Inspection Tracking & Inspection Tracking &

Improvement AnalysisImprovement Analysis

MSE601, Fall 2011MSE601, Fall 2011MorvaridMorvarid AmirfathiAmirfathi

MaryamMaryam RavanRavan DoustDoust

Anthony Anthony ““AJAJ”” SchulteSchulte

AgendaAgenda

1.1. Introduction about ASCIntroduction about ASC

2.2. Project GoalProject Goal

3.3. Analysis of Previous Inspection WorkflowAnalysis of Previous Inspection Workflow

4.4. Analysis of Current Inspection WorkflowAnalysis of Current Inspection Workflow

5.5. Conclusions.Conclusions.

About ASCAbout ASChttp://http://aschome.comaschome.com//

•• ASC is a leading manufacturer of specialized process equipment, ASC is a leading manufacturer of specialized process equipment, control systems, and control systems, and custom manufacturing software used in the composites, plastics, custom manufacturing software used in the composites, plastics, glass, solar, lumber, and glass, solar, lumber, and concrete, coatings, and finishing industries.concrete, coatings, and finishing industries.

•• Our product lines include composite autoclaves, glassOur product lines include composite autoclaves, glass--laminating autoclaves, concrete laminating autoclaves, concrete autoclaves, industrial ovens, composite ovens, electroplating auautoclaves, industrial ovens, composite ovens, electroplating automation systems, process tomation systems, process control software, autoclave control software, oven control softwcontrol software, autoclave control software, oven control software, and crane and hoist are, and crane and hoist control software including scheduling.control software including scheduling.

•• We're located in Valencia, CA and support thousands of systems aWe're located in Valencia, CA and support thousands of systems and hundreds of nd hundreds of customers worldwide. .customers worldwide. .

Project GoalProject Goal

•• Problem Statement:Problem Statement:

–– ASC has moved into a new facility and the inspections ASC has moved into a new facility and the inspections create a bottle neck in production.create a bottle neck in production.

–– Workers have to wait for inspectors to finish before Workers have to wait for inspectors to finish before proceeding. Inspectors also have a larger area to proceeding. Inspectors also have a larger area to cover.cover.

•• Demonstrate inspections per day has increased with an Demonstrate inspections per day has increased with an expeditorexpeditor

•• Analyze current inspection inspection/time and number Analyze current inspection inspection/time and number of inspection per day. of inspection per day.

•• Analyze new inspection/ time and number of inspection Analyze new inspection/ time and number of inspection with implementation of an expeditor. with implementation of an expeditor.

•• Confirm Inspections Per Day has increase.Confirm Inspections Per Day has increase.

Inspection ProcedureInspection Procedure

•• Shop Calls in Inspection Request and Shop Calls in Inspection Request and

States location.States location.

•• Inspector goes to location and radios Inspector goes to location and radios

document control personnel (time starts)document control personnel (time starts)

•• Inspector checks assembly (drawing Inspector checks assembly (drawing

verification)verification)

•• Upon completion, inspection radios in Upon completion, inspection radios in

done (end time)done (end time)

Prior Analysis By ASC QualityPrior Analysis By ASC Quality

•• Previous Inspector Shop FlowPrevious Inspector Shop Flow

Prior Analysis By ASC QualityPrior Analysis By ASC Quality

Results(AverageResults(Average Time Loss)Time Loss)

•• Total time spent obtaining inspection Total time spent obtaining inspection

documentation a day documentation a day –– 1 hour, 25min1 hour, 25min. .

•• Total time spent obtaining measuring tools Total time spent obtaining measuring tools

such as calipers such as calipers –– 30 min30 min (8 of the 25 (8 of the 25

inspections requiring other measuring tools).inspections requiring other measuring tools).

•• Total time spent submitting inspection records Total time spent submitting inspection records

to Document Control to Document Control –– 1 hour, 25min1 hour, 25min. .

•• Total time spent obtaining disposition Total time spent obtaining disposition –– 2 hours2 hours(8 of the 25 inspections are non(8 of the 25 inspections are non--conformance conformance

and require disposition).and require disposition).

Prior Inspection Flow DataPrior Inspection Flow DataDayDay DateDate TimeTime # # InspInsp Time/ Time/ InspInsp DayDay DateDate TimeTime # # InspInsp Time/ Time/ InspInsp

1616 5/16/115/16/11 7:247:24 3030 0:140:14

11 5/1/115/1/11 11:2311:23 3535 0:190:19 1717 5/17/115/17/11 12:2012:20 4242 0:340:34

22 5/2/115/2/11 11:5911:59 3838 0:180:18 1818 5/18/115/18/11 4:454:45 5252 0:190:19

33 5/3/115/3/11 7:167:16 2323 0:180:18 1919 5/19/115/19/11 3:193:19 4242 0:210:21

44 5/4/115/4/11 11:0411:04 3232 0:430:43 2020 5/20/115/20/11 7:397:39 3838 0:310:31

55 5/5/115/5/11 8:148:14 2929 0:170:17 2121 5/21/115/21/11 4:404:40 4242 0:230:23

66 5/6/115/6/11 9:569:56 3838 0:150:15 2222 5/22/115/22/11 2:432:43 4242 0:210:21

77 5/7/115/7/11 5:235:23 3333 0:310:31 2323 5/23/115/23/11 12:5312:53 4040 0:190:19

88 5/8/115/8/11 8:548:54 4545 0:110:11 2424 5/24/115/24/11 6:576:57 5757 0:190:19

99 5/9/115/9/11 10:0210:02 4545 0:130:13 2525 5/25/115/25/11 4:224:22 4242 0:230:23

1010 5/10/115/10/11 3:483:48 4141 0:230:23 2626 5/26/115/26/11 6:376:37 4848 0:230:23

1111 5/11/115/11/11 10:5810:58 3030 0:210:21 2727 5/27/115/27/11 6:306:30 3232 0:120:12

1212 5/12/115/12/11 7:307:30 3131 0:140:14 2828 5/28/115/28/11 5:345:34 4848 0:210:21

1313 5/13/115/13/11 1:371:37 3232 0:250:25 2929 5/29/115/29/11 11:2911:29 3838 0:180:18

1414 5/14/115/14/11 5:475:47 2424 0:140:14 3030 5/30/115/30/11 10:1110:11 3232 0:190:19

1515 5/15/115/15/11 5:415:41 2929 0:110:11 3131 5/31/115/31/11 9:419:41 3232 0:180:18

Histogram of Inspection Times Histogram of Inspection Times

(Previous System)(Previous System)

Probability PlotProbability Plot

Statistical SummaryStatistical Summary

Histogram of Number of Histogram of Number of

Inspection (previous)Inspection (previous)

Probability PlotProbability Plot

Statistical Summary (Previous Statistical Summary (Previous

System)System)

Proposed Solution by ASC QualityProposed Solution by ASC Quality

•• Implementation of ExpeditorImplementation of Expeditor

1.1.A Designated Document Control A Designated Document Control representative will be designated to expedite representative will be designated to expedite inspection documentation, tools, returning inspection documentation, tools, returning inspection records to document control and inspection records to document control and obtaining disposition on any inspection obtaining disposition on any inspection related nonrelated non--conformances.conformances.

2.2.Reduce the time spent by 3 QC Inspectors in Reduce the time spent by 3 QC Inspectors in preparing/completing inspections.preparing/completing inspections.

Map of Map of ASCASC’’ss Proposed SolutionProposed Solution

ASCASC’’ss GoalsGoals

•• AchievementsAchievements

–– Increased the number of inspectionsIncreased the number of inspections

–– Improvement of Inspection Request response, Improvement of Inspection Request response,

resulting in an increase of production resulting in an increase of production

efficiency.efficiency.

Current Inspection Flow DataCurrent Inspection Flow DataDayDay DateDate TimeTime # # InspInsp Time/ Time/ InspInsp DayDay DateDate TimeTime # # InspInsp Time/ Time/ InspInsp

2727 9/2/119/2/11 20:4020:40 5353 0:230:23

11 8/1/118/1/11 19:1219:12 5959 0:190:19 2828 9/6/119/6/11 8:128:12 8383 0:230:23

22 8/2/118/2/11 21:0921:09 6767 0:180:18 2929 9/7/119/7/11 12:3712:37 6262 0:120:12

33 8/3/118/3/11 15:1115:11 4848 0:180:18 3030 9/8/119/8/11 20:5220:52 5757 0:210:21

44 8/4/118/4/11 20:0020:00 6161 0:430:43 3131 9/9/119/9/11 1:431:43 8585 0:180:18

55 8/5/118/5/11 8:148:14 2929 0:170:17 3232 9/12/119/12/11 19:2519:25 6161 0:190:19

66 8/8/118/8/11 12:3412:34 4848 0:150:15 3333 9/13/119/13/11 23:0223:02 7676 0:180:18

77 8/9/118/9/11 17:2317:23 3333 0:310:31 3434 9/14/119/14/11 6:216:21 9898 0:180:18

88 8/10/118/10/11 8:548:54 4545 0:110:11 3535 9/15/119/15/11 20:1120:11 5454 0:220:22

99 8/10/118/10/11 8:548:54 4545 0:110:11 3636 9/16/119/16/11 3:193:19 8282 0:190:19

1010 8/11/118/11/11 9:099:09 4141 0:130:13 3737 9/19/119/19/11 6:116:11 9494 0:190:19

1111 8/12/118/12/11 11:3411:34 3030 0:230:23 3838 9/20/119/20/11 13:3313:33 8181 0:270:27

1212 8/15/118/15/11 11:2011:20 3131 0:210:21 3939 9/21/119/21/11 21:1121:11 7474 0:170:17

1313 8/16/118/16/11 7:457:45 3232 0:140:14 4040 9/22/119/22/11 23:0223:02 8484 0:160:16

1414 8/17/118/17/11 10:1310:13 2424 0:250:25 4141 9/23/119/23/11 0:030:03 8282 0:170:17

1515 8/18/118/18/11 7:007:00 2929 0:140:14 4242 9/26/119/26/11 19:3619:36 9191 0:280:28

1616 8/19/118/19/11 5:535:53 3030 0:110:11 4343 9/27/119/27/11 12:5512:55 112112 0:190:19

1717 8/22/118/22/11 18:1718:17 7474 0:140:14 4444 9/28/119/28/11 9:429:42 9393 0:210:21

1818 8/23/118/23/11 0:060:06 8383 0:340:34 4545 9/29/119/29/11 13:0413:04 6767 0:330:33

1919 8/23/118/23/11 0:060:06 8383 0:340:34 4646 10/3/1110/3/11 4:534:53 9090 0:190:19

2020 8/24/118/24/11 16:0716:07 5050 0:190:19 4747 10/4/1110/4/11 23:2723:27 8181 0:170:17

2121 8/25/118/25/11 7:457:45 8787 0:210:21 4848 10/5/1110/5/11 21:1821:18 7676 0:160:16

2222 8/26/118/26/11 10:0810:08 6666 0:310:31 4949 10/6/1110/6/11 5:355:35 9595 0:180:18

2323 8/29/118/29/11 15:5315:53 4040 0:230:23 5050 10/10/1110/10/11 4:234:23 8787 0:190:19

2424 8/30/118/30/11 7:557:55 9191 0:210:21 5151 10/7/1110/7/11 4:034:03 7979 0:210:21

2525 8/31/118/31/11 21:1721:17 6666 0:190:19 5252 10/11/1110/11/11 14:3714:37 8080 0:280:28

2626 9/1/119/1/11 1:571:57 7878 0:190:19 5353 10/12/1110/12/11 8:558:55 2222 0:240:24

Histogram of Inspection Times Histogram of Inspection Times

(New System)(New System)

Probability PlotProbability Plot

Statistical SummaryStatistical Summary

Histogram of Inspection Per Day Histogram of Inspection Per Day

(New System)(New System)

Probability PlotProbability Plot

Statistical SummaryStatistical Summary

Hypothesis TestingHypothesis TestingTwo-sample T for Time/Inspection vs Time/Inspection(New)

N Mean StDev SE Mean

Time/Insp 31 20.26 7.00 1.3

Time/Inspection(New) 53 21.13 6.43 0.88

Difference = mu (Time/Insp) - mu (Time/Inspection(New))

Estimate for difference: -0.87

95% CI for difference: (-3.95, 2.20)

T-Test of difference = 0 (vs not =): T-Value = -0.57 P-Value = 0.572 DF = 58

Conclusion:

Demonstrating T-test, could not give us enough evidence to reject the null

hypothesis, so we can not say that base on this # the process has improved;

Specially since the confidence interval covers 0 value.

Hypothesis TestingHypothesis TestingTwo-Sample T-Test and CI: No. Insp, No. Inspection(New)

N Mean StDev SE Mean

No. Insp 31 37.48 7.99 1.4

No. Inspection(New) 53 65.5 23.1 3.2

Difference = mu (No. Insp) - mu (No. Inspection(New))

Estimate for difference: -27.97

95% CI for difference: (-34.90, -21.04)

T-Test of difference = 0 (vs not =): T-Value = -8.05 P-Value = 0.000 DF = 70

Conclusion:

This T-Test actually confirms that the change we have made to the process

has improved the outcome of the system which means number of inspection

per day has increased .

Regression Analysis: Regression Analysis:

Time/Time/Inspection(NewInspection(New) versus No. ) versus No.

Inspection(NewInspection(New) ) The regression equation is:

Time/Inspection(New) = 19.0 + 0.0330 No. Inspection(New)Predictor Coef SE Coef T P

Constant 18.973 2.690 7.05 0.000

No. Inspection(New) 0.03297 0.038 0.85 0.400

S = 6.45089 R-Sq = 1.4% R-Sq(adj) = 0.0%

Thank YouThank You

Questions?