Prepared by: Gary J. Ainsworth - UMass Lowell...
Transcript of Prepared by: Gary J. Ainsworth - UMass Lowell...
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Preparedby:GaryJ.AinsworthPrincipalConsultantArcCompleta,Inc.
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Dr.ErikN.Schlosser,PhD
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
BecauseoftheStart-UpChallengeTheclockisticking– Start-upsareinaconstantnon-profitablecashburnscenarioNoprecedenceinknowingwhatmightbeimportantorwhathasthehighestrisk
LiteratureSearchandBasicResearcharethenormsLoworNoProductionVolumestogainunderstandingofcriticalrequirements
EveryBuildCountstocreateacollectiveknowledgebase,butinfrastructureisoftenabsentandunablecollectcriticalknowledgeSimultaneousKnowledgeAccumulationinproductandprocessdevelopment,test,andmanufacturing
Inexperiencedmanagementteam,needingtofocuslimitedresourceswithstrongpersonalitiesPoorcommunityhabits,includinginconsistentcommunicationofdirectionandpriorityGreatinnovatorsarenotnecessarilygreatorganizersandmanagersInvestorsneedconcise,quantitative messagingonresultsandcommittedworkagainstmilestones
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
prob·lem/ˈpräbləm/
NounAmatterorsituationregardedasunwelcomeorharmfulandneedingtobedealtwithandovercome.
Athingdifficulttoachieveoraccomplish.
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
BeabletocometoanagreementthatthereisaproblemBeabletowriteaproblemstatementDeterminehowtomeasuretheproblem,asdefinedbytheproblemstatementStatethedesiredoutcomeindicatingtheproblemhasbeensolvedAchieveabasicunderstandingofmeasurementerror’scontributiontoconfoundinginterpretationofexperimentalresponsesandoutcomes
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Problemshave:a Beginninga MiddleandanEnd
BeginningProblem
Identification and Statement
Middle
End
Problem Solving, Inputs & Outcomes
Measurement
Solution and Control
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
TeamMembersdonotrespecttheproblem:FailtodetermineandagreeonnatureofaproblembyalwaysinsistingtheanswerisobviousDon’tlistentocustomers(internalandexternal)aboutthenatureoftheproblemWastetimeandresourcesbyjumpingaheadto“thesolution”withoutobjectivemeasurementofsuccess
Iftheproblem’ssolutionwaseasy,itwouldhavebeensolvedTakeastepbacktoseewhoistalkingaboutaproblem,whileobservingtheresourcesandsalariesintheroomTheproblemislikelycostingandhasalreadycostthecompanysignificantmoney
Answerthequestion:Whyareweinbusiness?
Toidentify,describe,define,andobjectivelymeasureoutcomesasfastaspossible
Tofollowthroughandlearnfromoutcomes
Tosustainachievedimprovements
Toincreasestability,allowingusbuildoncontinualimprovement
Innovationinbusinessrequiresustobuildafoundationofknowledge!
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
AProblemDefinitionandStatementAlimitedandquantifiablestatementofaconditionthatisundesirableorresultsinnegativeexternality
ScopeTheproblemstatementshouldaddresstheconditionofinterestThestatementshouldframethecurrentconditionorbehaviors,whilecontrastingthedesiredoutcome
AgreementThecustomerwhoisexperiencingtheproblemandreceivingtheproblemsolvingservicesshouldapprovethestatementAlso,thereshouldbeagreementontheasuccessfuldesiredoutcomeandthedirectmeansofmeasurement,thatifmet,theoutcomewillSOLVEtheproblem
CommunicationtoCustomerandTeamMembersExperiencedProblemsSolverLeadssometimedon’tgetbeyondProblemDefinitionandStatementbeforesomeonepreviouslyleftoutofthecommunicationloopsexplains:
“…ohthat,that’sbeenhappeningforyearsbecausewefailedto…”
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Bad: PrintHeadHeateruniformityiscausingprintinginconsistency
Good:Frommechanical,electronic,andfluidictoleranceanalysis,theprintheadendtoenduniformitymustbevarynomorethan+/-1°Cduringoperation
Bad: Chip’sSiliconDioxide/SiliconNitrideboundariesalwaysfailduringdeviceburn-in
Good:TheSiliconDioxide/SiliconNitridemustbeabletosurvivewithoutdegradationfora50%longerdurationatthespecifieddirectcurrent,duringinitialburn-in
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Bad: CompanyAhastoomanytransactionsontheproductionfloor
Good:Transactionsinlowcycletimeworkareasarecollectingupto30%oftheirtotalcyclebasedondatainputdelays,impactingOnTimeShipping
Bad: Wecan’tmeasureweldedtubes…Good:Measuringweldedtubeconcentricityisatimeconsuming
process,requiringupto5-7minutesperpart,whichis60%ofthetotaltimerequired
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
UsingQualitativeLanguageinaQuantitativeWorldUsedirect,repeatablemeasurementsystems,withsufficientresolutionEventhoughtheteammaynothaveadirectmeasurement,thereareoften“indicative”measurementsthatarehintingthere’saproblemUseanindicativemeasurementuntiladirectmeasurementisestablishedForsometypesofproblems,indicativemeasurementisthebestwaytotrackperformance
OverallDeviceTestYield,ThinFilmUniformityasa%,TrainingEfficacyinTermsofCycleTime,VisualDefectsReductionbyvisualrankordercorrelationtoparametricinputs
ScopeCreepIfuponstudyingaproblem,thescopestartstocreepintootherrelatedareas,theteammayhavetodeclareithascompoundingproblems
Prioritizethemosthighestimpactcandidate,andparkthesubordinate(s)forlaterconsideration
ExecutingthiskindofdecisionsplitiscriticaltomaintainfocusBettertosolveONEdefinedproblemanddraintheswampabit,thantowasteresourcesonanimpossiblybroadscope
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Refusingtousethe“BigBrain”AccountableproblemsolvingteamsshouldneverexceedatotalofthreetofourassignedpeopleButthecommunicationoftheproblem’sdefinitionandclues,experiments,andinterimresultsshouldbesharedbroadly,welcomingotherstakeholderstothinkabouttheproblemandpossiblesolutionsProgressandcontentshouldbestoredinacommonnotebookandifneededonaserverRegularupdatesshouldbeformalizedperiodicallyexplainingstatus,progress,andusageofcompanyresourcesAskforhelpwhenstalled;sometimesafreshsetofbrainsandeyeswillseesomethingwhenyou’retiredandsaturated
Everyprocessorpieceofcapitalequipmentrequiresasuitabledirectquantitativemetrologysystem forequipmentacceptancefromtheequipmentsupplier,outcomemeasurement,andprocesscontrol
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Hi-Temp Stainless Steel
Nickel Super Alloy
Welded and Machined To Final Outer Diameter
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Problemshave:a Beginninga MiddleandanEnd
BeginningProblem
Identification and Statement
Middle
End
Problem Solving, Inputs & Outcomes
Measurement
Solution and Control
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
Doesyourcompanyneedabasicfoundationforsuccess?
December8,Noonto1p.m.-MovingfromTacticaltoStrategicPlanning
If so, The UMass Lowell Enlightened Bites Entrepreneurship Series presents the final part of this breakthrough series
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
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
Arc Completa, Inc. Ó 2016 - Not to be Used Without Permission
a rc c o mp le ta
ThiscontentisakeyandimportantsubsetofmethodsthatI’veappliedtotechnicalproblemsolvinginR&D,ProductDevelopment,ManufacturingandTestProcessDevelopment,andSupplyChainCertificationandQualificationMymethodsarederivedfromtraditionalstatisticalprocesscontrol(SPC),DesignofExperiments(DOE),advancestatisticalcorrelationmethodsofmultiplemetrologysystems,andpracticalconsiderationsinthemigrationofearlydevelopmentmetrologytoproductionusageThetheoryandpracticeisheavilyinfluencedbyShaininStatisticalEngineeringÓmethodsShaininalwaysstatesthatdevelopingacorrectlysizedandstatedproblemdefinitionstatementandhavingconfidenceinameasurementsystemtodiscriminatebetweenBetter(improved)vs.Current(thecontrol)isthehardestpartofsolvingproblems