Teaching Six Sigma Quality with R

Teaching 6σ Using R

09/02/2011

Emilio L. Cano

Six SigmaMethodology

Introduction

Six Sigma with R

Six Sigma Software

R Advantages

R Packages for Six Sigma

Teaching Resources

The Book

The package

Assessment Tools

Teaching Six Sigma Qualitywith R

Emilio L. Cano, Javier M. Moguerza andAndres Redchuk

Department of Statistics and Operations ResearchUniversity Rey Juan Carlos (Madrid)

Obuda University, Budapest, February 2012

1st International Workshop on Teaching Decision Sciences and Technologies 1/33

http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Outline

1 Six Sigma MethodologyIntroduction

2 Six Sigma with RSix Sigma SoftwareR AdvantagesR Packages for Six Sigma

3 Teaching ResourcesThe BookThe packageAssessment Tools


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Outline





http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

The BasicsQuality

Classical approachThe Key Characteristic of aproduct/service/processmust be inside thespecification limits

Six Sigma approachThe Key Characteristicapproximate the target,with as less variation aspossible.

Observed value of the characteristicC

ost o

f Poo

r Q

ualit

y

TLSL USL


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Why 6 and why SigmaThe Basics

Sigma refers to the Z-Score of the process:

Z = min

{(USL− x)

σ,

(x − LSL)

σ

};ZLT = ZST−1.5.

CTQ

Fre

quen

cy

Short TermLong Term

1.5σ 4.5σ

> (1-pnorm(4.5))*(10^6)

[1] 3.397673

DPMO


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

The Scientific Method & SixSigma

DefineAsk a question

Measure

Analyze

Improve

Control

Do some backgroundresearch

Construct a hypothesis

Test the hypothesiswith an experiment

Analyze the data and draw conclusions

Communicate results

DMAIC Cycle Scientific Method


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Outline





http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Commercial SoftwareState-of-the-art

ProgramsMinitab

SPSS

StatGraphics

JMP & SAS

Any statisticalsoftware, or evenspreadsheets


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Commercial SoftwareTrends

InternetSoftware as aService

WebApplications

Everywhere

Every display

Open

TechnologiesLinux

OpenOffice

R

. . .


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

IntroductionR Project

A system for statistical computing andgraphingMassively used for academic and researchpurposes, important Companies use R:Google, Pfizer, . . .Ross Ihaka and Robert Gentleman,following the work at Bell Laboratorieswith the S Language


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Free TechnologyR Project

Open Source

Freely available

Platform independent

Huge communitygiving support


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

PackagesR Project

http://cran.r-project.org

3115 Contributed Packages (04/07/2011)

3586 (05/02/2012)

Task views

Manuals

Publications


http://www.urjc.es

http://cran.r-project.org


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

R for TeachingAdvantages

Portable (e.g. for labs)

Documentation

Reproducible research

Learn by code

Teacher’s packages

Assignment capabilities


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Packages for Six SigmaOther authors

Specific

qcc quality control charts

IQCC quality control charts

qualityTools Tools for the DMAIC cycle

qAnalyst Control charts and capability analysis

Graphics

lattice Multivariate

ggplot2 Grammar of graphics

plotrix Varied charts


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Packages for Six SigmaOther authors

Specific

qcc quality control charts

IQCC quality control charts

qualityTools Tools for the DMAIC cycle

qAnalyst Control charts and capability analysis

Graphics

lattice Multivariate

ggplot2 Grammar of graphics

plotrix Varied charts1st International Workshop on Teaching Decision Sciences and Technologies 14/33

http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Outline





http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

The BookSix Sigma with R

FeaturesTitle:Six Sigma with R

Due June 2012

Wide backgroundscope

Examples, a CaseStudy andpractices


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

R: SixSigma PackageFocus in Applications

Version History1 0.2.1 April 2011

2 . . .

3 0.5.0 Jan 2012(current)

Datass.data.rr, ss.data.ca,ss.data.bolts,ss.data.pastries.

Functionsss.pMap

ss.ceDiag

ss.rr

ss.ci

ss.study.ca

ss.ca.yield

ss.ca.z

ss.ca.cp

ss.ca.cpk

ss.heli

ss.lf

ss.lfa


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

HelicopterTraining Stuff

Template in pdf format to build paperhelicopter prototypes (?)

> ss.heli()

null device

1

> #vignette("HelicopterInstructions") for instructions


http://www.urjc.es

Six Sigma with R | Paper Helicopter template

cut

fold ↑ fold ↓tape?

cut

fold

↓↓

cut

fold

↑↑

cutta

pe?

tape

?

clip?

min

(6.5cm)

std

(8cm)

max

(9.5cm)

← b

ody

leng

th →

← body width →min

(4cm)

min

(4cm)

max

(6cm)

max

(6cm)

min

(6.5cm)

std

(8cm)

max

(9.5cm)

← w

ings

leng

th →


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

DiagramsSixSigma Package

Cause-and-effect Diagram

> example(ss.ceDiag)

ss.cDg> #Data

ss.cDg> effect<-"Flight Time"

ss.cDg> causes.gr<-c("Operator", "Environment", "Tools", "Design",

ss.cDg+ "Raw.Material","Measure.Tool")

ss.cDg> causes<-vector(mode="list", length=length(causes.gr))

ss.cDg> causes[1]<-list(c("operator #1", "operator #2", "operator #3"))

ss.cDg> causes[2]<-list(c("height", "cleaning"))

ss.cDg> causes[3]<-list(c("scissors", "tape"))

ss.cDg> causes[4]<-list(c("rotor.length", "rotor.width2", "paperclip"))

ss.cDg> causes[5]<-list(c("thickness", "marks"))

ss.cDg> causes[6]<-list(c("calibrate", "model"))

ss.cDg> ss.ceDiag(effect, causes.gr, causes, sub="Paper Helicopter Project")


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Cause-and-Effect DiagramSixSigma Package

Six Sigma Cause−and−effect Diagram

Paper Helicopter Project

Flight Time

Operatoroperator #1

operator #2operator #3

Environmentheight

cleaning

Toolsscissors

tape

Design

rotor.lengthrotor.width2

paperclip

Raw.Material

thicknessmarks

Measure.Tool

calibratemodel


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

DiagramsSixSigma Package

Process Map

> example(ss.pMap)

ss.pMp> inputs.overall<-c("operators", "tools", "raw material", "facilities")

ss.pMp> outputs.overall<-c("helicopter")

ss.pMp> procs<-c("INSPECTION", "ASSEMBLY", "TEST", "LABELING")

ss.pMp> input.output<-vector(mode="list",length=length(procs))

ss.pMp> input.output[1]<-list(c("sheets", "..."))

. . .

ss.pMp> x.parameters<-vector(mode="list",length=length(procs))

ss.pMp> x.parameters[1]<-list(c(list(c("width", "NC")),list(c("operator", "C")),

ss.pMp+ list(c("Measure pattern", "P")), list(c("discard", "P"))))

. . .

ss.pMp> y.features<-vector(mode="list",length=length(procs))

ss.pMp> y.features[1]<-list(c(list(c("ok", "Cr"))))

. . .

ss.pMp> ss.pMap(procs, inputs.overall, outputs.overall,

ss.pMp+ input.output, x.parameters, y.features,

ss.pMp+ sub="Paper Helicopter Project")


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Process Map DiagramSixSigma Package

Six Sigma Process Map

Paper Helicopter Project

INPUTSX

operators tools raw material facilities

INSPECTIONIN

PU

TS

sheets...

Param.(x): width NCoperator CMeasure pattern Pdiscard P

Featur.(y): ok

ASSEMBLY

INP

UT

S

sheets

Param.(x): operator Ccut Pfix Protor.width Crotor.length Cpaperclip Ctape C

Featur.(y): weight

TEST

INP

UT

S

helicopter

Param.(x): operator Cthrow Pdiscard Penvironment N

Featur.(y): time

LABELING

INP

UT

S

helicopter

Param.(x): operator Clabel P

Featur.(y): label

OUTPUTSY

helicopter LEGEND(C)ontrollable(Cr)itical(N)oise(P)rocedure


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Gage R&R StudyMeasurement System Analysis

> #... Some theme instructions

> ss.rr(time1, prototype, operator,

+ data=ss.data.rr, sub="Helicopter Project")

Analysis of Variance Table

Response: var

Df Sum Sq Mean Sq F value Pr(>F)

part 2 1.20072 0.60036 28.0396 2.952e-06

appr 2 0.05294 0.02647 1.2363 0.3140

part:appr 4 0.08339 0.02085 0.9737 0.4462

Repeatability 18 0.38540 0.02141

VarComp %Contrib

Total Gage R&R 0.0220358 25.50

Repeatability 0.0214111 24.77

Reproducibility 0.0006247 0.72

appr 0.0006247 0.72

part:appr 0.0000000 0.00

Part-To-Part 0.0643901 74.50

Total Variation 0.0864259 100.00

. . .


http://www.urjc.es

Six Sigma Gage R&R Study

Helicopter Project

Components of Variation

Pe

rce

nt

0

20

40

60

80

G.R&R Repeat Reprod Part2Part

%Contribution %Study Var

Var by Part

var

1.0

1.2

1.4

1.6

1.8

prot #1 prot #2 prot #3

●

●

●●●

●

●

●

●

●●●

●

●

●

●●

●

●

●

●

●

●●

●

●

●

Var by appraiser

var

1.0

1.2

1.4

1.6

1.8

op #1 op #2 op #3

●

●

●●●

●

●

●

●

●●●●

●

●

●●

●

●

●

●

●

●●

●

●

●

Part*appraiser Interactionva

r

1.1

1.2

1.3

1.4

1.5

1.6

1.7


●●

●

●

●

●

●

●

●

op #1op #2

op #3

x Chart by appraiser

part

var

1.1

1.2

1.3

1.4

1.5

1.6

1.7


●●

●

op #1


●

●

●

op #2


●

●

●

op #3

R Chart by appraiser

part

var

0.1

0.2

0.3

0.4

0.5


●

●

●

op #1


●

●

●

op #2


●

●

●

op #3


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Further DevelopmentOn the Way

Functions for a wide range of tools alongall the DMAIC phases.

Improved graphics

Tackle Further methodologies (DFSS,Lean, . . . )

Non-normal / Non-linear methods

Bayesian perspective

Maybe a GUI


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Further ProjectsPlatform

Open Platform for Quality

MethodologiesImproving the European Factory (link)

FP7 PPP Funding Scheme

Proposal submitted

The project will also benefit teaching


http://www.urjc.es

http://cordis.europa.eu/partners/web/req-1202


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Package examsTeaching with R

Automatic generation of exams

Customized assignements

Solutions document

http://cran.r-project.org/web/

packages/exams/


http://www.urjc.es

http://cran.r-project.org/web/packages/exams/

http://cran.r-project.org/web/packages/exams/


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Package RGIFTTeaching with R

Open format GIFT

Integration with Moodle

Automatic correction

http://cran.r-project.org/web/

packages/RGIFT/


http://www.urjc.es

http://cran.r-project.org/web/packages/RGIFT/

http://cran.r-project.org/web/packages/RGIFT/


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Generating DocumentationTeaching with R

Sweave: R + LATEX

Literate programming

Reproducible research

Merge materials into different formats:presentations, lecture notes, assignments.

Extended packages: pgfSweave andknitr


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Summary

R is becoming a real alternative tocommercial software for Six Sigma.

R provides innovative ways of teachingand assessment.

R allows being more productive and haveless errors

Further steps

SixSigma package developmentPublications in preparationSix Sigma platform?


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Summary




Further stepsSixSigma package development

Publications in preparationSix Sigma platform?


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Summary




Further stepsSixSigma package developmentPublications in preparation

Six Sigma platform?


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Summary




Further stepsSixSigma package developmentPublications in preparationSix Sigma platform?


http://www.urjc.es


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Acknowledgements

R peopleKurt Hornik, R Core Team

SpringerMarc Strauss. Springer

This work has been partially funded by VRTUOSIproject, www.vrtuosi.org, within the Virtual Campusmethodological framework of the EU Lifelong LearningProgramme (LLP, code502869-LLP-1-2009-ES-ERASMUS-EVC) andAGORANET project (IPT-430000-2010-32)


http://www.urjc.es

www.vrtuosi.org


09/02/2011

Emilio L. Cano


Introduction

Six Sigma with R

Six Sigma Software

R Advantages


Teaching Resources

The Book

The package

Assessment Tools

Discussion

Thanks for yourattention !

Any question?

[email protected]

@emilopezcano


http://www.urjc.es

Teaching Six Sigma Quality with R

Education

Transcript of Teaching Six Sigma Quality with R