel version to version.

Illustration of How to create forecast in excel?

The last 9 months’ bike selling quantity is given below as;

MonthBike Selling Quantity
Jan1102
Feb2104
Mar3105
Apr4101
May599
Jun689
Jul7105
Aug8115
Sep9103
Oct10??

We have calculated a 4-Months Moving Average Forecast.

MonthBike Selling Quantity4-Months Moving Average Forecast
Jan1102NA
Feb2104NA
Mar3105NA
Apr4101NA
May599 =average(select top 4 months bike selling quantity)
Jun689 =average(104,105,101,99)
Jul7105 
Aug8115 
Sep9103 
Oct10?? 

Excel Function = Average (Select data array of 4 months)

In the above table we have mentioned the excel function. Accordingly calculated the 4-months moving average forecast value, the same table is given below. Just try to calculate the value by yourself in excel and verify the same.

MonthBike Selling Quantity4-Months Moving Average Forecast
Jan1102NA
Feb2104NA
Mar3105NA
Apr4101NA
May599103.00
Jun689102.25
Jul710598.50
Aug811598.50
Sep9103102.00
Oct10??103.00
How to create forecast in excel

How to calculate Exponential Smoothening Forecast? By considering the alpha value 0.8

Excel function, ESF of desire month = (0.8*previous month bike selling quantity + 0.2* previous month ESF)

MonthBike Selling QuantityExponential Smoothening Forecast (factor, alpha=0.8)
Jan1102NA
Feb2104102
Mar3105=(0.8*Bike selling quantity of Feb. month + 0.2*ESF of Feb. month) 
Apr4101 
May599 
Jun689 
Jul7105 
Aug8115 
Sep9103 
Oct10?? 
MonthBike Selling QuantityExponential Smoothening Forecast (factor, alpha=0.8)
Jan1102NA
Feb2104102
Mar3105104
Apr4101105
May599102
Jun689100
Jul710591
Aug8115102
Sep9103112
Oct10??105

Linear Regression Forecasting calculation in Excel:

MonthBike Selling Quantity
Jan1102
Feb2104
Mar3105
Apr4101
May599
Jun689
Jul7105
Aug8115
Sep9103
Oct10??

Based on the above data “month” & “bike selling quantity” plot the scatter diagram including linear regression function as per below;

How to create forecast in excel
How to create forecast in excel

From the Scatter diagram, you can get the function, here y=0.416*X + 100.4

By using the function we have calculated the forecast value which is given in the below table.

MonthBike Selling QuantityLinear Regression
Jan1102101
Feb2104101
Mar3105102
Apr4101102
May599102
Jun689103
Jul7105103
Aug8115104
Sep9103104
Oct10??105

Accordingly, you can calculate the Forecast value using several types of methods. But if you would like to choose or decide the best forecast value among all types then read our previous article.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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How to make a box plot in excel | Manufacturing Example

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box plot in excel

How to make a box plot in excel | Manufacturing Example:

Hi Readers! If are really searching to learn about how to make a box plot in excel then you are on the right platform. So here we are going to explain the same in detail with manufacturing or industrial examples for better understanding. And you can easily apply it in your manufacturing process to know the data symmetric. But also you can use several other tools as well. First of all, here we will learn what are box plots and their uses & interpretation.

What is Box plot?

The box plot (Boxplot) or box and whisker plot is a graphical representation of numerical data spread and skewness. It helps to know whether numerical data are symmetric or not. As you know that it is also called as box and whisker plot, so the plot contains box and lines (Whiskers). It generally consists of five number summary i.e. zero quartile (Q0), First quartile (Q1), Second quartile (Q2), Third quartile (Q3), Fourth quartile (Q4).

box plot in excel

[Box plot Sample figure]

Box plot terminology:

  • Zero Quartile (Q0) or Minimum number: This is the minimum value of the data set.
  • First quartile (Q1): Lowest 25% value of the data set.
  • Second quartile (Q2) or Median: Lowest 50% value of the data set or middle value of the data set.
  • Third quartile (Q3): Lowest 75% value of the data set.
  • Fourth quartile (Q4) or Maximum number: Maximum value of the data set.
  • Inter Quartile Range (IQR): Third Quartile (Q3) – First Quartile (Q1)

How to make a box plot in excel? (Step by Step guides with manufacturing example):

Suppose a manufacturing company produces an automobile part. One day a process quality engineer has instructed to quality supervisor to record the pouring temperature reading for knowing the data symmetric by making a box plot. So the supervisor started collecting data from shift-wise and recorded the data in excel for making the boxplot. The same data are given in the below table.

Pouring Temperature in °C
1495°C
1496°C
1498°C
1499°C
1500°C
1505°C
1499°C
1497°C
Now, we have to calculate the quartile value of each quartile so the Excel function of each quartile is given below;
  • Zero Quartile (Q0) or Minimum number: =QUARTILE(array, quart)
  • First quartile (Q1): =QUARTILE(array, quart)
  • Second quartile (Q2) or Median: =QUARTILE(array, quart)
  • Third quartile (Q3): =QUARTILE(array, quart)
  • Fourth quartile (Q4) or Maximum number: =QUARTILE(array, quart)

Note, in the above excel function the “array” is the data set means for the above data table its pouring temperature data set and “quart” will be different for different quartiles. Try the given below function and calculate the each quartile value (note we have calculated all the functions and box plots by using excel 2007 version only).

Final excel function of each quartile:
Pouring Temperature in °C
1495
1496
1498
1499
1500
1505
1499
1497
  • Zero Quartile (Q0): =QUARTILE(Select pouring temperature data set,0)
  • First quartile (Q1): =QUARTILE(Select pouring temperature data set,1)
  • Second quartile (Q2) or Median: =QUARTILE(Select pouring temperature data set,2)
  • Third quartile (Q3): =QUARTILE(Select pouring temperature data set,3)
  • Fourth quartile (Q4) or Maximum number: =QUARTILE(Select pouring temperature data set,4)
Calculation of Quartiles by Using Excel Function:

Zero Quartile (Q0) or Minimum: By using the excel function given in the below figure, try to calculate the Q0 value. After applying the mentioned excel function in a given data set we found the value is 1495.

quartile calculation

First quartile (Q1): Similarly we have calculated the first quartile and the rest of the quartiles by applying the above excel function. We have mentioned the excel function in the below figure and applied the same in the pouring temperature data set and found the value is 1497.

quartile calculation
Second quartile (Q2) or Median:

Go through the below figure and calculate the second quartile value, we have found the value 1499.

quartile calculation in excel
Third quartile (Q3):
quartile calculation

Fourth quartile (Q4) or Maximum number: Apply the excel function, given in the below figure and calculate the quartile value.

quartile calculation

After applying the individual quartile’s excel function, we have summarized the all values and recorded them in the below table. Next, we are going to make a box plot in excel, so follow the below given complete guidelines or step-by-step process to make the box and whisker plot in excel.  

Q1 =1497
Min. or Q0 =1495
Q2 =1499
Max. or Q4 =1505
Q3 =1499
Upper error bar (Q4-Q3) =6
Lower error bar (Q1-Q0) =2
Step by Step Guides on How to make a box plot in excel:

Step1:

As you know that we have already calculated the quartiles values, just arrange the quartile value as per the given below figure and select the all values after that follow the step-1 to step-4 (as per the below figure).

box plot in excel

Step2: Select the option “Switch Row/Column” in excel

box plot in excel

Step3: Select the excel option as per instructions given in the below figure.

box plot in excel
Step4:

In the above process, we have plotted the box and now we have to make the whisker, so follow the below instruction as per beneath figure.

box plot in excel

Step5: Follow the below instruction

box plot in excel
Step6:

Here, we will learn the steps to make the lower whisker, so go through the below figure and follow the given instructions.

box plot in excel

Step7: similarly, we will make the upper whisker by following the below given steps

box plot in excel
Step8: Follow the steps in the below figure
box plot in excel

Step9:

box plot in excel
Conclusion and Interpretation of the above Box Plot:

As you can see the above box plot that the data are not spread in symmetric. Here we are also going to plot the histogram to compare the both boxplot and histogram to know the comparison value. You can learn more about the step-by-step guide to plotting histogram in excel with examples and also can download the histogram template or format.

Histogram:

Step1: Enter the Pouring temperature reading in excel and then calculate the interval value by using the excel function given in below figure. Next select the option “data” in excel sheet and then select “Data analysis” option and then finally select the histogram option.

box plot in excel

Step2: Select the appropriate data set as per below instruction given in figure

box plot in excel
Histogram

 Now, Histogram is ready so here we will compare the both the plot histogram vs Box plot

comparison

From both the graph we have concluded that data are not symmetrically distributed (Graph are not symmetric).

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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Attribute MSA |How to do Attribute type MSA Study| Example |Acceptance Criteria

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Attribute MSA

Attribute MSA | How to do Attribute type MSA Study | Example | Acceptance Criteria

Hi readers! Today in this section we will be discussing in several topics on Attribute MSA, how to do Attribute MSA analysis, and acceptance criteria with practical industrial manufacturing examples. Measurement system analysis is one of the core AIAG tools, which is frequently used in automotive /automobile manufacturing industries to know the percentage of effectiveness, consumer risk, producer risk, etc. of those persons who are visually checking or doing inspection of parts, components, in-process products or finish products, etc.

You would love to read the below topic;

Gage R and R |How to do MSA Study | Acceptance Criteria

Attribute MSA

As you know how important visual checking /inspection is in the manufacturing industry, your wrong checking /inspection can affect the product performance or there may be a chance of rejection of the product at any stage. So it’s a very important to periodically monitor the effectiveness, miss-alarm, and false-alarm of inspectors, otherwise there will be high producer and consumer risks.

How to do Attribute type MSA Analysis?

Step-1: List out the appraisers.

Step-2: Need to have 50 references and at least 10 ‘not ok’ items.

Total references /items /components =50 nos
Ok reference =34 nos
Not OK reference =16 nos

Step-3: Note the observation of all three appraisers with 3-trials per appraiser

 Appraiser-1Appraiser-2Appraiser-3
No of opportunities150 nos150 nos150 nos
No of trial per appraiser333

Step-4: Calculate the percentage of effectiveness, misalarm and falsealarm of all individual appraisers.

Interpretation of Result and Acceptance Criteria with Example:

Suppose an organization appointed three inspectors at the final dispatch area for visual checking of the finished product. They are basically being engaged to check the visual defects. After a couple of Months Company got a customer complaint related to a visual defect and the same complaint has been analyzed by Sr. Engineer. During the validation of potential causes, he also studied the attribute type MSA of all three appraisers and he found that one of the appraiser’s percentage of miss-alarm was >5. So finally, Sr. engineer has further analyzed the root cause.  And according to the root cause action plan has been taken by him as on-job training and also he has increased the frequency of Attribute-MSA study. In this scenario, you can imagine that how important the Attribute type MSA studies are for inspectors who are doing the visual inspection.

Acceptance Criteria:

Another important part is the interpretation of the attribute type MSA study report and its decision, generally, the appraiser can be acceptable when the percentage of effectiveness is greater than or equal to 90, the miss-alarm less than or equal to 2, False-alarm less than or equal to 5. And also appraiser can be marginally acceptable but may need improvement when percentage of effectiveness greater than or equal 80, miss-alarm less than or equal to 5, False-alarm less than or equal to 10.

Similarly, the appraiser can be unacceptable when the percentage of effectiveness is less than 80, the miss-alarm greater than 5, False-alarm greater than 10.

The general thumb rule of kappa is that, if the kappa value > (greater than) 0.75 then it indicates good agreement (but note one thing that the maximum kappa value will be 1 and it indicates excellent agreement). and similarly, the kappa value < (less than) indicates the poor agreement.

Please note that all the above acceptance criteria are the general thumb rule.

learn more about multiple types of questions and answers of MSA. then click here.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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How to calculate effective Production Sequencing?

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Production Sequencing

How to calculate effective Production Sequencing?

Hi readers! Today we will be discussing on how to calculate effective production sequencing. Production sequencing is the most important part of PPC (Production planning and control). Its helps to meet the on-time customer delivery and enhance customer satisfaction and the Brand name.

Before doing the production sequencing, at least prioritize and consider some factors like processing time, due date, delivery time, flow time minimization, work-in-process inventory minimization, idle time of machines minimization, etc. for effective sequencing. And another important part is the methods of priority for production sequencing like [1] FCFS ( First come first served), [2] SOT ( Shortest operating time), [3] STR (Slack time remaining), [4] EDD (Earliest due date), [5] STROP (Slack time remaining per operation), [6] CR (Critical Ratio), [7] LCFS (Last- come first served).

Understanding of Several Methods:

  • First come first served: Production is run w.r.t first arriving in the department, let’s say the first week of the month the “X” customer has ordered 5nos and 10nos of product-1 and product-2 for supply within the next two weeks. And later the same customer ordered product-3 in the second week of the same month and they need product supply at the end of the second week. Now the important thing is how to apply FCFS methods to select the product sequence means with the product need to be started first for manufacturing. Details of the calculation have discussed below example.
  •  Shortest operating time: Manufacturing the product with the shortest processing time means the shortest completion time.
  • Slack time remaining: Time remaining before the due date remaining completion time.
  • EDD (Earliest due date): Produce the product with the earliest due date first.
Production Sequencing
Production Sequencing

Step by step calculation of effective Production Sequencing with manufacturing example:

Here, we are going to calculate the production sequencing with the different scenarios by applying multiple methods.

Manufacturing Example:

Suppose a company namely XYZ Pvt. Ltd has got an order of 6 types of product, details of orders are given below.

Product NameDelivery DaysProcessing Time (Days)
A-Prod64
B-Prod75
C-Prod83
D-Prod97
E-Prod32
F-Prod21

After getting the orders, the production supervisor has applied several methods like [1] FCFS ( First come first served), [2] SOT ( Shortest operating time), [3] STR (Slack time remaining), [4] EDD (Earliest due date), [5] STROP (Slack time remaining per operation), [6] CR (Critical), [7] LCFS (Last- come first served) and selected the effective production sequence among all the methods.

First, he has applied the FCFS (First-Come First Served) Method. All the above products (Prod-1 to Prod-6) are completed in a single machine.

Methods-1 (FCFS):
Product NameProcessing Time (Days)Delivery DaysFlow Time in DaysOn-time or late delivery in days
A-Prod464On-time
B-Prod574+5=9Late=2
C-Prod384+5+3=12Late=4
D-Prod794+5+3+7=19Late=10
E-Prod234+5+3+7+2=21Late=18
F-Prod124+5+3+7+2+1=22Late=20
First come first served Method

According to the FCFS method, the supervisor has calculated the sequence, on-time, and late delivery time in days. As we can see that only A-prod can deliver on time. and the rest 5 products will be late by 2,4,10,18,20 days. On average a job will be late by 9 days.

Method-2-SOT (Shortest operating time):
Product NameDelivery DaysProcessing Time (Days)Flow Time in DaysOn time or late delivery in days
F-Prod211On time
E-Prod321+2=3On time
C-Prod831+2+3=6On time
A-Prod641+2+3+4=10Late=4
B-Prod751+2+3+4+5=15Late=8
D-Prod971+2+3+4+5+7=22Late=13
Shortest operating time Method

The above data indicates that 3 products will be on time. and the rest three products will be late by 4,8 and 13 days. On average, a product will be late by 4.17 days (4+8+13 /5).

Method-3- EDD (Earliest due date):
Product NameDelivery DaysProcessing Time (Days)Flow Time in DaysOn-time or late delivery in days
F-Prod211On-time
E-Prod321+2=3On-time
A-Prod641+2+4=7Late=3days
B-Prod751+2+4+5=12Late=7days
C-Prod831+2+4+5+3=15Late=12days
D-Prod971+2+4+5+3+7=22Late=15days
Earliest due date Method

After applying the method-3, you can see that only 2 products i.e. “F-Prod”, “E-Prod” will be on-time. And rest 4 products will be late. But on an average a product will be late by 6.16days.

Conclusion:

Here, we will compare the above three methods and will find the best among them and accordingly the schedule will be decided.

MethodsFlow Time in Days (total)Average Lateness in daysOn-time delivery(total)
First come first served87 days9 days1 number
Shortest operating time57 days4.17 days3 number
Earliest due date60 days6.16 days2 number

According to the above comparison of three methods, the shortest operating time method result is the best one compared to the other two methods. In this way, you can select the best and most effective production sequencing.

As per the SOT (Shortest operating time) method, First, you have to start production of “F-Prod” and then. need to follow the below sequence as;

Product NameProduction Sequence
F-Prod1st
E-Prod2nd
C-Prod3rd
A-Prod4th
B-Prod5th
D-Prod6th

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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Turtle Diagram Example | QMS Standard Requirement | Free Template | Format

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Turtle Diagram Example

Turtle Diagram Example | QMS Standard Requirement | Free Template |Format:

Hi readers! Today, we will discuss on various types of turtle diagram example of the manufacturing process, incoming inspection process, internal auditing process and pre-dispatch inspection process, etc. and also we have provided the link for the sample template/ format of the turtle diagram in below. Just download the format and customize it according to your process requirements. 

DOWNLOAD– Sample Turtle Diagram Template/format.

Turtle Diagram:

The turtle diagram is a visual tool that is generally used to represent details elements of a process like input, output, method, resources, performance, etc. it helps to improve the process performance. In many industries they are using the turtle diagram for process details and interaction, mapping, etc. so it’s a very useful and popular visual tool.

QMS Standard (ISO 9001 & IATF 16949) Requirement w.r.t Turtle Diagram:

The turtle diagram is not a mandatory requirement of QMS standards like ISO 9001 and IATF 16949, but you can use this diagram to represent the process details like the process’s method, resource requirement, process measurement, process interaction, input and output of the process, etc. To comply the clause-4.4.1 of the QMS standard (ISO 9001 & IATF 16949) requirement, many organizations have implemented the Turtle diagram but there is so many other diagrams also exist that you can use like Matrix, Flow charts, process mapping, SIPOC, etc. but Turtle Diagram is a very useful and easy diagram so that, many organization is being used it.

How to Implement Turtle Diagrams in the Manufacturing Industry? And Nomenclature:

Before discussing of implementation of the Turtle Diagram, we have to illustrate the terms related Turtle Diagram, first. If your organization is certified with QMS standards like ISO 9001 and IATF 16949 Then, you are compulsory to comply with the standard requirement of clause 4.4.1, To do so, you may prepare a turtle diagram but you can represent it in other ways as well. But the Turtle Diagram is a frequently used diagram and very easy to use. So, here we are going to describe it in detail.

As you know that in the wide range the QMS standard asked for process details like Process interaction, Input of process, Output of process, resources, methods, and Process results, etc.

Note, that a Turtle diagram is not a mandatory requirement of the standard to represent the process requirement, but you can prepare it to do so.

Nomenclature of Turtle Diagram:
Turtle Diagram Example

In the above Turtle Diagram, we have divided resources into two categories like [1] With Whom [2] With What. Details of Each and every category are mentioned below.

With Whom: It is nothing but its talk about the people (Personnel) involved with the Process.

With What: Resources requirement to execute the process like infrastructure, Machine, instrument, equipment, material, etc.

How Done: Method, Phases how to complete the process in successfully. For example, a list of documents like Procedures, Work instructions, test methods, specifications, drawings, etc.

What Result: Process-related objectives and targets, monitoring and measurement-related results, etc.

Input: Details of process requirement.

Output: Process output.

How to Implement Turtle Diagram in Manufacturing Industry?

Here, I’m going to share my own experience regarding turtle diagram implementation with an industrial example. Two years back, when our organization thought about QMS certification, Our MR has prepared QMS implementation Roadmap and he has given me one important responsibility for preparing the documentation and implementation of ISO/IATF clause 4.4.1 requirement for the Incoming material inspection process and they have imparted training on this subject as well. I think this is the right platform to share my own experience on it so that other can get benefits and they can prepare this diagram, also. But the requirement of ISO/IATF clause 4.4.1 documentation is fulfilled by preparing various docs. But turtle diagram is one of them, but the turtle diagram is not a mandatory requirement of the standard. Anyway, I am going to share how to prepare the turtle diagram for the Incoming material Inspection Process.

Step By Step Process:
  • Understand the process in detail by consulting with the pertinent process owner or head.
  • List out the resource requirements, like trained personnel, inspector, infrastructure, machine, instrument, equipment, lighting facility, details input to execute the process, process method, SOP, other related support, Process results, and finally, the output of this process.
  • After getting all the information, now it’s time to prepare the Turtle Diagram.

On the same subject (Incoming Material Inspection Process), we have prepared the Turtle Diagram for your easy understanding, just go through it.  

Turtle Diagram Example
Turtle Diagram Example (Incoming Material Inspection Process)

FAQ:

There is a misunderstanding in many organizations that the Turtle diagram is the mandatory requirement of QMS Standard to visualize the process details of each and every element.

But the one-line answer is “NO”, there is no such specific requirement for a turtle diagram. You can represent and fulfill the QMS standard requirement by your own principle as well. But many organizations are being used the Turtle Diagram.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com\

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Plan Do Check Act Cycle | PDCA Cycle Manufacturing Example | Implementation

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Plan Do Check Act Cycle

Plan Do Check Act Cycle | PDCA Cycle Manufacturing Example | Implementation:

Hi readers! Here, we will discuss the details on PDCA cycle (Plan Do Check Act Cycle) with the Industrial/ Manufacturing example. The PDCA Cycle is the most popular cycle/ method used in industry/ organization for continuous/continual improvement and process improvement and problem solving. The PDCA cycle consists of four phases i.e. [1] Plan, [2] Do, [3] Check, & [4] Act. The Plan-Do-Check-Act Cycle is also called as Deming Cycle/Wheel, PDSA Cycle (Plan-Do-Study-Act), or Plan-Do-Check-Adjust Cycle.  

Plan Do Check Act Cycle / PDCA Cycle / Deming Cycle:

Plan Do Check Act Cycle

Basically, the PDCA (Plan-Do-Check-Act) cycle is used for continual/ continuous improvement. If you find any problem in the production process or would like to improve the production process then you can easily apply this management approach. But you can apply this PDCA cycle to any type of improvement project/ objectives. It is not only used for Process improvement but also used for Problem-solving. The details of individual stages /phases are described in below.

Plan: To develop the Potential solutions.

Do: To execute the Plan.

Check: To Review, verify, inspect, evaluate, analyze the data, and compare the results (Before and after) w.r.t Objectives that the plan/solution is satisfactory or not.

Act: If the solution is satisfactory then implement it. If it is not satisfactory then take the containment action and repeat the Cycle.

How to Implement PDCA Cycle in the Manufacturing Industry for Continuous/ Continual Improvement:

I am so excited to share my own experience. I have implemented so many improvement projects through the PDCA Cycle, but here I am going to share only manufacturing process improvement-related examples.

When we had prepared the monthly quality report of the manufacturing process, we got that the shrinkage problem was a vital problem and almost contribute the 30% among the entire problem and on the basis of the report we have decided to improve the process and to reduce at least shrinkage defect from 30% to 5%. Accordingly, objective has been taken and followed the PDCA cycle to resolve it and to improve the manufacturing process.

PLAN:

Before applying the method, we have formed a Team and described the problem, took the objective, and prepared the plan, which is described as below.

Step-by-step method that we have followed to prepare the Plan:

1] To Form a Team.

2] To Take an Objective.

3] To Prepare the Roadmap /Activities flow chart.

Team Formation:
Name of Project Leader: Mr. S
Name of Team members:
Mr. G
Mr. P
Mr. N

Note: During the team formation, you may consider the members from different and different sections, that are directly associated with your process activity. Because you can easily manage your activities.

Now, the next step is to take an Objective.

Objective: To reduce the Shrinkage defect contribution from 30% to 5% within 3 months.

According to the above objective we have prepared the Plan. And details of the plan are described below.

ActivitiesResponsibilityTime-Line
Data CollectionMr. GWithin 7 days from the starting date of assignment.
Cause and Effect diagram PreparationMr. G & Mr. P(Within 9 days from the starting date of assignment)
Identify the significant causesMr. G & Mr. PWithin 15 days from the starting date of assignment.
Why-Why AnalysisMr. G, Mr. P & Mr. NWithin 20 days from the starting date of assignment.
Identify the Root CauseMr. G, Mr. P & Mr. NWithin 21 days from the starting date of assignment.
Corrective Action planMr. G, Mr. P & Mr. NWithin 25 days from the starting date of assignment.
Preventive Action planMr. G, Mr. P & Mr. NWithin 25 days from the starting date of assignment.
Trial implementationMr. G, Mr. P, Mr. N & Mr. SWithin 75 days from the starting date of assignment.
Comparative study w.r.t ObjectivesMr. G, Mr. P, Mr. N & Mr. SWithin 90 days from the starting date of assignment.
[Table-A, Activities Plan Flow, Plan do check act example /PDCA Example]

 Note: The above activities may change according to the nature of the improvement project. Or whatever objective you have taken. The Aforesaid plan template is only for your reference.

In this way, you may prepare the Plan. Now, we have to move on to the next phase of the PDCA Cycle i.e. “DO”

DO:

In the “DO” phase, you are supposed to implement the Plan that you have prepared in Plan phase. As you can see that we have already prepared the Activity plan and represented in Table-A, and the same implemented.

According to the management approval, we have manufactured the 5-samples as trial implementation. And next activity was done in the “Check” phase.

CHECK:

After trial implementation, whatever data we have collected, just we analyzed all the things, did the gap analysis and we compared the results w.r.t Objectives. And recorded the significant points & collected the feedback as well.

As you know that this phase is important so you have to study and analyze all the things. Similarly, we have compared the results w.r.t Objectives and found the below result.

Before Data (old methods/ before implementation of improvement plan)

Shrinkage defect contribution = 30%.

After Data (New methods/ after implementation of improvement plan)

Shrinkage defect contribution = 5%.

Plan Do Check Act Cycle

Conclusion: We have found that the improvement plan is effective and satisfactory.

We have achieved the Objective’s target value. So we have informed to top management about the action plan results to act on it.

ACT:

In the above example, we have found that the solution/improvement plan is satisfactory. So we have finally implemented the new action plan and standardized it. 

If applicable then do the horizontal deployment also.

FAQ:
What do you need to do if your objective will not be achieved?

Ans.: In the “Check” phase when you will find that your objective is not achieved, then you have to take the containment action and you have to repeat the PDCA cycle until resolve the problem or improve the process.

What does PDCA stand for?

Ans.: The full form of PDCA is Plan-Do-Check-Act, and also it is called as Plan do study act, plan do check adjust, Deming Cycle, and Shewhart Cycle.

How does PDCA Improve Quality?

Ans.: Go through the above manufacturing example (Shrinkage Issue), step by Step-by-step phases are mentioned there.

How do you use the PDCA cycle?

Ans.: As you know the PDCA cycle is generally used for continuous /continual improvement. To do so, you have to follow the cycle principles.

1] To form a team

2] To take an objectives

3] To prepare the roadmap/ activities plan

4] Step by step implement the plan.

5] Study the data and compare the results with respect to the objective.

6] Implement the solution (Final implementation); if the result is coming satisfactory otherwise take a containment action and repeat the PDCA cycle again until achieve the Objective’s target value.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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