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Implementing Six Sigma: Are you Getting Results Fast Enough?
JMP, A Business Unit of SAS
PresenterChuck Boiler- Analytical Strategist
WCBF – Dallas, TXFebruary 15 – 17 2005
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28 years
Wor
ldw
ide
Rev
enue
$1B
SAS - 28 Years of Growth
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JMP, A Business Unit of SAS
- Founded by John Sall, Executive Vice President of SAS and Co-Founder of SAS Institute
- JMP founded in 1989
- Providing analytics to Engineers in Manufacturing with tools to rapidly impact the bottom line
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Recursive Partition: Growing a Tree without digging a hole
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Figure 6: Machining data with bad cuts highlighted
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Figure 7: Machining data with good cuts highlighted
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Figure 8: recursive partitioning windows before analysis
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Figure 9: Predicting good and bad cuts with three splits
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Figure 10: Predicting good and bad cuts with four rules
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Figure 11: Predict lubricant amount
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Figure One: Graphs that Live
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Survey data distribution Figure 2
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Survey data distribution Figure 3
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Survey data Table 1, Table 2 E
ase
Resp
on
siv
e
Tim
ely
Pro
fess
ion
al
Qu
ali
ty
Th
oro
ug
h
Co
llab
ora
tio
n
Ex
pecta
tio
ns
Valu
e
Co
mm
un
icati
on
Ease 3 34 34 34 34 34 345 34 34 345
Responsive 34 3 34 34 34 34 345 34 34 345
Timely 34 34 3 34 34 34 345 34 34 345
Professional 34 34 34 3 34 34 45 34 34 345
Quality 34 34 34 34 3 34 345 34 34 345
Thorough 34 34 34 3 3 3 345 34 3 345 Collaboration 03 03 03 03 03 03 3 34 03 034 Expectations 034 034 3 30 03 034 345 3 3 345 Value 345 34 34 34 34 34 345 34 3 34
5 Communication 034 034 3 03 034 034 34 03 03 3
3 When respondent chose 3 on question shown on column… 03 Chose 0 and 3 almost equally 34 Chose mostly 3, sometimes 4 34 Chose 3 and 4 equally 034 Chose mostly 3, sometimes 0 or 4 345 Chose mostly 3, sometimes 4 or 5 03 Chose mostly 0, sometimes 3 345 Chose 3, 4, and 5 almost equally 345 Chose 3 and 4 almost equally, sometimes 5
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Survey data Subsetting Figure 4
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Survey data subset Figure 5
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Designed to save money
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Table 3, 4: Experimentation costs
Resource Cost Workers time $500 Materials $500 Down time/Opportunity costs $5,000 Total Cost per run $6,000
Number of Runs
Total Experiment Costs
1 $6,000 10 $60,000 50 $300,000 100 $600,000 150 $900,000
Experimental Cost
Total Experimentation costs
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Figure 12: Response surface (weld, time)
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Figure 13: Custom design, four hot-tool temps
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Figure 14: Custom Design 8 Hot tool temps
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Table 5: Costs of Experiments
Experiment
Runs Cost
($6,000 per run)
Cost ($50,000 per run)
Response Surface (weld, time) 8 $48,000 $400,000 Response Surface replicated 4 hot-tool temps
32 $192,000 $1,600,000
Response surface replicated 8 hot-tool temps
64 $384,000 $3,200,000
Custom Design, 4 hot-tool temps, minimum runs
15 $90,000 $750,000
Custom Design, 8 hot-tool temps, minimum runs
27 $162,000 $1,350,000
Custom Design, 8 hot-tool temps, user specific runs
42 $250,000 $2,100,000
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Conclusion
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Implementing Six Sigma: Are you Getting Results Fast Enough?
JMP, A Business Unit of SAS
PresenterChuck Boiler- Analytical Strategist
WCBF – Dallas, TXFebruary 15 – 17 2005