Collect & Interpret Data
The
Quality
Improvement
Model
Define
Process
Select
Measures
Collect &
Interpret
Data
Collect & Interpret Data:
Diagnosing Variability
Purpose: Begin to understand
why there is
variability in data
collected
Is
Process
Stable
?
No
Investigate &
Fix Special
Causes
Yes
Improve
Process
Capability
No
Is
Process
Capable
?
Yes
Use SPC to
Maintain
Current
Process
5-1
Collect & Interpret Data
What size shoe do you wear?
Size 11 Shoes
1
2
3
4
5
6
7
8
9
10
11 12
Why aren’t size 11’s all the same size?
5-2
GC CHDM Test Method Example
Collect & Interpret Data
Histogram of % Water
Time Series Plot of % Water
14
0.50
12
10
Frequency
% Water
0.45
0.40
8
6
4
0.35
2
0.30
39
43
47
51
55
Batch
59
63
67
71
75
0
0.325
0.350
0.375
0.400
0.425
% Water
0.450
0.475
0.500
Why don’t we get the same %Water value?
5-3
Collect & Interpret Data
Cause & Effect Matrix – A Tool to Identify and
Quantify Sources of Variation
9
10
4
8
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
Process Step
Process Input
Mixing
Mixing
Mixing
Mixing
Mixing
Mixing
Mixing
Mixing
Mixing
Total Rate
Mixer Speed
Al2O3 Quality
Recycle Composition
Recycle Rate
Nitric Acid
Water Temperature
Water Flow
Recycle Water Rate
0
0
1
1
1
0
0
0
0
3
1
9
1
1
9
1
9
3
0
1
9
1
1
9
1
9
3
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
3
3
0
0
0
1
Dust/Fines
Content
% Moly & %
Nickel
4
Moly
Distribution in
Pellett (within
& between)
8
Catalyst
Performance
8
Plugging
Cycle Time
Length
Distribution
Porosity
Distribution
Color
Rating of Importance to Customer
0
0
3
0
3
0
0
0
0
0
0
0
9
9
0
0
0
1
Total
24
12
140
104
138
108
12
108
48
Cause & Effects Matrix
5-4
Collect & Interpret Data
Cause and Effects Matrix





Relates the key inputs to the key outputs (customer
requirements) using the process map as the primary
information source
Key outputs are scored as to importance to the customer
Key inputs are scored as to relationship to key outputs
Pareto of key inputs to evaluate in the FMEA and
control plans
Input into the initial evaluation of the Process Control
Plan
5-5
Collect & Interpret Data
Cause & Effect Matrix Steps




Identify key customer requirements (outputs) from
process map or other sources
Rank order and assign priority factor to each Output
(usually on a 1 to 10 scale)
Identify all process steps and materials (inputs) from
the Process Map
Evaluate correlation of each input to each output



low score: changes in the input variable (amount, quality,
etc.) have small effect on output variable
high score: changes in the input variable can greatly affect
the output variable
Cross multiply correlation values with priority factors
and sum for each input
5-6
Collect & Interpret Data
Examples
Bottle Production Big Block Diagram
Bottle Production
Upstream
Resin IV
Other resin Properties
Bottle Design
Etc…
Inputs
Regrind %
Barrell Temperature
Screw Speed
Screw Design
Etc…
Note: Only a partial list
Outputs
Break % at Molder
Bottle Output
Melt Temperature
Clarity
Weight
Wall Thickness Variation
Etc…
Downstream
Break % at Filler
Etc…
5-7
Collect & Interpret Data
Bottle Production Example
Bottle Production Block Steps Diagram
Inputs
Resin
Outputs
Vacuum out of
box
Pellet change
Blending with
Regrind
Dryer Hopper
(Regrind + virgin)
Vacuum into
machine hopper
Resin
Regrind%-C
Barrel temperature-C
Screw speed-C
Meter cooling temp-C
Screw design-C
Barrel/screw condition-U
Melt Resin
Melt Temperature
Melt strength
MW/IV
Throughput
Extrude Parison
Parison programming-C
Head adapter design-C
Head design (PVC, HDPE)-C
Tooling
Zone temps
Die tip temp
Support air (straight and controlled)
Parison cut
Note: Only a partial Map
Parison length
Parison diameter
Parison temp
Thickness Profile
Clarity
Melt stability
5-8
Collect & Interpret Data
Cause & Effect Matrix Form
1. List Key
Outputs
7
8
9
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
10
11
12
13
14
15
Requirement
6
Requirement
5
Requirement
4
Requirement
3
Requirement
2
Requirement
1
Requirement
Rating of
Importance to
Customer
Total
Process Step Process Input
1
2
3
4
5
6
7
8
0
0
0
0
0
0
0
0
Excel Template C&E Matrix.XLS
5-9
Collect & Interpret Data
Bottle Production Example
Process Step
1. List
Key
Outputs
2
3
4
5
Melt Temp
Bottle Output
Clarity
Weight
6
Wall Variation
1
Break %
Rating of
Importance to
Customer
Total
Process Input
0
0
0
0
0
0
0
0
0
0
0
0
0
The Outputs are defined in Step 1 of Process Mapping
5-10
Collect & Interpret Data
Cause & Effect Matrix Form
Rating of
Importance to
Customer
13
14
15
Requirement
2. Rank
Outputs as to
Customer
Total
importance
Requirement
Requirement
12
Requirement
11
Requirement
10
Requirement
9
Requirement
8
Requirement
7
Requirement
6
Requirement
5
Requirement
4
Requirement
3
Requirement
2
Requirement
Requirement
1
Process Step Process Input
1
2
3
4
5
6
7
8
0
0
0
0
0
0
0
0
5-11
Collect & Interpret Data
1
9
9
5
8
1
2
3
4
5
6
Melt Temp
Bottle Output
Clarity
Weight
2. Rank Outputs as
to Customer
importance
Process Step
Wall Variation
Rating of
Importance to 10
Customer
Break %
Bottle Production Example
Total
Process Input
5-12
Collect & Interpret Data
Cause & Effect Matrix Form
7
8
9
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
10
11
12
13
14
15
Requirement
6
Requirement
5
Requirement
4
Requirement
3
Requirement
2
Requirement
1
Requirement
3. List Key
Inputs by
Process Step
Requirement
Rating of
Importance to
Customer
Total
Process Step Process Input
1
2
3
4
5
6
7
8
Note: Information obtained from process map
0
0
0
0
0
0
0
0
5-13
Collect & Interpret Data
9
9
5
8
2
3
4
5
6
Bottle Output
Clarity
Weight
Inputs by
1
Process
Step
Break %
Note: Only a
partial list of
inputs
Process Step
Melt
Melt
Melt
Melt
Melt
Resin
Resin
Resin
Resin
Resin
Melt Resin
Melt Resin
Extrude Parison
Extrude Parison
Extrude Parison
Extrude Parison
Extrude Parison
Wall Variation
Rating of
3. List
Importance
to Key
10
1
Customer
Melt Temp
Bottle Production Example
Process Input
Resin
Barrell Temp
Screw Speed
Screw Design
Regrind%
Barell/Screw
Condition
Screw Tip
Cooling
Programing
Die Tip Temp
Head Design
Tooling
Support Air
This step uses the Process Map inputs directly. Notice the Process Inputs
follow the Process map step-by-step.
5-14
Collect & Interpret Data
Cause & Effect Matrix Form
7
8
9
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
10
11
12
13
14
15
Requirement
6
Requirement
5
Requirement
4
Requirement
3
Requirement
2
Requirement
1
Requirement
4. Relate
Inputs to Rating of
to
OutputsImportance
Customer
Total
Process Step Process Input
1
2
3
4
5
6
7
8
0
0
0
0
0
0
0
0
5-15
Collect & Interpret Data
Relating Inputs to Customer Requirements
You are ready to relate the customer requirements to the
process input variables
 Correlational scores: No more than 4 levels


0, 1, 3 and 9
Assignment of the scoring takes the most time
 To avoid this, spell out the criteria for each score:

0 = No correlation
1 = The process input only remotely affects the customer requirement
3 = The process input has a moderate effect on the customer
requirement
9 = The process input has a direct and strong effect on the customer
requirement
5-16
Collect & Interpret Data
Bottle Production Example
1
Melt Resin
1
Melt Resin
2
2
2
2
2
Extrude
Extrude
Extrude
Extrude
Extrude
Parison
Parison
Parison
Parison
Parison
2
Extrude Parison
1
2
3
4
5
6
Wall Variation
8
Note: Only a
partial list of
inputs
Weight
Resin
Resin
Resin
Resin
Resin
5
Clarity
Melt
Melt
Melt
Melt
Melt
9
Bottle Output
1
1
1
1
1
9
Melt Temp
Process Step
1
Break %
4. Relate
Inputs to
Outputs
Rating of
Importance to 10
Customer
9
3
3
3
3
9
9
9
9
1
3
9
9
9
1
9
1
1
1
3
9
3
3
1
3
9
3
3
1
3
324
168
168
142
106
3
3
3
1
1
1
82
1
1
3
0
3
3
77
3
3
3
3
1
3
3
9
3
0
9
3
3
3
9
0
9
3
3
0
9
3
3
3
1
9
9
9
9
1
231
228
180
174
104
3
3
3
3
1
1
100
Total
Process Input
Resin
Barrell Temp
Screw Speed
Screw Design
Regrind%
Barell/Screw
Condition
Screw Tip
Cooling
Programing
Die Tip Temp
Head Design
Tooling
Support Air
Lower Manifold
This is a subjective estimate of how influential the key inputs are on the key outputs
5-17
Collect & Interpret Data
Cause & Effect Matrix Form
7
8
9
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
Requirement
10
11
12
13
14
15
Requirement
6
Requirement
5
Requirement
4
Requirement
3
Requirement
2
Requirement
1
Requirement
Rating of
Importance to
Customer
5. Crossmultiply and
prioritize
Total
Process Step Process Input
1
2
3
4
5
6
7
8
0
0
0
0
0
0
0
0
Sum of (Rating x Correlation Score) values for all
Requirements
5-18
Collect & Interpret Data
Bottle Production Example
1
Melt Resin
1
Melt Resin
2
2
2
2
2
Extrude
Extrude
Extrude
Extrude
Extrude
Parison
Parison
Parison
Parison
Parison
2
Extrude Parison
8
1
2
3
4
5
6
Wall Variation
5
Note: Only a
partial list of
inputs
Weight
Resin
Resin
Resin
Resin
Resin
9
Clarity
Melt
Melt
Melt
Melt
Melt
9
Bottle Output
1
1
1
1
1
1
Melt Temp
Process Step
Rating of
Importance to 10
Customer
Break %
5. Crossmultiply and
prioritize
9
3
3
3
3
9
9
9
9
1
3
9
9
9
1
9
1
1
1
3
9
3
3
1
3
9
3
3
1
3
324
168
168
142
106
3
3
3
1
1
1
82
1
1
3
0
3
3
77
3
3
3
3
1
3
3
9
3
0
9
3
3
3
9
0
9
3
3
0
9
3
3
3
1
9
9
9
9
1
231
228
180
174
104
3
3
3
3
1
1
100
Total
Process Input
Resin
Barrell Temp
Screw Speed
Screw Design
Regrind%
Barell/Screw
Condition
Screw Tip
Cooling
Programing
Die Tip Temp
Head Design
Tooling
Support Air
Lower Manifold
We now start getting a feel for which variables are most
important to explaining variation in the outputs
5-19
Bottle Production Example
1
9
9
5
8
1
2
3
4
5
6
Blow Bottle
Extrude Parison
Extrude Parison
Blow Bottle
Melt Resin
Melt Resin
Melt Resin
Blow Bottle
Tail Detab
Weight
Blow Bottle
Clarity
Resin
Mold Design
Programing
Die Tip Temp
Mold Water
Temp
Water
Volume/Cooli
ng Rate
Head Design
Tooling
Pinch Design
Barrell Temp
Screw Speed
Screw Design
# of Mold
Cooling
Zones
Time from
extraction to
Detab
Bottle Output
Melt Resin
Blow Bottle
Extrude Parison
Extrude Parison
Melt Temp
Process Input
Break %
Process Step
Wall Variation
Rating of
Importance to 10
Customer
9
9
3
3
9
0
3
3
3
9
9
3
9
9
0
9
9
0
9
3
9
9
9
9
324
324
231
228
9
0
9
3
0
0
198
9
0
9
3
0
0
198
3
3
9
3
3
3
9
3
0
9
9
9
3
3
9
9
9
9
3
3
0
1
1
1
3
3
0
3
3
1
9
9
0
3
3
1
180
174
171
168
168
142
9
0
3
0
0
0
117
9
0
3
0
0
0
117
Total
Collect & Interpret Data
We have sorted on the crossmultiplied numbers and find
that the input variables in the
box above are the most
important
We can now evaluate the
control plans for these input
variables
Note: Only a
partial list of
inputs
5-20
Collect & Interpret Data
General Approach

Place the outputs across the top of the matrix and rank



Place inputs down the side of the matrix starting with the
first process step and moving to the last
This approach is okay for small process with relatively few
steps
Should only be used for processes with a relatively
small number of steps and inputs
5-21
Collect & Interpret Data
Focused Approach

Phase I





Place the outputs across the top of the matrix and rank
Place the process steps down the side of the matrix
Correlate process step to outputs
Pareto the process steps
Phase II
Start a new C&E Matrix with the inputs from the top three or four
process steps
 Recommended when first starting a project

o Focuses the efforts and gives the team a feeling that they’re working
on the important process steps first
o Gives you a running start at the FMEA and preliminary Control Plan
Analysis
5-22
Control Plan Evaluation

Collect & Interpret Data
Standard Operating Procedures






Do they exist?
Are they understood?
Are they being followed?
Are they current?
Is operator certification performed?
Is there a process audit schedule?
5-23
Control Plan Evaluation

Controllable Input Variables:






Collect & Interpret Data
How are they monitored?
How often are they verified?
Are optimum target values and specifications known?
How much variation is there around the target value?
How consistent are they?
Other Questions:


How often is the input variable out of control?
Which input variables should have control charts?
5-24