Professional Documents
Culture Documents
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CONTENTS
üRequires UNDERSTANDING
ühas VARIATION
ühas a CAPABILITY
üneeds IMPROVEMENT
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Control: What & Why
qOptimization of performance
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Taken from Presentation: How to Streamline, Integrate and Synergize Project Management and
Six Sigma Techniques for Optimal Results, by Candace G. Medina, CGM Associates, LLC, 2006 7
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three issues:
qQuality
qDelivery
qprice
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What is quality?
customer.
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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Some basic SPC tools are: process flowcharting (what is done);
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Taken from Six Sigma for Dummies , by Craig Gygi At All, Wiley Publishers, 2005 13
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Pareto Chart: (80:20 rule)
It’s a vertical bar chart that relates non-
numerical or qualitative categories to their
respective frequency or cost.
It charts the causes in descending order of
frequency or cost from left to right.
A Pareto chart is used to graphically
summarize and display the relative
importance of the differences between
groups of data.
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Land Owners In Pakistan
120
100
80
60
40
20
0
Private
Armed Forces / Business
Feudals Industrial Employed Labour
Government Tycoons
Sector
Series2 55 25 9 6 4 1
Series1 55 80 89 95 99 100
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Cause & Effect Diagram
Measurements Material Personnel
Safety
Related
Incidents
This plot enables us to see wood rather than tree which is not the
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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This is
rather
like a set
of traffic
lights
which
signal:
‘stop’,
‘caution’
or ‘go’.
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Questions to be asked
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This approach may be applied to both variables
investigation.
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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The run chart becomes a control chart if decision lines are added
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Some variation is just natural and cannot be eliminated. The
natural forces of nature naturally work to mix up
things for us because human created processes are
nature manipulation. For example heads and tails variation
in coin toss is natural. If the mail man arrival is 11:30 am
daily. But he comes (5 days of week) at 11:30:21, 11:29:45,
11:31:00, 11:30:10 and 11:29:59 am. This is perfectly
natural. But he some day comes at 12:30 pm or 10:30 it is
special cause variation. It may be due to schedule change or
flat tire.
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Long Term Variation (Shift)
Taken from Six Sigma for Dummies , by Craig Gygi At All, Wiley Publishers, 2005 34
Short Term Variation
Taken from Six Sigma for Dummies , by Craig Gygi At All, Wiley Publishers, 2005 35
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Taken from Six Sigma for Dummies , by Craig Gygi At All, Wiley Publishers, 2005
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About Sampling:
only link to the entire target population, you want that sample to be
really good.
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A good sample represents the target population. The sample doesn't
being included in the sample. In other words, the process you use
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"Less good information is better than more bad information, but
the sample size, but the bigger the sample size, the more accurate
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A quick and dirty formula to calculate the accuracy of a survey is to
divide by the square root of the sample size. For example, a survey
margin of error.
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Normal Distribution Curve
size, the greater will be this tendency. Also, Grand or Process Mean
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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100.
4 Calculate the Process Mean X – the average value of X and the Mean
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5 Plot all the values of X and R and examine the charts for any
possible miscalculations.
6 Calculate the values for the action and warning lines for the
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Some Terms
vGrand Mean
vState of Control
vProcess Capability
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Total number of readings should be at least 50 and:
üNO Mean or Range values which lie outside the Action Limits
üNO more than about 1 in 40 values between the Warning and Action
Limits (Zone 2)
üNO incidence of two consecutive Mean or Range values which lie
outside the same Warning Limit on either the mean or the range chart
(Zone 2)
üNO runs of more than six sample Means which lie either above or
below the Grand Mean (Zone 1)
üNO trends of more than six values of the sample Means which are
either rising or falling (Zone 1)
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Charts for individuals or run charts
and the individual values, not means of samples, are plotted. The
target value. The action lines (UAL and LAL) or control limits (UCL
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When plotting the individual results on the i-chart, the rules for
either side of the mean are usually drawn, and action taken if four
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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The zone control chart
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Taken from Statistical Process Control, 5th Ed by John S. Oakland
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Pre-control
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vDifference Charts
vZ Charts
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Going
Practical
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Taken from Statistical Methods for Industrial Process Control by David Drain, CRC Press
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Taken from Modern Control Engineering, 2003, Lecture Notes
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Taken from Modern Control Engineering, 2003, Lecture Notes
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Taken from Statistical Methods for Industrial Process Control by David Drain, CRC Press
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Taken from Statistical Methods for Industrial Process Control by David Drain, CRC Press
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All following figures, tables and
graphs are based on Practical
industrial data. Either reproduced
or copied as such from industrial
presentations.
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% oxygen in furnace flue gases
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Fuel Gas Flow in KSCFH to two cells of
furnace
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Pressure Variability Limits
TAG Norma UPPER LOWER UPPER LIMIT CONTROL LOWER LIMIT CONTROL
l LIMIT LIMIT PHILOSPHY PHILOSPHY
PRC - 101 505# 595# 490% On low load or other plant tripping to To control load
control battery limit press. According
to load
PRC - 102 589# 650/650 550 To avoid design limits of vessel D-2503
A/B
PRC - 103 479# 488/490 - To avoid design limit of vessel D-2510
PRC - 132 On high pressure P-2503 may trip on O/L Anti surge of K-2502 may open
amps.
PRC - 319 94# 100# 60# May damage burners, coil temp increase May burners Extinguish.
PRC - 306 240# 250# 160# May pop PSV - 929 Process air reduce.
KGT rpm may decrease
Six Sigma and ( continued )
Case Study – 3
Before PI
Thermo-compressor would have been sent to workshop for its opening for
internals’ inspection. Activity would have taken a minimum of two days,
resulting in low-pressure steam venting.
After PI
Motive steam flow trends from PI showed that the drop in efficiency
happened over a period of two months, contributed by scaling on the
motive steam path. This was confirmed by boroscopy. Thermo-compressor
was back in service after four hours of downtime required for cleaning.
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BIBLIOGRAPHY :
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BIBLIOGRAPHY :
schungsbereich in 2002
ØSix Sigma for Dummies, by Craig Gygi, Neil De Carlo and Bruce Williams
Sons in 2003
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Thank You
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