Data Set 1
Run 1 Run 2 Run 3 Run 4 Avg GrMean UCL LCL Stacked Process Mean UCL LCL Stacked Spec Mean Spec USL Spec LSL Desc Stats
1 6.45 5.56 5.53 6.81 0.00 0.00 0.00 0.00 0.00 0.00
2 6.47 6.99 5.65 5.74 0.00 0.00 0.00 0.00 0.00 0.00 The Mean from Desc Stats MUST be in cell U3
3 5.80 5.32 6.32 6.09 0.00 0.00 0.00 0.00 0.00 0.00
4 5.87 5.13 5.06 6.82 0.00 0.00 0.00 0.00 0.00 0.00
5 5.43 5.26 5.15 6.68 0.00 0.00 0.00 0.00 0.00 0.00
6 6.92 6.44 5.80 5.94 0.00 0.00 0.00 0.00 0.00 0.00 TheStdDev from Desc Stats MUST be in cell U7
7 6.35 6.45 5.21 6.26 0.00 0.00 0.00 0.00 0.00 0.00
8 6.55 5.53 5.92 5.94 0.00 0.00 0.00 0.00 0.00 0.00
9 5.85 6.13 6.33 6.71 0.00 0.00 0.00 0.00 0.00 0.00
10 5.98 6.50 6.78 5.71 0.00 0.00 0.00 0.00 0.00 0.00
11 5.80 6.20 6.33 5.86 0.00 0.00 0.00 0.00 0.00 0.00
12 5.89 5.33 6.00 6.09 0.00 0.00 0.00 0.00 0.00 0.00
13 6.49 6.81 5.33 5.89 0.00 0.00 0.00 0.00 0.00 0.00
14 5.08 6.24 5.71 6.10 0.00 0.00 0.00 0.00 0.00 0.00
15 5.09 6.60 6.83 5.03 0.00 0.00 0.00 0.00 0.00 0.00
16 6.45 6.88 5.95 5.29 0.00 0.00 0.00 0.00 0.00 0.00
17 6.54 5.33 6.89 6.37 0.00 0.00 0.00 0.00 0.00 0.00
18 6.72 6.43 5.29 6.25 0.00 0.00 0.00 0.00 0.00 0.00
19 6.38 5.99 6.66 5.45 0.00 0.00 0.00 0.00 0.00 0.00
20 6.33 5.17 5.02 5.09 0.00 0.00 0.00 0.00 0.00 0.00 Place IM chart plotted against process mean/UCL/LCL here
Grand Mean 0.00 0.00 0.00
Std Dev 0.00 0.00 0.00
0.00 0.00 0.00 Format Axis to Max of 8.0; Min of 4.0
0.00 0.00 0.00 Axis Major Unit = .5
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
Place X-bar chart here 0.00 0.00 0.00
X-bar ONLY 0.00 0.00 0.00 Place analysis of IM chart plotted against process limits here
0.00 0.00 0.00
Format Axis to Max of 6.8; Min of 4.8 0.00 0.00 0.00
Axis Major Unit = .2 0.00 0.00 0.00
0.00 0.00 0.00
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Place analysis of X-bar chart and data here 0.00 0.00 0.00
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0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00 Place IM chart using Spec Mean, USL and LSL here
0.00 0.00 0.00 Format axis to max of 7.2; Min of 4.8
0.00 0.00 0.00 Major unit 0.2
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00 Place analysis of IM chart plotted against spec limits here
0.00 0.00 0.00
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Questions DS 1
You have just completed the first test run of the widget production. Answer the questions below and follow the instructions.
What is the customer specification for the widget mean?
What is the customer USL for the widget?
What is the customer LSL for the widget?
X-bar chart
What is the Grand Mean of the test data?
What is the calculated UCL of the test data?
What is the calculated LCL of the test data?
Is there an issue with the grouped data and the customer specifications? (Y/N)
What is the issue?
IM charts
What is the calculated UCL of the test data?
What is the calculated LCL of the test data?
How many widgets are out of specification?
Is there an issue with the IM data and the customer USL and LSL? (Y/N)
What is the issue?
What is your suggestion to correct the problem?
Based on your analysis, do you make corrections and do another test sample? (Y/N)
If no, why?
If yes, proceed to Data Set 2, and repeat the steps for Data Set 1
Data Set 2
Day 1 Day 2 Day 3 Day 4 Avg Mean UCL LCL Stack Mean UCL LCL Stack Mean S USL LSL Desc Stats
1 5.69 5.36 5.72 5.11 0.00 0.00 0.00 0.00 0.00 0.00
2 5.58 5.67 5.64 5.37 0.00 0.00 0.00 0.00 0.00 0.00 The Mean from Desc Stats MUST be in cell U3
3 5.39 5.75 5.75 5.83 0.00 0.00 0.00 0.00 0.00 0.00
4 5.49 5.47 5.44 5.54 0.00 0.00 0.00 0.00 0.00 0.00
5 5.44 5.55 5.84 5.47 0.00 0.00 0.00 0.00 0.00 0.00
6 5.27 5.27 5.73 5.23 0.00 0.00 0.00 0.00 0.00 0.00 TheStdDev from Desc Stats MUST be in cell U7
7 5.28 5.21 5.44 5.21 0.00 0.00 0.00 0.00 0.00 0.00
8 5.27 5.37 5.27 5.84 0.00 0.00 0.00 0.00 0.00 0.00
9 5.25 5.76 5.69 5.54 0.00 0.00 0.00 0.00 0.00 0.00
10 5.29 5.49 5.60 5.85 0.00 0.00 0.00 0.00 0.00 0.00
11 5.31 5.42 5.80 5.53 0.00 0.00 0.00 0.00 0.00 0.00
12 5.33 5.37 5.32 5.11 0.00 0.00 0.00 0.00 0.00 0.00
13 5.57 5.81 5.70 5.80 0.00 0.00 0.00 0.00 0.00 0.00
14 5.60 5.43 5.76 5.44 0.00 0.00 0.00 0.00 0.00 0.00
15 5.59 5.55 5.20 5.78 0.00 0.00 0.00 0.00 0.00 0.00
16 5.34 5.35 5.49 5.78 0.00 0.00 0.00 0.00 0.00 0.00
17 5.56 5.87 5.85 5.16 0.00 0.00 0.00 0.00 0.00 0.00
18 5.74 5.81 5.55 5.41 0.00 0.00 0.00 0.00 0.00 0.00
19 5.68 5.60 5.56 5.73 0.00 0.00 0.00 0.00 0.00 0.00
20 5.82 5.23 5.80 5.74 0.00 0.00 0.00 0.00 0.00 0.00 Place IM chart plotted against process mean/UCL/LCL here
Grand Mean 0.00 0.00 0.00
Std Dev 0.00 0.00 0.00
0.00 0.00 0.00 Format Axis to Max of 6.2; Min of 4.8
0.00 0.00 0.00 Axis Major Unit = .1
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
Place X-bar chart here 0.00 0.00 0.00
X-bar ONLY 0.00 0.00 0.00 Place analysis of IM chart plotted against process limits here
0.00 0.00 0.00
Format Axis to Max of 6.2; Min of 4.8 0.00 0.00 0.00
Axis Major Unit = .2 0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
Place analysis of X-bar chart and data here 0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00 Place IM chart using Spec Mean, USL and LSL here
0.00 0.00 0.00 Format axis to max of 6.1; Min of 4.9
0.00 0.00 0.00 Major unit 0.1
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00 Place analysis of IM chart plotted against spec limits here
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
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0.00 0.00 0.00
0.00 0.00 0.00
Questions DS 2
You have just completed the second test run of the widget production. Answer the questions below and follow the instructions.
What is the customer specification for the widget mean?
What is the customer USL for the widget?
What is the customer LSL for the widget?
X-bar chart
What is the Grand Mean of the test data?
What is the calculated UCL of the test data?
What is the calculated LCL of the test data?
Is there an issue with the grouped data and the customer specifications? (Y/N)
Why?
IM charts
What is the calculated UCL of the test data?
What is the calculated LCL of the test data?
How many widgets are out of specification?
Is there an issue with the IM data and the customer USL and LSL? (Y/N)
Why?
What is your suggestion to correct the problem, if any?
Based on your analysis, do you make corrections and do another test sample? (Y/N)
If no, why?
COURSE PROJECT SCENARIO
Introduction
The student will be provided with a project scenario via an Excel spreadsheet that will require the use of several analytical tools to arrange, display and analyze data.
Directions
Project
You are the Quality Manager for Widgets, Inc. You have just won a contract to produce a specialized widget that the customer requires a very tight specification limit. This widget is to be 5.50†in length, plus or minus .50â€. This gives the total specification limit of 5.00†to 6.00â€.
You have set up the production line to produce a test run of the widgets (Data Set 1). The sample size consists of a total of 20 samples per run, with a total of four (4) runs. A total of 80 samples will be used to determine if the process is capable of producing the widgets within specification.
Due to the specifications of the customer, and the setup of the manufacturing processes, the systematic random sampling technique was used to ensure that samples from each run were collected at the same point in time on different days. This provides the basis for the X-bar chart to group the sample from each run into logical subgroups.
Requirements:
1. Calculate the subgroup mean for each numbered sample
1. Calculate the grand mean and standard deviation of the subgroup samples
1. Calculate the UCL and LCL of the grouped samples
1. Create the X-bar chart
1. Provide detailed analysis of the X-bar chart
To ensure that the process in actually producing individual widgets within specification limits, you have decided to use an Individual Measurement chart that will plot each of the 80 samples against a calculated UCL and LCL, as well as plotting the data against the customer specification limits.
Requirements:
1. Stack the sample data (place the run data into a single column. Run 1 first, Run 2 second, etc)
1. Using the Data Analysis Toolpak, create the Descriptive Statistics for the stacked data
1. Using the Descriptive Statistics output, calculate the UCL and LCL
1. Create the IM chart using the calculated UCL and LCL
1. Recopy the stacked data, and enter the customer specification limits
1. Create the IM chart of the sample data against the customer specifications
1. Provide a detailed analysis of both IM charts
Answer the questions on the “Questions DS 1†tab on the spreadsheet, and follow the instructions.
Repeat the steps for Data Set 2.
Additional Project Information
The basic information for you to complete the project is contained in the Course Project Scenario document. This is additional information that you will need to know in order to create the charts and perform the analyses correctly.
1. You are a widget manufacturer. This is for a special production of widgets with extremely tight tolerances. Since you specialize in widget design and production, you can assume that the processes that are similar in nature with regard to the specification limits are valid to base a process capability.
2. The initial run of the widgets should be considered a trail run. This is due to the fact that you make widgets similar in tolerance, but maybe not as tight as those required by this customer. You can assume that based in your experience in widget manufacture, the first 4 runs of the prototype widget will meet specification.
However, you’re more concerned with the tolerances of the machines. The question is whether the current process and machinery is capable of making the widgets to the close tolerances required by the customer. This is why you selected a sample of the population runs (each run * 20 samples)
3. The UCL and LCL are calculated using data set 1 as a population. They will provide a more reliable assessment on the current manufacturing process. To calculate UCL and LCL, you simply add and subtract the mean of each subgroup to 3*std dev. To get these values, copy the following formulas into the appropriate cells:
Column F – Avg: Cell F2 =AVERAGE(B2:E2) Copy this formula to the end of the table
Grand Mean: Cell F22 =AVERAGE(F2:F21)
Std Dev: Cell F23 =STDEV.S(F2:F21)
These formulas will also be used in Data Set 2.
The Project Video will demonstrate how to perform these functions/formulas. You should watch the video at least twice before attempting to do anything with the project data. This will help you better understand what to do, and to do it correctly.
4. Create a line chart using the subgroups averages, mean, UCL and LCL (columns F-I). This will be the X-bar chart for the subgroup data. Follow the format instructions on Data Set 1 tab.
5. The IM charts are columns K-R. You MUST stack the data as instructed on the project document. You must then do descriptive stats on the stacked column and place the results in the area shown. Make sure you follow the placement help for the mean and stddev!!
6. The first IM chart is plotted against the process mean and will use the desc stats for the calculations. Create a line chart using the stacked data, process mean, UCL and LCL just like the x-bar and follow the formatting directions.
7. Copy the stacked data into column “O†and enter the SPECIFICATION limits into the appropriate cells. Make sure you copy these data for the entire stacked column length!!! Create another IM chart based on these data.
8. For all charts you must provide a detailed analysis. Be detailed and thorough, but not lengthy.
9. Answer the Questions for data set 1.
10. After the analysis of data set 1, you have determined that process improvements must be made. You have done this and have collected another set of data to see if you are now within the customer specification limits. These data are found in data set 2.
11. Repeat steps 3-9 for data set 2.
IMPORTANT:
The Project comes with text boxes for you to type in your analysis. There is NO REQUIREMENT to use the Report Template for the Project.
The Project spreadsheet file is a self-contained examination. ONLY the Project spreadsheet will be used to document your charts and analyses of each chart.
The Project video demonstrates how to modify the text boxes to allow for your analysis of the data.
Analysis MUST be concise, but detailed. Instructions on how to scope your analysis is also part of the Project video.
The Project video IS NOT a representation of the actual data you will be using. It is solely for instructional purposes only.
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