I.4 Implementation Issues

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I.4 Implementation Issues

• Fundamentals of Problem Solving
• DOE Implementation Issues
• DOE Stages
• Helicopter Experiment
• Project Reports
• Problem Solving/DOE Levels of Understanding

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Fundamentals of Problem SolvingThe Scientific
Method

• Science is built of facts the way a house is
  built of bricks but an accumulation of facts is
  no more science than a pile of bricks is a house.
• -Henri Poincare

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Fundamentals of Problem SolvingThe Scientific
Method

• The Scientific Method
• Cycle Between Theories (or Hypotheses) and Data
  Collection/Analysis to Repute or Refute the
  Theories
• The Shewhart/Deming Plan-Do-Study-Act Cycle Is
  Based on This

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Fundamentals of Problem SolvingPDSA Cycle--The
Shewhart/Deming Cycle

• Most Problem Solving Strategies Are Elaborations
  on the PDSA Cycle

PLAN
ACT
DO
STUDY
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Fundamentals of Problem SolvingThe PDSA Cycle


Problem And Its Scope


Define
Processes

PLAN
Assess Current Situation
Analyze Causes
DO
Experiment With Theories
STUDY
Analyze The Results

Verify Conclusions
Adopt or Abandon The Change

Revise The Standard Operating Procedure
ACT
Plan Continuous Improvement
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Fundamentals of Problem SolvingComments

• Getting Rid Of ACV (Assignable Or Special Cause
  Variation) Is NOT Process Improvement!
• Conclusions Drawn From Data Collected When The
  Process Is Not Stable Are Suspect!

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DOE Implementation IssuesDOE Stages

• Stages and Substages Are Just An Elaboration Of
  The PDSA Cycle and The Seven Steps

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DOE Implementation IssuesDOE Stages

• A DOE Project Is ComposedOf A Number Of Stages
• The Preliminary Stage
• The Basic Understanding Stage
• The Refinement Stage
• The Verification Stage
• Each One Of These Stages And Their Substages Have
  Certain Objectives

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DOE Implementation IssuesDOE Stages - Objectives

• The Overall Objective Of The Project
• Oftentimes Broad And Not Specific
• E.g, The Overall Objective May Be To Simply
  Improve A Process
• Stage Objectives Are Specific

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DOE Implementation IssuesDOE StagesThe
Preliminary Stage

• Considerations
• Measurement Methods
• Factor Selection
• Process and Measurement Variation
• Some Relevant Objectives For This Stage
• Determining The Quality Of The Measurement
  Process
• Understanding The Current Situation

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DOE Implementation IssuesDOE StagesTo Fix These
Ideas Lets Design a Helicopter

• Background
• Product Development at We R Toys is developing
  a cheap "distraction" toy for use at restaurants
  to keep young children entertained while waiting
  for service. The toy - a paper helicopter -
  needs to be simple in design since the children
  will be assembling it using scissors, tape, paper
  clips, etc. A study done using the prototype has
  discovered that customer satisfaction is directly
  related to the the total flight time of the
  helicopter.

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DOE Implementation IssuesDOE StagesTo Fix These
Ideas Lets Design a Helicopter

• Background
• Engineering has been assigned the task to
  optimize the flight time. Because of the
  assembly requirements, the modifications should
  not result in a design that is drastically
  different in form for that of the prototype.

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DOE Implementation IssuesDOE StagesHelicopter
Experiment - The Basic Design
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DOE Implementation IssuesDOE StagesHelicopter
Experiment - Stage Objectives

• Overall Objective To increase flight time.
• Stage One Objectives Brainstorm to decide on
  factors that possibly influence flight time.
  Decide which factors are control factors and
  which ones are noise factors.
• Stage Two Objectives Decide on factors that are
  to be included in an eight run screening design
  and determine their levels for the design.

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DOE Implementation IssuesDOE StagesHelicopter
Experiment - Stage Objectives

• Stage Three Objectives Run the DOE from Stage
  Two to screen out active factors from inactive
  ones. For the active factors, decide on possible
  settings for the next DOE Decide on what new
  factors might be included in the next design.
• Stage Four Objectives Run the DOE for the
  factors and their settings decided in the
  previous stage.

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DOE Implementation IssuesDOE StagesHelicopter
Experiment - Stage Objectives

• Stage Five Objective ???????
• Stage ???? (The Validation Stage) Objective
  Your sequence of DOE's have led you to some
  "Ideal Factor Setting" that "Optimize" the
  performance of the helicopter with regard to its
  flight time. This was done under laboratory
  conditions. Will this performance be replicated
  under normal operating conditions? This is the
  purpose of the validation stage.

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Problem Solving/DOELevels of Understanding

• The Operational Level - Empirical Model Building
• What Factors Affect the Response
• How Do They Affect the Response
• The Basic Research Level - Fundamental Theories
• Why Do They Affect The Response

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Problem Solving/DOELevels of Understanding

• Two Approaches To Correct Defects - Theoretical
  and Empirical
• Theoretical Approach (Mechanistic Models and
  Technical Analysis) - Theoretical Principles are
  Used to Search for Cause-and-Effect Relationships
• Statistical Based (Empirical Model Building)
  Allows One to Discover Corrective Measures.

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Problem Solving/DOELevels of UnderstandingTale
of the TV Tuner(Karatsu)

• Statistical analysis discovered that a TV tuner
  should be placed as far as possible from the
  speaker to avoid malfunction. There was no good
  theoretical explanation for this.