Visual Controls –

How to know if machine is Ok?

Machine  sirens tell us the machine is down and not part of the planned down time so it’s for
immediate

Visual Controls

 Dashboards
o Will signal warnings
o Dashboards are cluttered  hard to update so that it’s not real time and no longer
 Not too many; keep the few critical
Goal : to make monitoring real time

Ongoing Data Collection & Process Control

- If what you’re monitoring happens daily (good to monitor the process using the
control chart)
o Control charts to plot data and identify signals of special causes
o Use special cause and common thinking to reduce variation

Control Charts:

- Help us determine if process is capable

- I-Chart (Individuals Chart of Luggage Reported Missing on Flights into Springfield

X- axis is always the passage of time

Y- axis : lost luggage (whatever the variable of interest is)

Special causes -> assignable causes (you can assign a cause for that outlier)

Specific control charts depending on the type of data that you have

You can also chart Sales!

If you can’t identify why a Special Cause happened – you can’t remove it. You have to know why

You can omit when: You can identify the cause or you’re sure it won’t happen again

Control Limits - VoP

Spec Limits – VoC

Subgroup sampling (manufacturing)

We present the average of the group

Control Chart for Sub Grouping – manufacturing

It’s discouraged to use subgrouping in Service Industry

NP or P charts - you count the defective units – if sample sizes are equal

P Chart of Unanswered Calls

0.150 UCL=0.1516

0.125
Proportion

0.100 _
P=0.0957

0.075

0.050
LCL=0.0397

1 3 5 7 9 11 13 15 17 19 21
Sample
Tests are performed with unequal sample sizes.
*Not all percentages should be plotted on a p-Chart

c- Chart

Area of opportunity is equal. One contract = 1 data point

C chart – you count defects (per unit)

p- percentage

discrete data (defective or not) - P or NP

Percent Occupancy = P

Number of rooms occupied = NP

# of adjustments divided by number of statements processed = U

Percent of statements that need adjustment = P (We are counting statements)

Number of recordable injuries = 1 person can be injured multiple times = C

Number of recorded injuries divided by hours worked per month = U

Percent insurance policies renewed = p