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Statapult Exercise

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Group Activity

Launch #1Using what you are given, baseline

the process for shooting the statapult.

Remember: Customer desires a rapid-fire, precise, and accurate launcher that can launch projectiles over mountain ranges.

333

LaunchSequence Distance

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Statapult Instructions Launch #1

Every shot will be launched from a pull back angle of 177/65 degrees.

Each person on the team will perform an equitable number of launches (or as close as possible).

"Launching” means pulling back and releasing.

Time between each shot cannot exceed 15 seconds.

Record the distances on the table to the left.

Record the longest distance (Max) and the shortest distance (Min) and compute Range = Max - Min.

Range = ______________

Objective: To fire the statapult and record the distance for each of the launches. The measured distance will be from the back of the launcher to the point where the ball first lands. Record the distances in the order in which they were obtained.

444

Statapult Launch #1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Launch Sequence

Distance

See graphing.pdfVI-19

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Short term data is considered free of assignable causes◦ One shift, one operator

Long term data is considered to contain both assignable and common caused variation◦ Multiple shifts, multiple operators

Processestend to exhibit more variation in the long term than the short

Sigma Values

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Levels of MapsMaps can be created for many different levels of the process. Just like highway maps…

You can use a map of the USA…or if you need more detail, a map of the state...or if you need more detail, a map of the city.

Mapping works much the same way. Depending on the detail you need, create the map at that level. If you need more detail, then create a more detailed map of the sub-process.

High Level

Detail

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Skin/Core Assembly

Upper Skin Assembly

Spar Assembly

Misc Details

65VLay-up

6A3Cure

Press L, M, or N

6A3Clean Tool

6P4Band SawHenri Line

6PAMech Assy

6PABond ClosuresBond Details

65QTap and Ziess

Post Bond

Closures

Misc Details

6PBClean Part

6P4Devlieg

Lay-up and Cure Clean and Inspect

65VTest Heater

Balnket

65QInspect

6PABond Details

65QInspect

6PAFill A/STRP

Electrical Assy

6PBLeak Test

6P8Paint

6PGStatic Balance

6PAElectrical Assy

Mech Assy

6PGTouch-up Paint

65QFinal Inspect

Fairings

6PA GatherComponents

Process Flow Diagram◦ Used to identify the steps in a

process◦ Good for process documentation

and knowledge gathering◦ May be used in definition, detail

design, analysis and control portions of a project

High Level Process Map

Visually sets the process steps in

order

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To provide a graphical representation of the process with regards to ◦ the people involved, ◦ their responsibilities, ◦ functional interfaces and dependencies,◦ as well as process steps over time where

necessary.

Critical tool for transactional processes and when mapping information flow for industrial processes

Segregates steps by who does them or where they are done

Makes handoffs visible

Swim Lane (Functional or Deployment Maps)

A Swim Lane is a process flow diagram with resource responsibilities

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Functional or Deployment Flow Diagram

Business Unit

I.T.

Finance

Top Mgt/ Corporate

Define needs

Prepare paperwork

Review &

approve

Review & approve standard

Review &

approve

Review &

approve

Acquire equipment

Supplier

Configure & install

Receive & use

Issue payment

Supplier

Sourcing

Process Steps

Resources Responsible for Process Steps

Graphical summary or roles & responsibilities for a process

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Process Flow ChartObjective: Develop a process flow diagram that explains the current process of how to launch a ball.

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SIPOC

Input Output

Supplier Customer

SIPOC is a process scoping tool that provides a high level definition of a process –

SIPOC should be used on all Six Sigma projects

Suppliers Inputs Process Outputs Customers

(Providers of the required resources)

(Resources required by the process)

(Process require-ments for the Inputs)

(Top level description of activity)

(Deliverables from the process)

(CustomerRequire-ments of the Outputs)

(Anyone who

receives a deliverable

from the process)

Process

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SIPOC – The Process Steps

Process CustomersRequirements Requirements

Brg suppliers, D/S Structures Brg data, shaft dia

Shaft dia, life, brg capacity, TRL's, cost, wt, reliability

Assess brg choices and select

brg selection or new bearing design brg spec Brg supplier

Shaft suppliers

Shaft mat'l characteristics, cost, special handling and machining reqm'ts

strength, buckling stability, fatigue life, dyn tuning, cost, wt, repairability, thermal compatibility with T/B

Assess shaft mat'l choices and select Shaft material selection

Special handling reqm'ts Manufacturing

" Cost, repairability Product support

Shaft suppliersShaft length availability, cost

cost, wt, tuning, handling, shaft length availability

Select one vs two piece shaft handling, shipping Product support

VOC, Product SupportAcceptability of long shaft handling, stocking, cost

"

Shaft suppliers Shaft mat'l characteristics, cost

Static strength, torsional buckling, stiffness and wt for dyn tuning, overall wt, cost, impact on sizing of bearing and end fittings

Size shaft Shaft sizing Shaft sizing D/S Design

Shaft size, plus existing data on damper sizing

Sizing as previously tested, fatigue strength, stiffness, clearances for shaft motion, compact design

Sizing as previously tested, fatigue strength, stiffness, clearances for shaft motion, compact design

Layout damper damper design drawing, build-to-print PO

Lord Corp

Fatigue, D/S StructuresStructural allowables and fastening options. New test data as req'd.

Strength, ease of assembly and installation

Design end fittings End fitting design dwgs End fitting design dwgs Manufacturing

Fatigue, D/S StructuresStruct allowables and detail sizing

Strength, compact design, bearing retention

Design bearing housing and damper attachments

Brg housing dwgs Brg housing dwgs Manufacturing

Fatigue, D/S StructuresStruct allowables and detail sizing

Ease of assembly, heat dissipation, compact sizing

Design shaft sleeve for bearing mount Sleeve design

Sleeve design with ease of assembly Manufacturing

Fatigue, D/S Structures Struct allowables and detail sizing

Shaft clearance for run-up motion, no shaft damage when sleeve and snubber contact

Design snubber and sleeve assembly

Snubber and sleeve dwgs

Ease of assembly Manufacturing

D/S Dynamics, D/S Design, Propulsion Design (oil cooler responsibility)

Natural freqs and mode shapes, allowable mods to oil cooler blower

Dynamic tuning, structural mods req'd to T/B struct., attachment options to oil cooler blower

Determine damper placement and forward attachment location

Best geometry for damper placement and forward end

Best geometry for damper placement and forward end

D/S Design

D/S Dynamics, D/S Design, Propulsion Design (oil cooler responsibility)

Natural freqs and mode shapes, allowable mods to oil cooler blower

Lightest overall wt, oil cooler attachment possibilities, minimize number of bearings, overall cost impact

Determine options for attachment of forward end of shaft

Best forward attachment concept

Best forward attachment concept D/S Design

D/S Design, Airframe Structures, A/F Design

Prefered placements of damper and snubber supports, T/B stiffness, T/B deflections

Damper placement requirements, tailboom strength and stiffness

Determine impact to T/B structure & design the mods

Dwgs of T/B mods Dwgs of T/B mods Manufacturing

Suppliers Inputs Outputs

Suppliers Inputs Process Outputs Customers

(Providers of the required resources)

(Resources required by the process)

Process Requirements for the Inputs

( Top level description of activity)

(Deliverables from the process)

Customer’s Requirements of the Outputs

(Anyone who

receives a deliverable

from the process)

1What is the process?

4Who is the customer of each output?

5What does

each customer

expect from each output?

8What does

the process expect

from each input?

6What

Inputs are required to enable this process to

occur?

7Who is the supplier of

each input?

3What are

the outputs from the

process?

2When does the process end?

Boundary

2When does theProcess start?

Boundary

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Group Exercise - SIPOCINPUTS OUTPUTSPROCESS

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Create a relationship matrix for the previous SIPOC

Relationship Matrix

*Input/Output relationships can be rated as:

Strong: 9Moderate: 3

Weak: 1Nonexistent: Blank or 0

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Basic Structure – C&E Diagram(Fishbone)

Project Y

Inputs (X’s) Output (Y)

Level 1 Cause

Level 2 Cause

Main CategoryMeasurementsMaterials People

EnvironmentMethods Machines

C = Control Factor (controllable)N = Noise factor (out of our control)X = Experimental variable

C

N

X

N

C

N

X

C

C

By identifying the correct inputs, you can achieve optimal results in the shortest time.

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Cause & Effect C/N/X’s

C = those variables which must be held constant and require standard operating procedures to insure consistency. Consider the following examples: the method used to enter information on a billing form, the method used to load material in a milling or drilling process, the autoclave temperature setting.

N = those variables which are noise or uncontrolled variables and cannot be cheaply or easily held constant. Examples are room temperature or humidity.

X = those variables considered to be key process (or experimental) variables to be tested in order to determine what effect each has on the outputs and what their optimal settings should be to achieve customer-desired performance.

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METHOD

MOTHERNATUREMEASUREMENT

MANPOWER MACHINE

MATERIAL

Cause and Effect Diagram Objective: Develop a C&E diagram that explains the variability of the launching process. Label as C/N/X.

VIII-13317

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In groups Conduct a process FMEA for “shooting the

statapult” Generate Risk Priority Numbers and

develop controls that will minimize risk

FMEA

Product or

ProcessFailure Mode Failure Effects SEV Causes OCC Controls DET RPN Actions Plans PS PO PD prpn

                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                

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SOPObjective: Develop a SOP that accurately defines each controlled step of the improved launching process.

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LaunchSequence Distance

123456789

10111213141516171819202122232425

Statapult Instructions Launch #2

Every shot will be launched from a pull back angle of 177/65 degrees.

Each person on the team will perform an equitable number of launches (or as close as possible).

"Launching” means pulling back and releasing.

Time between each shot cannot exceed 15 seconds.

Record the distances on the table to the left.

Record the longest distance (Max) and the shortest distance (Min) and compute Range = Max - Min.

Range = ______________

Objective: To fire the statapult and record the distance for each of the launches. The measured distance will be from the back of the launcher to the point where the ball first lands. Record the distances in the order in which they were obtained.

212121

Statapult Launch #2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Launch Sequence

Distance

See graphing.pdfVI-19

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Concentration Chart

www.duetsblog.com/uploads/image/AT&T.jpg

http://www.qualitytrainingportal.com/resources/problem_solving/problem-solving_tools-concentration_diagrams.htm

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Measures of Variation

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Data is collected using samples because the entire population may not be known or it may be too costly to measure.◦ Population is every possible item◦ Sample is a subset of the population

Population vs. Sample

X

µ

Sample

Population

Population

Sample

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Step #1 Add the data points and divide by the number of data point to determine the mean (average)

Step #2 Subtract the mean from each individual data point and square the result (data point – Mean)2

Step #3 Add together all the squared data points

Step #4 Divide the total of the squared data points by n-1 if a sample, or n if a population (n= number of data points)

Step #5 Calculate the square root of the sum of step #4.

The result is the standard deviation for the process.

Calculating Standard Deviation

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Launch #1

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Launch #2

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Graphical View of Variation and Six Sigma Performance

Each unit of measure is a numerical value on a continuous scale

Size Size Size Size

Pieces vary from each other

Variation common and special causes

But they form a pattern that, if stable, is called a normal distribution

Histogram or

Frequency Distribution

Normal Distribution

VII-31

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Normal DistributionThere are three terms used to

describe distributions

3. Location Mean

1. ShapeBell

2. Spread

Standard

Deviation

VII-31

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Correlation vs. Causation

313131

Scatter Diagram Example:

Dis

tanc

e

Angle

Angle Distance

VII-16

Y=f(x)

323232

Histogram examplesWhat speculations can you make about the following processes

based on the histograms?

LSL USL 10 9 X 8 X 7 X 6 X 5 X 4 X X 3 X X X 2 X X X X 1 X X X X X

.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507

1.

LSL USL 10 9 X 8 X 7 X X X X 6 X X X X 5 X X X X 4 X X X X X X X 3 X X X X X X X X X X 2 X X X X X X X X X X X X X X X 1 X X X X X X X X X X X X X X X

.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507

2.

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Histogram examples

LSL USL 10 9 X 8 X 7 X 6 X 5 X X X 4 X X X 3 X X X 2 X X X X X 1 X X X X X X X

.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507

3.

LSL USL 10 X 9 X 8 X 7 X X X 6 X X X X 5 X X X X X 4 X X X X X 3 X X X X X X X 2 X X X X X X X X 1 X X X X X X X X

.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507

4.

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Instructions◦ Refer to Launch #1 and #2 and convert the run

charts shown on these pages to histograms, using 4-inch intervals as the class width.

◦ The student may then choose the 12-inch range (3 consecutive 4-inch intervals) centered around the average to be the specification range.

◦ Draw those spec limits on the histogram and complete the following table:

Computing Cost Of Poor Quality

Launch #1

Launch #2

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Calculate our statistics

The HeightExample

Inches? Inches?

Hey buddy...whatchagot in the case?

Step 1Collect

Data

Heights Dev. from Avgerage.

Total

Xbar(average) »Sigma!!

Let’s practice

Find:

MeanMedianModeRangeSigma -population -sample

5’ = 60”6’ = 72”

363636

Plot height data and use the statistics

Step 2Create a

Histogram

Xbar =

Scale - (Use 2"increments)

Sigma Area % Height Span Realistic? (Y/N)+/- 1 Sigma+/- 2 Sigma+/- 3 Sigma+/- 6 Sigma

Step 3Add Sigma

Limits

Step 4Analyze