quality tools

Session 111

Manage and Expand Lean Six Sigma Initiative Through Value Chain

Gary Jing, Entegris

One typical problem many organizations have is that at individual project level, improvements are well established and clearly documented; yet at the organizational level, those individual improvements don’t necessarily translate into the business success or competitive advantage. The overall business performance metrics don’t necessarily improve. Certainly there are many factors confounding to each other and affecting the overall performance. One factor is where to allocate the improvement effort. The improvement efforts may not reflect the Pareto principle. To manage improvement through value chain is one way to gain high leverage. It becomes a new trend in the Six Sigma world. This presentation will show various practices done at multiple companies.

The speaker is a long time Six Sigma practitioner. He was the founding MBB at the world’s largest Disc Drive Design Center (Seagate TCO, 1998 - 2005). He serves on the Editorial Review Board for Six Sigma Forum Magazine. His Sigma work generated 2 patents. He now manages the Sigma program at Entegris as the MBB and the Senior Manager of Global Lean Sigma.

Session 112

Standard Approaches to Computer Validation

Thomas Rudzinski, Medtronic

There are standards and regulations throughout the world that define how computer systems that are either integrated into products or used to automate the manufacture of products are to be validated and verified. Application of these various country or region specific standards is a requirement for many products to gain access to these markets.

In the past, claiming "FDA approval" or "CE" marking made most of these markets accessible. Today, though the "CE" and "FDA approval" help speed up market access, it does not open the door to every market carte blanche.

This talk will discuss the various components typically required for computer validation and what standards are available to guide compliance for these components. In addition, considerations required for applying requirements globally and to global companies will also be discussed.

Session 113

Success: Global Companies Deliver High Quality, Satisfaction

Barbara Everitt Bryant, Ross School of Business University of Michigan

Business Week defines successful companies on three lists: The 50 Best Performers, The 25 Customer Satisfaction Champs, The 25 Leaders in Innovation. Here we look at 30 global consumer companies measured in the University of Michigan/ASQ American Customer Satisfaction Index (ACSI) that appear on these overlapping lists. How do their customers rate them, compared to others in their industries, for quality, customer satisfaction, and value?

Session 114

Understanding Capability Indices – CP, CPK, PP, PPK

Louis Asher, 3M Company

Many companies use Capability Indices (i.e. CP, CPK, PP, PPK) but a lot of their employees are confused by them. This session will provide a concise and understandable explanation of the four capability indices - complete with colored handouts.

If you are confused, amused or simply curious about CP, CPK, PP and PPK , attend this session and do not be surprised if you understand and can intelligently use them after this brief session!

minnesota concil for quality baldrige

Session 121

Achieving Organizational Excellence: Minnesota Council for Quality

Brian Lassiter, Minnesota Council for Quality

This session introduces participants to an ASQ partner, the Minnesota Council for Quality. You will receive an overview of the Council’s mission, focusing on new programs that have recently been developed. The session highlights changes to the Council’s core service (Baldrige-based organizational assessments) as well as many other resources that help organizations implement improvement initiatives.

Session 122

Case Studies on the Journey to Excellence – Winona Health Care and Mate Precision

Kevin Nicholson

This session highlights how two Minnesota organizations – a manufacturer and a healthcare provider – integrated a variety of quality approaches to reach higher levels of performance. Hear how Mate Precision Tooling and Winona Health are both integrating quality frameworks such as Baldrige, Six Sigma, Lean, and Balanced Scorecard to maximize the value of each.

Session 123

The Role of a Minnesota Quality Award Evaluator: How it Benefits you and the State

Margie Kissner and James Hill

This unique session will focus on the role – and benefits – of becoming an Evaluator in the Minnesota Quality Award. We will hear from 3-4 Evaluators on why they got involved in the program, what they learned, and how they benefitted. This is an interactive panel discussion.

Jim Hill is a Senior Project Manager with the Nuclear Management Company at the Prairie Island nuclear plant in Red Wing MN. Jim started evaluation in 1996, and is currently a team leader and new evaluator trainer, and serves on the Panel of Judges. Jim has an electrical engineering degree from the University of Illinois, an MBA from Cardinal Stritch University, and is a licensed Professional Engineer. Jim is a Senior Member of ASQ, holding Auditor and Manager of Quality/Organizational Excellence certifications, and holds certification from the Project Management Institute as a Project Management Professional.

Session 124

Minnesota’s New Entry Level Quality Award

Pat O’Boyle, Quality Instructor at Century College and Normandale College

This is a hands-on session where participants assume the role of a fictitious organization that is applying for Minnesota's new Entry Level Quality Award. You'll receive a guided tour of what it would be like to submit an organizational application using this new application process. It covers the basic application, information review, and feedback report. Intended audience - business owners, management, business excellence, all interested quality professionals.

six sigma

Session 131

Case Study: Design For Six Sigma and Design For Reliability in the Disc Drive Industry

Joe Liu, Seagate

Design for Six Sigma and Design for Reliability are two major focuses in the competitive world of high tech companies. A case study from the Seagate Six Sigma initiative will be presented. In this session, Joe Liu, Six Sigma Director at Seagate Design Center, will present how it's done at Seagate. Seagate won IQPC ( International Quality PC) DFSS award in 2004 for its efforts in Six Sigma. This award is one of the major Six Sigma recognitions in the world public domain. Hear this success story. Dr. Joe Liu, Business Excellence Lead of product and technology development centers, will share how Seagate incorporates these processes into its daily work.

Joe Liu earned his Ph.D. in Mechanical Engineering, with a minor in Electrical Engineering, from the University of Wisconsin-Madison. He joined Control Data's disc drive subsidiary in 1982 and was instrumental in developing various test and measurement methods for design and product quality assurance. Control Data was acquired by Seagate in 1989 and then Joe transferred to Singapore in 1997 to establish a mechanical lab in the company's design center.

When Seagate began engaging in DFSS in 2000, he was trained as a design Master Black Belt and led the deployment for Seagate's Asia Pacific facilities. In 2002, Seagate delivered its first consumer electronics hard disc drive designed using DFSS methodology, which lead to winning the 2004 Six Sigma IQ's Excellence Award for "Best DFSS Project of the Year." Since 2005, Joe has been responsible for sustaining the DFSS initiative globally within Seagate and expanding the company's Business Excellence practice into all of Seagate's product and technology development sites.

Session 132

A New DMAIC Model

Rip Stauffer, Woodside Quality Solutions

The DMAIC life cycle currently in use by organizations worldwide lacks some important focus. I will discuss the common DMAIC cycle, point out some inherent weaknesses, and propose some reasonable adjustments that could make DMAIC considerably more powerful. Hear how to improve your closed-loop cycle.

Session 133

Practical Problem Solving – DMAIC style

Glen Peace, Quality Engineer, E-Z-Go Golf Carts

As any company strives toward improving its processes, one of the common weaknesses and noted opportunities for improvement is in effective Practical Problem Solving (PPS). The intent of this paper is to lay out one approach to defining PPS requirements, structuring the PPS foundation, laying out the implementation strategy, and implementing and fine-tuning the program.

This presentation will discuss the efforts through which a cross functional team was created, a clear project statement was generated, and project goals with measurable results were developed. Discussions of the PPS foundation effort will include structuring of a multi-purpose data entry form and electronic data storage and retrieval. Development of a detailed process flow including roles and responsibilities, specific step-by-step instructions, and rules for root cause escalation will be fully discussed. Risk assessment will also be addressed including an explanation of the process for identifying potential problems, installing preventative checks, and defining countermeasures where needed.

The implementation strategy will be explained including the rationale for the approach adopted. This will include explanations for the logic in establishing the implementation sequence and priority of implemented areas. With unforeseen weaknesses in the system and unpredicted problems arising during the Implementation Phase, the paper will also share lessons learned and the remedial steps taken to address these issues.

Glen has co-design Quality responsibility for E-Z-Go with specific responsibility for robust design, statistical methods, complex problem solving, and technical training.

He is the author of A Hands-on Approach to Quality Engineering, a book on Robust Design.

Glen holds B.S. Degrees in Electrical Engineering and Accounting and a Masters Degree in Business Administration. Glen is also a Senior Member of The American Society for Quality and is a Certified Quality Engineer, Certified Six Sigma Master Black Belt and a Certified Taguchi Methods® Expert. He has over thirty-five years experience in the Quality and Safety Fields. He has trained and consulted with over 100 different companies spanning a variety of industries.

Session 134

A Sale with All the Trimmings

Summer Bissette, The Occasions Group

This project presentation explains the application of the DMAIC (Define, Measure, Analyze, Improve and Control) process and the use of various Six Sigma Tools when applying them to the process of gaining additional sales in an inbound call center. Through the application of these tools in each phase of the project, the team was able to identify "Critical to Quality" indicators that would impact the selling process and the output of additional sales dollar generation in a positive way.

This process provides a balance of positive benefits for the representative, the customer and the company in a variety of ways. For the call center representative, it has provided a more structured and enjoyable environment for selling, a more positive experience for our customers by giving them the options that are available to be able to utilize more purchasing power for every dollar spent, and for the company, it has provided the benefit of capturing the sale now without the risk of extra communication later to do so.

The presentation will outline which tools were utilized in which part of the process, why those tools were chosen, what was learned as the project progressed and why certain improvements were narrowed down and chosen for implementation.

Tools & Audits

Session 141

Comparison of Measurement Gages Across The Globe or Just Across The Room

Karyn Heydt, Hutchinson Technology, Inc.

Abstract

Measurement Systems Analysis tests take time and are not always easy to conduct but it is imperative that we understand the capabilities of these gages. You must be able to trust the results. Deciding if you should make an adjustment to your manufacturing process, determining if a process improvement effort was successful or if you should accept/reject a manufacturing production lot is based on the results you obtain from the measurement gage. There is a constant battle with suppliers and customers trying to ascertain why the results on their measurement gage do not agree with the results that are obtained on other measurement gages. It does not matter if the measurement gages of interest are in the same room or they are half way around world it is possible to determine in what way they agree or disagree. Nicholas R. Farnum suggests a method that can characterize the accuracy and precision between measurement gages. This presentation will show a step by step example of his method of conducting Measurement Gage Comparisons and how to interpret the results. We will also review what factors affect the quality of a Measurement System and what preliminary Measurement Systems Analysis tests should be conducted prior to running a Comparison Study. The credibility of the results you obtain from your Comparison study is dependent on the preliminary Measurement Systems Analysis tests result

Session 142

Quality Auditing for the Boss

Dennis Arter, Columbia Audit Resources

This audit presentation is directed at management. It comprehensively covers what auditors should do to help their organization be successful and what bosses must do to help the auditors. The session covers the challenges of auditing a variety of quality systems, ranging from simple quality systems of software, government, healthcare or GMP applications.

Session 143

Value Added Audits in a Global Economy

Pat O’Boyle, Quality Instructor at Century College and Normandale College, Intermediate

This session focuses on expanding the role of the internal audit function, from one of compliance with an identified standard, to management audits that cover initiatives such as: Six Sigma, Lean, Baldrige criteria, disaster recovery situations (business continuity), or assessing the readiness of internal processes for potential outsourcing opportunities. Some of the key audit program changes that are needed in order to perform management audits include:

• Maintaining, or if needed, strengthening senior management support
• Linking the audit program objectives to the organizational objectives

Maintaining or improving the creditability of the audit function by:

• Providing ongoing status reports
• Giving management and auditee’s the ability to provide feedback
• Maintaining audit processes, procedures, and work instructions
• Providing ongoing auditor training, mentoring, and or coaching
• Taking steps to ensure the quality of the audit report
• Recognizing and celebrating auditor accomplishments

Session 144

From Prototype to Production in China – Global Supply Chain Management

Demress Stockman, Carestream Health

What supplier quality management issues arise when a product is designed in the United States, manufactured in China with globally-supplied components across multiple commodities, and sold worldwide? What organizational models, processes, and tools can assist the organization in meeting cost, quality, and delivery goals? The process used to select and qualify suppliers for a new medical printer is described. The presentation explores the following areas/questions with real-world examples:

Team Structure and Communications Models

1. How can the supply chain management and purchasing functions be integrated with the development, manufacturing, and project management functions during product development in order to optimize overall results?
2. How can early supplier involvement and feedback be accomplished when the supplier is in China and the design team is in the United States?
3. How can quality and supply issues be escalated to ensure rapid resolution and prevent line outages?

Supplier Selection, Qualification, and Design Transfer Methods

1. What processes and tools should be used to select and qualify suppliers?
2. How much might the processes and tools depend on where the supplier is located (United States vs. China) and the maturity of the design (new product vs. mature product)?
3. What risk management practices can be used to prevent schedule slips or quality issues?
4. How might design for manufacturability issues be affected by supplier location?

Logistics, Transportation, and Lean Manufacturing Considerations

1. What logistics and transportation issues should be considered in a global supply chain and how can quality be affected?
2. How can lean integration be accomplished when overseas suppliers are used?
3. How might supply chain management approaches vary with the site of the final component integration (United States vs. China)?

lean topics

Session 151

Lean Solutions

John Miller, Dunwoody College of Technology

Many organizations on the quality improvement journey use Lean as their roadmap to success. With the practical hands-on approach that Dunwoody is famous for, we will help you apply Lean solutions to strengthen your company. This session will cover actual case studies and how Lean helps both customers and the bottom line in a variety of companies.

Session 152

Is Design of Experiments A Part of Lean?

Perry Parendo, Perry’s Solutions, LLC

Lean is currently being successfully implemented in many areas with the focus of eliminating waste. Six Sigma training exposes people to the concept of DOE, but some past improvement programs have suggested that continuous improvement applies beyond the manufacturing floor. More people are willing to "give DOE a try". DOE applications might now occur in marketing, procurement and product development areas and be accompanied with Lean. The author’s belief is that cost-effective improvements should occur in all company areas but that not just any tool should be used. A framework for assessing the different situations will be provided to help perform cost effectively. Case studies will clarify applications through the group discussion in this interactive session.

Session 153

Lean Journey to the Shingo Prize for Excellence in Manufacturing

Greg Radtke, Hearth & Home Technologies

Hearth and Home Technologies Lake City facility has created an empowered, member- driven culture of continuous improvement that achieves world class results. Lake City decided to pursue the Shingo Prize as a way to improve performance. The preparation that Lake City did for the Shingo application, the subsequent on-site visit, and the benefits gained through the process lead to being awarded the Shingo Prize for Excellence in Manufacturing. This is a success story not to be missed!

Session 154

Lean Product Development

Mark Larsen, Medtronic

Medtronic does design some of the best Medical Devices in the world, but we’re not always fast and inefficient. Recently, some at Medtronic have tried to crack the difficult nut of lean product development. What we’ve learned may surprise and disappoint. There is no miracle cure. But a lot of good questions have been raised and a few answered. These include:

• Why does the typical stage-gate process not always deliver as expected?
• What are the top causes of schedule slippage?
• What unique roles do the layers of organization play in slowing development?

reliability

Session 161

Trapped by MTBF

Fred Schenkelberg Consultant, Ops A La Carte

Mean Time Between Failure, or MTBF, is one of the worst four-letter acronyms ever. It leads to misunderstanding, misinterpretation and misinformed decisions. Unfortunately, MTBF is widely used. It is embedded in countless industries as 'the way' of discussing reliability. MTBF is the one parameter for the exponential life distribution with simple estimation techniques. MTBF is often the key element of modeling, planning, test development and vendor selection. This presentation will review the common problems with the use of MTBF and how these problems have often led to significant errors. Next, we explore what to do given that most industries will continue to use MTBF. What questions should you ask? How should you clearly explain the issues and proper use of MTBF and related probabilities? And, what basic calculation should you conduct every time you run across MTBF? Hear this dynamic speaker clarify the common misconceptions.

Session 162

ROHS: What is it and How does it affect me?

Larry Akre, Process Engineer, Emerson Process

This presentation will provide an insight into the reliability concerns in the use of non- lead plating in the global economy. Discussion will center on the impact of RoHS in the areas of failure mechanisms, whisker growth, solder joint strength, solderability, and shelf life. If your company has changed over to comply with ROHS or commercial components are procured, you want to hear the details of the problems with ROHS compliance.

Session 163

Reliability in a Global Supply Chain

Chris Deepak Reliability Manager Halliburton

This session will examine how to set up a reliability program where your organization is involved with technology and supplier bases across the globe. Real-life examples of what to do, and more importantly, "what not to do" when setting up a successful reliability program will be presented. Find out how to integrate quality and reliability tools to ensure an effective global supply chain process.

Session 164

Design of Experiments for Ruggedness Testing – Power versus Resolution

Mark Anderson, Consultant, Stat-Ease, Inc

Experience: Mark is a principal and general manager of Stat-Ease, Inc. Prior to joining the firm, he spearheaded an award-winning quality improvement program for an international manufacturer, generating millions of dollars in profit. Mark offers a diverse array of experience in process development, quality assurance, marketing, purchasing, and general management. Prior to joining Stat-Ease, Mark was General Manager for WR Medical Electronics, a medical device manufacturer. Mark is also co-author of two books, "DOE Simplified: Practical Tools for Effective Experimentation" and "RSM Simplified: Optimizing Processes Using Response Surface Methods for Design of Experiments," and has published numerous articles on design of experiments (DOE).