Prepared by: Gary J. Ainsworth - UMass Lowell Blogsblogs.uml.edu/etvp/wp.../12/Product2_Problems...30.pdf · Prepared by: Gary J. Ainsworth ... Experienced Problems Solver Leads sometime

Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission

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Preparedby:GaryJ.AinsworthPrincipalConsultantArcCompleta,Inc.


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Dr.ErikN.Schlosser,PhD


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BecauseoftheStart-UpChallengeTheclockisticking– Start-upsareinaconstantnon-profitablecashburnscenarioNoprecedenceinknowingwhatmightbeimportantorwhathasthehighestrisk

LiteratureSearchandBasicResearcharethenormsLoworNoProductionVolumestogainunderstandingofcriticalrequirements

EveryBuildCountstocreateacollectiveknowledgebase,butinfrastructureisoftenabsentandunablecollectcriticalknowledgeSimultaneousKnowledgeAccumulationinproductandprocessdevelopment,test,andmanufacturing

Inexperiencedmanagementteam,needingtofocuslimitedresourceswithstrongpersonalitiesPoorcommunityhabits,includinginconsistentcommunicationofdirectionandpriorityGreatinnovatorsarenotnecessarilygreatorganizersandmanagersInvestorsneedconcise,quantitative messagingonresultsandcommittedworkagainstmilestones


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prob·lem/ˈpräbləm/

NounAmatterorsituationregardedasunwelcomeorharmfulandneedingtobedealtwithandovercome.

Athingdifficulttoachieveoraccomplish.


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BeabletocometoanagreementthatthereisaproblemBeabletowriteaproblemstatementDeterminehowtomeasuretheproblem,asdefinedbytheproblemstatementStatethedesiredoutcomeindicatingtheproblemhasbeensolvedAchieveabasicunderstandingofmeasurementerror’scontributiontoconfoundinginterpretationofexperimentalresponsesandoutcomes


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Problemshave:a Beginninga MiddleandanEnd

BeginningProblem

Identification and Statement

Middle

End

Problem Solving, Inputs & Outcomes

Measurement

Solution and Control


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TeamMembersdonotrespecttheproblem:FailtodetermineandagreeonnatureofaproblembyalwaysinsistingtheanswerisobviousDon’tlistentocustomers(internalandexternal)aboutthenatureoftheproblemWastetimeandresourcesbyjumpingaheadto“thesolution”withoutobjectivemeasurementofsuccess

Iftheproblem’ssolutionwaseasy,itwouldhavebeensolvedTakeastepbacktoseewhoistalkingaboutaproblem,whileobservingtheresourcesandsalariesintheroomTheproblemislikelycostingandhasalreadycostthecompanysignificantmoney

Answerthequestion:Whyareweinbusiness?

Toidentify,describe,define,andobjectivelymeasureoutcomesasfastaspossible

Tofollowthroughandlearnfromoutcomes

Tosustainachievedimprovements

Toincreasestability,allowingusbuildoncontinualimprovement

Innovationinbusinessrequiresustobuildafoundationofknowledge!


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AProblemDefinitionandStatementAlimitedandquantifiablestatementofaconditionthatisundesirableorresultsinnegativeexternality

ScopeTheproblemstatementshouldaddresstheconditionofinterestThestatementshouldframethecurrentconditionorbehaviors,whilecontrastingthedesiredoutcome

AgreementThecustomerwhoisexperiencingtheproblemandreceivingtheproblemsolvingservicesshouldapprovethestatementAlso,thereshouldbeagreementontheasuccessfuldesiredoutcomeandthedirectmeansofmeasurement,thatifmet,theoutcomewillSOLVEtheproblem

CommunicationtoCustomerandTeamMembersExperiencedProblemsSolverLeadssometimedon’tgetbeyondProblemDefinitionandStatementbeforesomeonepreviouslyleftoutofthecommunicationloopsexplains:

“…ohthat,that’sbeenhappeningforyearsbecausewefailedto…”


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Bad: PrintHeadHeateruniformityiscausingprintinginconsistency

Good:Frommechanical,electronic,andfluidictoleranceanalysis,theprintheadendtoenduniformitymustbevarynomorethan+/-1°Cduringoperation

Bad: Chip’sSiliconDioxide/SiliconNitrideboundariesalwaysfailduringdeviceburn-in

Good:TheSiliconDioxide/SiliconNitridemustbeabletosurvivewithoutdegradationfora50%longerdurationatthespecifieddirectcurrent,duringinitialburn-in


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Bad: CompanyAhastoomanytransactionsontheproductionfloor

Good:Transactionsinlowcycletimeworkareasarecollectingupto30%oftheirtotalcyclebasedondatainputdelays,impactingOnTimeShipping

Bad: Wecan’tmeasureweldedtubes…Good:Measuringweldedtubeconcentricityisatimeconsuming

process,requiringupto5-7minutesperpart,whichis60%ofthetotaltimerequired


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Ask the question, does your measurement systems have

enough resolution and repeatability to actual see a

desired response without lying to yourself and your customers?

Response Distribution

Acceptable Measurement Error

Contribution

Low Limit Upper Limit

Unacceptable Measurement Error

Contribution


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4.994

4.996

4.998

5.000

5.002

5.004

5.006

5.008

5.010

5.012

0 1 2 3 4 5 6 7 8 9 10

OD(in

ches)

ToolHours

ToolWearasafunctionofODchangeovertime


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UsingQualitativeLanguageinaQuantitativeWorldUsedirect,repeatablemeasurementsystems,withsufficientresolutionEventhoughtheteammaynothaveadirectmeasurement,thereareoften“indicative”measurementsthatarehintingthere’saproblemUseanindicativemeasurementuntiladirectmeasurementisestablishedForsometypesofproblems,indicativemeasurementisthebestwaytotrackperformance

OverallDeviceTestYield,ThinFilmUniformityasa%,TrainingEfficacyinTermsofCycleTime,VisualDefectsReductionbyvisualrankordercorrelationtoparametricinputs

ScopeCreepIfuponstudyingaproblem,thescopestartstocreepintootherrelatedareas,theteammayhavetodeclareithascompoundingproblems

Prioritizethemosthighestimpactcandidate,andparkthesubordinate(s)forlaterconsideration

ExecutingthiskindofdecisionsplitiscriticaltomaintainfocusBettertosolveONEdefinedproblemanddraintheswampabit,thantowasteresourcesonanimpossiblybroadscope


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Refusingtousethe“BigBrain”AccountableproblemsolvingteamsshouldneverexceedatotalofthreetofourassignedpeopleButthecommunicationoftheproblem’sdefinitionandclues,experiments,andinterimresultsshouldbesharedbroadly,welcomingotherstakeholderstothinkabouttheproblemandpossiblesolutionsProgressandcontentshouldbestoredinacommonnotebookandifneededonaserverRegularupdatesshouldbeformalizedperiodicallyexplainingstatus,progress,andusageofcompanyresourcesAskforhelpwhenstalled;sometimesafreshsetofbrainsandeyeswillseesomethingwhenyou’retiredandsaturated

Everyprocessorpieceofcapitalequipmentrequiresasuitabledirectquantitativemetrologysystem forequipmentacceptancefromtheequipmentsupplier,outcomemeasurement,andprocesscontrol


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Hi-Temp Stainless Steel

Nickel Super Alloy

Welded and Machined To Final Outer Diameter


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After FDT, Defects Too Close

After Rework Grinding After FDTDefects Too Close

After Rework GrindingDefect GrowthAfter Welding and

Machining

After FDT,Contiguous

After Rework GrindingDefect Growth

Limited by 0.048 WT

After FDT,Contiguous

After Rework GrindingSize Failure


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MachiningHybridTubesrevealsdefectsafterdyetesting80%ofdefectsarecontiguousaftermachiningwhichisnotallowedIfthedefectsarenotconnected,buttheyareallowediftheyaresmallenoughTheteam’schallengeistodetermineiftheyaredealingwiththesamefailuremodesandonecompoundingproblemtobesolved-or- twoconditionsthatneedtobesplitandsolvedseparatelyorminimized,andperhapsmorequickly

Questionstheteammustaskthemselves:Cantheproblembemeasureddirectly,henceshowingimprovementorasolution?

PrimaryConstraint:Regardlessoflocationandnumbers,finalHybridTubewallthicknessmustbe>0.048inch,andifyougrindoutdefectthewallthinsuntilit’safailure.Thiscanbemeasureddirectly.SecondaryConstraint:Actualfrequency,location,andsizesofDyeDefectsarecluestofailuremodesthatneedtobesolvedtoimproveyield;canthesebequantified?

Ifproblemscannotbemeasureddirectly,inthebeginning,perhapsitbemeasuredindirectlybyusinganindicativevariabletoguidecluegeneration

Measuringincreasingoverallyield,weldingefficiencyincreases,andscrapcostsreductionsbecauseofalowernumberoffirsttimeDyeIndicationDefectsaccountsforlessreworkCycleTimeandTotalDyeIndicationsdecreasedafter2ndShiftIndicationDyeQAoperatorwasretrainedtonewvisualstandardscouldbeanotherclueandpossiblepathtosolution


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0.9800

0.9850

0.9900

0.9950

1.0000

1.0050

1.0100

1.0150

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Inches

Measurements

DiameterTotalRun-OutChanged Feeds and Speeds to

Eliminate Chatter

- Measurement Error


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65% 67% 69% 71% 73% 75% 77% 79% 81% 83% 85% 87% 89% 91% 93% 95% 97% 99%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

OpticalDeviceFibe

rCou

plingEfficiency

Weeks

NewToolingImprovedPerformance

“Better” Tooling

Implemented


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65% 67% 69% 71% 73% 75% 77% 79% 81% 83% 85% 87% 89% 91% 93% 95% 97% 99%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

FirstP

assY

ield

Weeks

GroupYield

Training Standards Implemented


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IstheProblemStatementandmeasurementofthedesiredoutcomestillvalid?IfYes:ContinueIfNo:Determineisreductionofscopeisneeded-or- asplitandpark

CanyoudiscriminatebetweenmeasurementswithknownconfidenceIfYes:ContinueIfNo:Yourmeasurementsystemeitherlacksresolutionorrepeatability(R&R)

Canyourdatashowaconvincingdifference(contrast)frombeforeandafter?IfYes:ContinueIfNo:EitheryourmeasurementsystemlacksR&R-or- theproblemwasnotcompletelysolved

CantheSolutionbereproducedmorethanonce?IfYes:ContinueIfNo:Reviewifthemeasurementsystemisstillvalidandifthesolution’sprocessandworkflowwasexecutedcorrectly

Canyousustainandcontrolthechange(thesolution),andmeasuretheperformanceovertimetoeliminatechanceofdriftingbacktoundesirablestate?

IfYes:ProblemisSOLVED!IfNo:Determinewhatcontroland/orprocesschangewillsustainthesolution’sdesiredresult


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Problemshave:a Beginninga MiddleandanEnd

BeginningProblem

Identification and Statement

Middle

End

Problem Solving, Inputs & Outcomes

Measurement

Solution and Control


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Doesyourcompanyneedabasicfoundationforsuccess?

December8,Noonto1p.m.-MovingfromTacticaltoStrategicPlanning

If so, The UMass Lowell Enlightened Bites Entrepreneurship Series presents the final part of this breakthrough series


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Myareaofpracticefocusesonemergingtechnologyproductcommercializationinhardwarestart-ups.Also,Iworkwithexistingcompaniesonnewproductintroduction,operations,andproductdevelopmentperformanceimprovement.InallinstancesIusuallyworkinthegrayareabetweenR&DandProductDevelopment-and- OperationsandSupplyChain,employingmethodstolowertheinherentnoiselevelallowingbetterdecisionmakinginamoreaccountableframework.I'mcurrentlyworkingwith UMASS Lowell'sNewVentureBusinessDevelopmentteamand iHub oncontentaroundunderstandingstart-upbehaviors,leadingtoahigherprobabilityofsuccessfulcommercializationandprofitability.

ContactInformation:GaryAinsworthArcCompleta,Inc.- [email protected]

[email protected](m)781-856-0448


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ThiscontentisakeyandimportantsubsetofmethodsthatI’veappliedtotechnicalproblemsolvinginR&D,ProductDevelopment,ManufacturingandTestProcessDevelopment,andSupplyChainCertificationandQualificationMymethodsarederivedfromtraditionalstatisticalprocesscontrol(SPC),DesignofExperiments(DOE),advancestatisticalcorrelationmethodsofmultiplemetrologysystems,andpracticalconsiderationsinthemigrationofearlydevelopmentmetrologytoproductionusageThetheoryandpracticeisheavilyinfluencedbyShaininStatisticalEngineeringÓmethodsShaininalwaysstatesthatdevelopingacorrectlysizedandstatedproblemdefinitionstatementandhavingconfidenceinameasurementsystemtodiscriminatebetweenBetter(improved)vs.Current(thecontrol)isthehardestpartofsolvingproblems

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Prepared by: Gary J. Ainsworth - UMass Lowell Blogsblogs.uml.edu/etvp/wp.../12/Product2_Problems...30.pdf · Prepared by: Gary J. Ainsworth ... Experienced Problems Solver Leads sometime