Analyse Phase Blog
The Analyse Phase is the statistical review of the process, for the
Analyse Phase of this project each of the three assembly processes were
analysed individually and as a combined process. The following tools were used
to analyse each process; Process 1 - A detailed process map, A
P-Control Chart (both Excel and Minitab), An Ishikawa diagram and a
brainstorming session. Process 2 - A detailed process map, A
P-Control Chart, An Ishikawa diagram and a brainstorming session. Process
3 - Brainstorming session. Combined Processes - A
P-Control Chart.
Process 1 - The P-Chart shown on the left was of Process 1 from
Jan - Dec 2015. There was special cause variation in both Jan & Dec 2015 as
the defective parts exceeded the UCL. In Oct 2015 a point falls on the LCL,
which indicates that the process was running at its lowest proportion of
defects. Overall process 1 is statistically out of control. On the 2 occasions
where the UCL is exceeded, this special cause variation could be attributed to
the fact that 2 new personnel where being trained on that process. After
reviewing the data, it was found that the night shift did not run in Oct, this
could explain why the number of rejects declined in Oct 2015. I found the
P-Charts useful throughout the Analyse phase as they clearly illustrate how a
process is performing, and it is easy to see when a process is veering out of
control. When there is special cause variation or unusual trends it is
important to investigate thoroughly and pinpoint anything that was done
differently. From the P-Chart for process 1 - we checked our training records
and they coincided with the hike in rejects in Jan & Dec 15. As for Oct 15
when the defective parts where at the lowest it became apparent that the night
shift did not run that month, it is understandable to have a higher reject rate
at night due to no Quality / SPC / Engineer present.
Process 2 - An Ishikawa diagram was constructed in Minitab in
order to determine the root causes for the high rate of defective parts
produced. When the diagram was complete, all the causes where listed as well as
a comment to explain the cause and a potential solution. A detailed process map
and a P-Chart where also constructed for process 2. The Ishikawa diagram was
found to extremely useful throughout the Analyse phase. The result was a clear
and categorical root cause analysis of each process, which was extremely
beneficial for the team.
Process
3
- It was decided for process 3 to concentrate on the brainstorming session that
took place in the Define Phase. All the points suggested in the brainstorm
warrant being investigated further in the Improve phase, however for the
Analyse phase these point were elaborated on.
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