SixSigma

Six Sigma Gage R&R Measure

Components of Variation Var by Part

80 1.8

60 1.7
Percent

1.6

var
40

20 1.5

1.4
0
G.R&R Repeat Reprod Part2Part
1 2 3
%Contribution %Study Var

R Chart by appraiser
Var by appraiser
1 2 3

1 2 1.8

0.4
1.7
0.3
var

1.6
var

0.2
1.5
0.1
1.4

1 2 3
1 2
part

x Chart by appraiser Part*appraiser Interaction

1 2 3
1.70
1 2
1.70 1.65
1.65
1.60
var

1.60
var

1.55
1.55
1.50 1.50
1.45 1.45
1 2 3 1 2 3
part 1 2

Batteries Project MSA

R
a b c
Effect

Effect

Effect
Causes Causes Causes

80/20 distribution Few Causes Many Causes

 Six Sigma Cause−and−effect Diagram

Personnel Weather
Training Rain
Inadequate Temperature
Wind

Delay

Errors Rework
Permissions Delays
Customer Materials
Planning Suppliers

Construction Example

R





 R

R
 R

0
5
10
15
20

Delays

Materials

Customer

Training

Rework
26.7 50.7 70.7 77.3 82.7 88

Errors

Rain

Wind

Permissions

Inadequate

Temperature
92 94.7 97.3 98.7 100
 Frequency

0
20
40
60
Delays

Materials

Customer

Training

Rework

Errors

Rain

Wind

Permissions

Pareto Chart for b.vector

Inadequate

Temperature

80%
Cumulative Percentage
 Pareto Chart for b.vector
1
70

Cumulative Percentage
0.8
50
Frequency
0.5
30

10
0 0
Delays
Materials
Customer
Training
Rework
Errors
Rain
Wind
Permissions
Inadequate
Temperature
Frequency 20 18 15 5 4 4 3 2 2 1 1
Cum. Frequency 20 38 53 58 62 66 69 71 73 74 75
Percentage 27 24 20 7 5 5 4 3 3 1 1
Cum. Percentage 27 51 71 77 83 88 92 95 97 99 100



 R

R
 LSL T USL
frequency

Variation

Observed value of the characteristic

−
= .

− −
= .
Cost of Poor Quality

LSL T USL

Observed value of the characteristic




= = × × ···× − × ,
=
 


= − = .

= ,

= × .
 





 
( − ) ( −)
= , .
= − . .



 ±

−
= .

 
− −
= , .

= =
 3 3

99.7% (Natural Tolerance Limits)

4 2 0 2 4
Number of SD’s
 


SixSigma

R
 Six Sigma Capability Analysis Study
Density Lines Legend
Target
Density ST
Theoretical Dens. ST

LSL USL Specifications

LSL: 740
Target: 750
USL: 760

Short Term Process Long Term

740 745 750 755 760
Mean: 749.7625 Mean: NA
SD: 2.1042 SD: NA
Check Normality n: 20 n: 0
Shapiro Wilk Test Zs: 3.14 Zs: 1.64
DPMO: 50550.5
p value: 0.07506
Short Term Indices Long Term
Lilliefors (K S) Test Cp: 1.5841 Pp: NA
p value: 0.2291 CI: [1.4,1.7] CI: [NA,NA]

Cpk: 1.5465 Ppk: NA

CI: [1.4,1.7] CI: [NA,NA]
Normality accepted when p value > 0.05

Winery Project



R

= =
 Roadmap of the DMAIC Cycle

[D] Define

[M] Measure

You are here [A] Analyze

[I] Improve

[C] Control
y−axis
x−axis
a b c
18 25 18

17 20 17
pc.volume

pc.volume

pc.volume

15
16 16
10
15 15
5
14 14
0
1.1 1.2 1.3 1.4 1.5 0 1 2 3 4 5 1 0 1 2 3 4
pc.density pc.density pc.density

Default plot Limits changed Aspect changed

R
 R

Barplot of defects by region

100

80

60

40

20

0
region.1

region.2

region.3

region.4

region.5

Printer cartdrige example

 Barplot of defects by region and type

60
region.1
region.2
50 region.3
region.4
region.5
40

30

20

10

0
pc.def.a pc.def.b
Printer Cartdrige Example

R
 a b
Frequency

Frequency
Values Values
Normal Distribution Leptokurtik Distribution

c d
Frequency

Frequency

Values Values
Bimodal Distribution Skewed Distribution
a Printer Cartridges Volume b Printer Cartridges Density

7 10
6
8
5
Frequency

Frequency
4 6

3 4
2
2
1

0 0
13 14 15 16 17 18 19 1.0 1.1 1.2 1.3 1.4 1.5 1.6
Volume Volume
Histogram of Volume Histogram of Density
 Printer Cartridge Volume
0.4
16; 1

0.3
Density

0.2

0.1

0.0

13 14 15 16 17 18 19
Volume
a b c
Y

Y
X X X
Positive correlation Negative correlation No correlation

( , )

R
 Searching correlation between Density
and Volume

18

17

Density
16

15

14

1.1 1.2 1.3 1.4 1.5

Volume of Ink
Printer Cartridge Example
 a b
Measurement

Measurement
1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20
Run Run
No patterns Recurring Cycles
c d
Measurement

Measurement

1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20
Run Run
Shift Trend

R
 Run Chart for the Volume
20

18
Volume

16

14

12

1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 22 24
Run
Printer Cartridge Example
 Tier Chart for Volume
20

18
Volume

16

14

12

1 2 3 4 5 6
Batch
Printer Cartridge Example
 [ − . × , + . × ],

R
 Box Plot of Volume by Filler

18

17
Volume

16

15

14

1 2 3
Filler
Printer Cartridge Example
 Box Plot of Volume
11
18

17

Volume
16

15

14

Printer Cartridge Example

R
 Group (Operator) Chart for Volume

20

D
B C
18
C
A B A A
D
Volume

B
16 C
B D
C D
C A
D
C B
D
A B
14
A

12

1 2 3 4 5 6
Batch
Printer Cartridge Example
 R

× × ×
 Multi−vari chart for Volume by color and operator
batch
1 l 2 l 3 l 4 l

1 2 3

3 3
B C
18

17

16 l
l
l l
l l l
l l l l
15 l l l l l
l
l l
l l
l l
l
14

2 2
B C
l 18
l
l

l
17
l
Volume

l l
l l l
l l
16
l
l l l
l
l l l 15
l l l
l
14

1 1
B C
l
18 l l

l
17 l l
l
l l
l
l
16 l l
l l
l l
l
15 l
l
l l
14 l

1 2 3
Filler

CRAN
 R

R
R
R

CRAN
 R

R
R
 ×

R Console
R

R
 


R
= .
 


= ( − )
= .

= ( − )
= .
−


= ( − )
= .
−

= ( )− ( ).

= (| − ( )|).
= − .



 Long Term / Short Term Variability

54

52

50
Variable

48

46

44

0 20 40 60 80 100 120
Time

= ,
( )
 −
= =
−
=

=| − + |

( ) = ( = ).

( ) = ( ≤ ).

( )
( )= ,


( ≤ ≤ )= ( ) .

= .
 ( )= − ( )

( ≥ )= − ( ≤ )= − ( )



 
[ ]= = ( ) [ ]= − ( )

[ ]= = ( − ) ( ) [ ]= − ( − ) ( )

 
[ ]= [ ]− [ ] .

[ ] = [( − ) ]
  
−
( = )= ( − ) ,


= ( − )

× ( − ) × ( − ) × . . .× × .

= [ ]= ,

= [ ]= ( − ).

= = .
[ ]= × = . [ ] = ×( − )= .

− ( ≤ )



3 2 2 3

( − )
( )= √ −
 Histogram of ss.data.strings$len

1.5

1.0
Density

0.5

0.0

949.5 950.0 950.5

ss.data.strings$len
 Normal Q−Q Plot

950.4
Sample Quantiles

950.0

949.6

949.2

2 1 0 1 2
Theoretical Quantiles




−
= .
 0.5

0.4

Probability
0.3

0.2

0.1

0.0

0 1 2 3 4
Elements in class A

< . = + = =
(( + )
)(( + −)( − ))
( − ) ( )= R
(+ )

∼ ( , ) ∼ ( , )

R
 0.15

= /
=( − )
0.10

Probability
( )= ( − ) − R

0.05

0.00
0 10 20 30 40
Items extracted until first success
 0.08

0.06

Probability
=
( − )
= = 0.04
− −
( )= − ( − )
R
0.02

0.00

10 20 30 40
Number of trials until 3 events

0.20

0.15
Probability

0.10

= =
−
( )= 0.05
R

0.00
0 5 10 15 20
Number of successful experiments per unit
 1.0

0.8

Probability Density
0.6

0.4

= = 0.2
( )= −

R
0.0

0 1 2 3 4 5
Random Variable X

0.8

0.6
Probability Density

0.4

( )
= + 0.2
= + ( − )
( )=
√ −( ( )− )
R 0.0

0 1 2 3 4 5 6
Random Variable X>0
 1.2

1.0

Probability Density
0.8

R 0.6

= + 0.4
= ( − )
( )= − , ≤ ≤ 0.2
R

0.0

−0.5 0.0 0.5 1.0 1.5

Random Variable X

0.4

0.3
Probability Density

0.2
=
=
( ) =( − − −
)
0.1
R

0.0

0 2 4 6 8 10
Random Variable X
 2.0

1.5

Probability Density
= + 1.0
=( + ) ( + +
( )= − ( − ) −
0.5
= (( )+( ))
R

0.0

0.0 0.2 0.4 0.6 0.8 1.0

Random Variable X
 0.6

0.5

Probability Density
0.4

0.3
 
= +
=    0.2
+ − +
( )=( − )
0.1
( )=
  − (− / )
R 0.0

0 1 2 3 4 5 6
Random Variable X

0.5

0.4
Probability Density

0.3

0.2 95%
R
, .
0.1

R 5%
0.0 1.73

−4 −2 0 2 4
Random Variable X
 0.08

0.06

Probability Density
0.04

R
, .
0.02 95%

R 5%
0.00 30.14

10 20 30 40 50
Random Variable X
 1.0

0.8

Probability Density
0.6
/
, = /
, , .
0.4 95%

0.2

R 5%
0.0 2.34

0 1 2 3 4
Random Variable X

R
R
R
 = .

= ,
( − )
= .

= ,
= ,

= .

= ( − )
= ,
−

[ ]=
 = ,

 
( / )
=  ,
− ( − )/

(·) R

= ,

= .

−
R
 


×( − )

= . = . = .

[, ] ≤ ≤
 
( − )
± − ,

= .
 


± / √ .

−
/ , −

± / , − √ .

≥
 


( − ) ( − )
≤ ≤ .
− / , − / , −
 


R
R



 Confidence Interval for the Mean

Mean: 950.016
95% CI: [949.967, 950.064]
StdDev: 0.267
P Var: unknown
n: 120
t: 1.98
Missing: 0

Histogram & Density Plot

Shapiro Wilks
1.4 Normality Test
1.2 0.985
p value: 0.19
1.0
density

0.8
0.6 Normal q q Plot
0.4
0.2
0.0
949.5 950.0 950.5
Value of len

= ,
= ,
 = ,
> .

<
= .

R
=,
= .
.
.
 


−
−

= .
= . − = .



 = ( )+ .

= + + ,

= + .

= ,

( − )( − )
= −

−
−
 120

data.sound$sound
100

80

60

40

949.4 949.6 949.8 950.0 950.2 950.4

data.sound$len




R
 Scatterplot for regression

120

100

type
String sound

A5
80
B2
D4
E1
60 E6
G3

40

20

949.4 949.6 949.8 950.0 950.2 950.4

String length

R
∼

= + ∼
R

R R
= −. +. × .





 Residuals vs Fitted Normal Q Q
3
40

Standardized residuals
39 39
2
20
1
Residuals

0 0

81 2 81
40 98
98

40 60 80 100 2 1 0 1 2
Fitted values Theoretical Quantiles

Scale Location Residuals vs Leverage

98 3
Standardized residuals

1.5 39
81 Standardized residuals 0.5
2
1
1.0

1
0.5
59 81 0.5
Cook’s
98 distance
0.0 3 1
40 60 80 100 0.00 0.05 0.10 0.15
Fitted values Leverage


| |

R
R


3.3

3.2

3.1

3.0

2.9

2.8

2.7

A5 B2 D4 E1 E6 G3



= + + ,
 A5
3.05

E1
3.00 B2

mean of power
E6
2.95

2.90

2.85 G3

2.80

2.75 D4
type
Factors



 Effects of factor Type of string

3.3

3.2

3.1
power

3.0

2.9

2.8

2.7

A5 B2 D4 E1 E6 G3
type

R
 R

R
 Roadmap of the DMAIC Cycle

[D] Define

[M] Measure

[A] Analyze

You are here [I] Improve

[C] Control
R
a b
14 13

13
12
12
11
11
Y

10

y
10
9
9

8 8

7 7
8 9 10 11 12 9.0 9.5 10.0 10.5 11.0
X x
Whole values range Controlled process values range

a b

27.5 136

27.0
response

response
factor2

130
134
132
134
26.5 136
132

26.0

130

78 79 80 81 82 78 79 80 81 82
factor1 factor1
Confusion of Effects Hidden Variable
 − +

− +
 


= ( )
 R




×
 = + + + +( ) +( ) +( ) +( ) + ,
= , = , = , = ... ,
∼ ( , ) ,

( )

( )
( )

( )

R
R
− − −
+ − −
− + −
+ + −
− − +
+ − +
− + +
+ + +
− − −
+ − −
− + −
+ + −
− − +
+ − +
− + +
+ + +
 = . + . × − . × ,

−
+

− +

= . + . × − . × ,

− +

− − = . − . − (− . ) = ..
. + . × + (− . )× = .

= . + . × + (− . ) × (− ) = ..
 coef(doe.model1)[1] + c(−1, 1) * coef(doe.model1)[2]

3
4
5
6
7

−1.0
−0.5
0.0
c(−1, 1)
0.5
1.0
 A_Flour C_Baking Powder

6.0

5.5
Score

5.0

4.5

4.0

−1 1 −1 1
Level
 7

6
score

5 bakPow
−
+

− +
flour



 Residuals vs Fitted Normal Q−Q
1.0

Standardized residuals
9 8 1.5 8 9

0.5
Residuals

0.5
0.0
−0.5

14
−1.0 −1.5 14

3 4 5 6 7 −2 −1 0 1 2
Fitted values Theoretical Quantiles

Constant Leverage:
Scale−Location Residuals vs Factor Levels
9 14
Standardized residuals

1.2 8
Standardized residuals 1.5 8 9

0.8 0.5

0.4 −0.5

−1.5 14
0.0
3 4 5 6 7
flour :
− +
Fitted values Factor Level Combinations
 Facebook Twitter

= ◦

− +
◦ ◦ − +
 − − + − − + + +
− − −
+ − −
− + −
+ + −
− − +
− +
− + +
+ + +



R
R
−

R CRAN

R
 Roadmap of the DMAIC Cycle

[D] Define

[M] Measure

[A] Analyze

[I] Improve

You are here [C] Control

 R

R





±
 14
13
12

10.08

8
7
6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Observation

14
Special cause
13
12

10.28

8
7
6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Observation
− −
 a
150

100

50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Observation

200

150

100

50

50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Observation

1000

500

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Observation
 I MR Chart
1

2 10
n xR Chart

> 10
Variable
xs Chart

Type

p Chart
Attribute
Proportion

Type

# Defects
u Chart

R
 =
=
=

= = = ... ,

= + ,

= − ,

=
= =| + − |.
−
 = ,
 
= × + ,
 
= × − .

= =
 xbar.one Chart
for pb.groups.one
16 UCL

14
Group summary statistics

12
CL

10

8
LCL

1
Group

Number of groups = 30
Center = 11.7454 LCL = 7.571247 Number beyond limits = 0
StdDev = 1.391386 UCL = 15.91956 Number violating runs = 0
 


= ,

= + × √ ,

= − × √ ,

=
= , = { ∈ }− { ∈ }.
Moving range of pb.humidity
mr chart of pb.humidity
5

0 5 10 15 20 25 30
index

= ,
 
= × + ,
 
= × −
 xbar Chart
for pb.groups.xbar

UCL

13.0
Group summary statistics

12.5

CL
12.0

11.5

11.0
LCL

1 2 3 4 5 6 7 8 9 11 13 15 17 19
Group
Number of groups = 20
Center = 12.07026 LCL = 10.87911 Number beyond limits = 1
StdDev = 0.8878313 UCL = 13.26141 Number violating runs = 0



 =
= = ,
  
−
= × + ,

  
−
= × − ,

=
= = ,
=

( − )
= + ,

( − )
= − ,


 p Chart
for stockouts

0.25
UCL

0.20
Group summary statistics

0.15

CL
0.10

0.05

LCL
0.00
1 3 5 7 9 11 13 15 17 19 21
Group
Number of groups = 22
Center = 0.1212294 LCL is variable Number beyond limits = 1
StdDev = 0.3263936 UCL is variable Number violating runs = 0

=
= = ,
=

= + ,

= − ,
 R

R
R
R

R
= × ×

R
R
R

R
R

R
 R

Calendar date Gantt chart (2012)

Jan Mar May Jul Aug Oct Dec

First task

Second task

Third task

Fourth task

Fifth task

High Low

Priorities
R

R R Console

R Console R
R
 R

R EMACS ESS
ECLIPSE IDE
StatET
R RStudio

R
R dvi
pdf

.Rnw

Sweave
 PDF Six Sigma with R book - Practice Chapter DoE
Book reader
R
January 23, 2012
Please fill in the scores of each recipe:

flour salt bakPow score

5 - - +
1 - - -
7 - + +
2 + - -
4 + + -
6 + - +
8 + + +
3 - + -

pdf

pdf
R

doc
 R
R CRAN
Sweave
R

R
R R
R Console

R Console

R
R
R

csv

SPSS
Minitab
Weka
Stata

csv
R
R
R
R
R
R
 R

Microsoft
Excel