Order from us for quality, customized work in due time of your choice.
Templates
Use the Individual Simulation Screen Captures_Calculations TEMPLATEDownload Individual Simulation Screen Captures_Calculations TEMPLATE
Instructions
Getting Started
Review the How to PlayLinks to an external site. instructions and video prior to beginning this activity.
You will submit a screen capture of:
Each chart you make
Each activity that gives you a result
You are to clearly label each screen capture with the Challenge # and a short description of what the capture entails.
You will copy and then paste each data set to your Excel Template for each Challenge
* Be sure that you are running Challenges 1 and 2 completely through from 7am until 10pm
* On Challenges 1 and 2, your generated charts will provide you with the X and R Average values you need (top right corner)
LINK TO PURCHASE HBP COURSEPACK Links to an external site.
image.png
Managing Quality with Process Control
Author: Roy D. Shapiro
Copyright: 2013
This article is used in conjunction with the Chapter 7 Process Capabilities chapter of the textbook.
Challenge #1
Overview
Be sure that you are completing the samples for the entire duration of 7:00 a.m. until 10:00 p.m.
Run this Challenge and grab the screen captures of the charts a minimum of 3 times.
Note that the X-Bar Average and R-Averages for each complete shift Run are shown in the top right corner above the charts (so you do not manually have to calculate these averages to then calculate your UCL/LCL for each of the X-Bar and R Charts.
Challenge 1A
RESULT: X-Bar chart showing means and ranges of samples, including the values calculated for UCL and LCL.
Simulate the daily production of a generic product, one batch at a time, by clicking “Run Next Batch” repeatedly to complete an entire day’s production (7am through to 10pm).
With each batch, the sample mean and range will plot on the control charts provided.
After completing one full day of production, copy the values to Excel (to be used in calculating the control limits – which are needed for Challenge 2).
Challenge 1B
RESULT: R-Chart showing means and ranges of samples, including the values calculated for UCL and LCL.
(This activity is combined with Part 1A as the charts are created together in the Simulation).
Challenge #2
Overview
RESULTS
-Create X-Bar and R-Charts reflecting the defect costs
-Analysis of the results of using different investment strategies.
Start by entering your controls limits from Challenge 1 (you may use any one set of control limits that you choose), then click “Run Next Batch”.
* Note for all runs that you do, use the same set of control limit values
At each interval, check the control charts to see if the process is in control – with the exception of the first run where you will make no changes –
* If yes, click “Yes, Run Next Batch”
* If no, you can:
-Recalibrate the machines
-Make a labor substitution
-Do both
Be sure that you run through the entire production day (from 7am through to 10pm).
If you would like, you may copy and paste your data to the Excel Template (so that you can go back and analyze the results in detail).
* Note: You can not access prior runs when you reset or navigate away from this screen.
Click “Reset” to repeat the process multiple times.
The goal of this Challenge is to keep the process in control while keeping costs as low as possible.
Challenge 2A
Run the Shift with no changes and document the internal defect costs, external defect costs, and total defect costs (as you will use this baseline information for future reference and comparison with how you make adjustments).
Challenge 2B
Run a minimum of two additional Shift Runs and document the internal defect costs, external defect costs, and total defect costs for each run.
Analysis: What did you notice about the changes in the internal/external defect costs as compared to the changes you made?
Challenge #3
Overview
Determine frequencies and statistical calculations for each of the four companies.
RESULTS:
-Screen capture showing the frequency chart of each of the four companies.
-Reflect the USL/LSL values for each of the four companies.
-Reflect the UCL/LCL values for each of the four companies.
-Calculate the Process Mean for each of the four companies.
-Calculate the Standard Deviation for each of the four companies.
-Calculate the Process Capability Index for each of the four companies.
-Calculate the Upper and Lower Cpk values for each of the four companies.
-Determine if the process is centered for each of the four companies.
-Determine if the process is capable for each of the four companies.
-Highlight which value you used to determine if the process is capable or not (either the Cp, Cpk Upper, or Cpk Lower).
Challenge 3A
Show the frequency chart for each company:
Company A
Company B
Company C
Company D
Challenge 3B
For each of the four companies, clearly identify and show the calculations shown below.
Do not use Descriptive Statistics to come up with your values, but rather use the formulas from the textbook to determine these values.
SHOW ALL OF YOUR WORK to receive partial credit where possible.
USL and LSL
Process Mean
Process Standard Deviation
UCL and LCL
State if the process is centered (yes/no); Note whether to use Cp or Cpk value; Calculate Cp and Cpk values
Determine if the process is capable (yes/no) and highlight which value (Cp or Cpk) used to make determination.
Challenge #4
Overview
Run this challenge one time without making any changes.
Then use the dropdown menus on the right to experiment with investments in prevention and appraisal (at a hospital lab).
After you select your investments, click “Run to End”.
Color-coded bar charts will display for each run you complete showing the relative costs across all 4 quality cost categories (Prevention, Appraisal, Internal Failures, External Failures).
If you would like, you can copy and paste your data after each run to your Excel Template to analyze each result in more detail (you won’t be able to access the data for prior runs when you navigate away from this screen).
Run this Challenge multiple times to try to reduce your total cost of quality.
RESULTS:
-Run the Challenge with no changes and provide a screen capture.
-Run the Challenge at least two additional times, in an effort to minimize your total cost of quality.
* You will share charts showing dollars spent for the prevention, appraisal, internal failure,
and external failure costs
-Analyze the impact of these investments on each cost of quality category.
Challenge 4A
Capture the total cost of quality without making any investments in improving any of the cost of quality categories as you will use this baseline information for future reference and comparison with your selected investments.
Challenge 4B
Complete a minimum of two additional charts showing different cost of quality category investments in quality decisions that positively impact defects and dollars spent (you want to be able to see the relationship between investments in the different cost of quality categories on defects and overall total costs).
Provide a brief analysis of the impact on the different cost of quality categories based on your investment decisions.
Submission
Submit your responses as one attached Excel document to the appropriate assignment in Canvas.
Rubric
MAN4520 INDIV Screen Caps/Calcs
MAN4520 INDIV Screen Caps/Calcs
Criteria Ratings Pts
This criterion is linked to a Learning Outcome1A – Screen capture of both X-Bar and R-Charts showing means and ranges of samples for the entire duration (7am to 10pm).
6 pts
Full Marks
0 pts
No Marks
6 pts
This criterion is linked to a Learning Outcome1B_1 — X-Bar LCL and UCL calculated.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome1B_2 — R-Chart LCL and UCL calculated.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome2A — Run the Shift with no changes and document the internal, external, and total defect costs with no improvements.
5 pts
Full Marks
0 pts
No Marks
5 pts
This criterion is linked to a Learning Outcome2B — Screen Capture of at least two Shift Runs showing defects, yield, and cost along with copied data with brief analysis of findings.
5 pts
Full Marks
0 pts
No Marks
5 pts
This criterion is linked to a Learning Outcome3A — Screen Captures of each of the four companies.
5 pts
Full Marks
0 pts
No Marks
5 pts
This criterion is linked to a Learning Outcome3B_1 — Determine the USL and LSL for each of the four companies.
5 pts
Full Marks
0 pts
No Marks
5 pts
This criterion is linked to a Learning Outcome3B_2 — Determine the Process Mean for each of the four companies.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome3B_3 — Determine the Standard Deviation for each of the four companies.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome3B_4 — Determine the UCL and LCL for each of the four companies.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome3B_5 — Calculate the appropriate Cp or Cpk values for each of the four companies.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome3B_6 — Determine if the process is centered or not centered for each of the four companies.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome3B_7 — Calculate the process capability index for each of the four companies.
8 pts
Full Marks
0 pts
No Marks
8 pts
This criterion is linked to a Learning Outcome4A — Screen capture of the cost of quality categories without making any improvements.
5 pts
Full Marks
0 pts
No Marks
5 pts
This criterion is linked to a Learning Outcome4B — Screen capture of at least two charts showing different cost of quality category investments in quality decisions that positively impact defects and dollars spent with brief analysis of findings.
5 pts
Full Marks
0 pts
No Marks
5 pts
Total Points: 100
Order from us for quality, customized work in due time of your choice.