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Kenneth Quiros Doe in Action
Kenneth Quiros Doe in Action
Kenneth Quiros
Continuous Improvement Manager & Lean Six
Sigma Master Black Belt Bridgestone Americas
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Learning Objectives
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Agenda
i. Bridgestone Company.
ii. Bridgestone Six Sigma Deployment and Strategy using
Qeystone & Minitab.
iii. DoE Theory.
iv. DMAIC Practical Problem- Yield Improving using a Binary
Logistic Regression.
i. Attribute DoE
v. DMAIC Practical Problem- Optimizing a Mixing Process
using a Mixture DoE
i. Formulation and Mixing Design.
vi. DMAIC Practical Problem- Increase the productivity in
Mixing Area using a DSD
i. Definitive Screening Design
vii. Summary and Questions
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Bridgestone Company
Corporate Name: Bridgestone Corporation
Conveyer Belts
Roofing material
2002 2003 2004 2005 2007 2008 2009 2010 2011 2013 2014 2015/16
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
Master Black Belts Provide
4 levels of DMAIC Training
• 2 full weeks training • Two 3-day week training • 1 week kaizen event • 1-2 day
with e-learning with e-learning awareness
• Focused training
• Large training project • Focused training project project • Exposure to
• Supports other belts • Supports yellow belt DMAIC process
• Can be taught by BB
and projects projects and tools
• e-learning version
• Design for Six Sigma • Transactional version • Basic problem
available
(DFSS) option available solving
available
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
What is Qeystone?
Qeystone is an enterprise system that consists of Qeystone Tools, a desktop
application, and Qeystone.com, a cloud-based Dashboard and repository.
.com
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
Why are we using Qeystone?
Where is the
final version of
the project?
Is there any
template
available?
Is there a visual
standard that
reminds me the
How can I
steps to do the
analysis ?
Belts access to others
projects?
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
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Bridgestone Six Sigma Deployment and Strategy
using Qeystone & Minitab.
Why are we using Qeystone?
Reports / Tracking
MBB 17
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Familiarize with DoE techniques.
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DoE Theory.
• In DOE, we purposefully manipulate KPIV’s to test their effects on Y.
• There are four main purposes of DOE:
USL
Outputs
External Inputs LSL USL
Y1 Y2
External Inputs PROCESS
Eliminate or
Optimize the
X4 X5 X6
KPIV’s for
best Y Ctr / Uncontrollable Inputs
X4 X5 X6
Spread?
Uncontrollable Inputs
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Types of DoEs
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DMAIC Practical Problem- Yield Improving
using a Binary Logistic Regression.
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Binary Logistic Regression Analysis
Problem Statement MSA
Improve the yield metric from 93% to 96%
in Tire Production.
Pareto
FUNNEL
A B
IPO Map
Possible
KPIVs
Binary Logistic Regression Analysis
Limitation of using a traditional regression analysis:
Y2 = f(x1, x2, x3, …, xk) • The response is bounded between 0 and 1.
• The response should theoretically range between -∞ and
+∞.
X Data
Attribute Variable
Attribute
Anova, Means
How Binary Logistic Regression handles the limitation?
Variable
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Binary Logistic Regression Analysis
Analizing a Binary Logistic Regression
1. Choose Stat>Regression>Binary Logistic Regression
2. Complete de dialog box as shown below.
OK/NG
Factors
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Binary Logistic Regression Analysis
Highlights of the Session Window:
KPIVs What is the
Link Function: Logit model?
Logistic Regression Table
Odds 95% CI
Predictor Coef SE Coef Z P Ratio Lower Upper
Constan -8.07005 2.49848 -3.23 0.001
X1 2.38615 0.610761 3.91 0.000 10.87 3.28 35.99
X2 0.0127474 0.0037120 3.43 0.001 1.01 1.01 1.02
𝑒 2.3865 𝑥1 +0.012(𝑥2)−8.07
𝑃=
1 + 𝑒 2.3865 𝑥1 +0.012(𝑥2)−8.07
Which factor is
more important?
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Panel x2 x1
Design of Experiments with attribute data
Freeman- Tukey Transformation
X3
X1
X4
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Binary Logistic Regression Analysis
Interaction Plot Control Chart
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DMAIC Practical Problem- Optimizing a
Mixing Process using a Mixture DoE.
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Optimizing a Mixing Process using a Mixture DoE
𝐴 + 𝐵 + 𝐶 + 𝐷 + 𝐸 = 100%
Optimizing a Mixing Process using a Mixture DoE
• What is orthogonality?
x2
x2
X1 = 0,5 X1 = 0,3
x1
X2 = 0,5 X2 = 0,7
0
1 1
Ingredients
Why Extreme
Vertices?
Use this design when the design has either upper and lower bounds or linear constraints,
which results in a design space that is no longer simplex.
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Optimizing a Mixing Process using a Mixture DoE
A,B,C,D,and E are physical properties
Creating a Mixture Design
3. Complete de dialog box as shown below. 4. Click Components.
What does
that mean?
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Optimizing a Mixing Process using a Mixture DoE
Highlights of the Session Window:
Components: 5 Design points: 62
Process variables: 0 Design degree: 2
Vertex
Mixture total: 100.00000 Centroid
Number of Design Points for Each Type
Axial Point
Point Type 1 2 0 -1
Distinct 15 31 1 15
Replicates 1 1 1 1
Total number 15 31 1 15 Edge Point
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Optimizing a Mixing Process using a Mixture DoE
A,B,C,D,and E are physical properties
1. Choose
Stat>DOE>Mixture>
Surface plots
2. Complete de dialog
box as shown below.
How about
the cost?
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Optimizing a Mixing Process using a Mixture DoE
A,B,C,D,and E are physical properties
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Optimizing a Mixing Process using a Mixture DoE
Trace Plot Optimizer
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Increase the productivity in Mixing Area using a DSD
Problem Statement MSA
Increase Kg/min in BB#3 from 120 Kg/min
to 126 Kg/min
Pareto
FUNNEL
IPO Map
x1
x2
x3
x4
x5
x6
Possible
KPIVs
Increase the productivity in Mixing Area using a DSD
What is a Definitive Screening Design?
Resolution: V
Alias Structure
A + BCDE
DSD Macro
1. Choose Tools> Options
2. Complete de dialog box as shown below.
MACROS
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Increase the productivity in Mixing Area using a DSD
DSD Macro
1. Go to Edit > Command Line Editor
2. Write the script below
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Increase the productivity in Mixing Area using a DSD
DSD Analysis
3. Choose Terms
1. Choose Stat>DOE>Response Surface >
4. Complete de dialog box as shown below
Analyze Response Surface
2. Complete de dialog box as shown below.
5. Choose Stepwise
6. Complete de dialog box as shown below
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Increase the productivity in Mixing Area using a DSD
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Optimizing a Mixing Process using a Mixture DoE
RSM Chart Optimizer
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Conclusion
• What is to be studied?
• How the data are to be collected ?
• How the data are to be analyzed?
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Questions?
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