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[]
["Part Details"]
["Characteristic",null,"Part number",null,"Gage number"]
["Unit of Measurement",null,"Part Description",null,"Gage description"]
[]
["Target Value",null,"Date",null,"Gage Least count"]
[]
["Tolerance",{"$nulls":3},"Gage R&R value"]
[]
["USL",null,"Study dates and Shift",null,"Gage Bias and Uncertainity (%)"]
[]
[]
["LSL",null,"Any other details"]
["Data Grouping and Sample details"]
["Number of Groups"]
[]
[]
["Number of Samples in Each group (It is prefereable to collect 5 samples continuously from the process so that the inherent variations are captured"]
[]
[]
[]
[]
[]
["Range Analysis"]
["Average Range (R-bar)",{"$nulls":3},"Samples","D3     D4"]
[{"$nulls":4},2,"0       3.267"]
["Upper Control Limit (UCL) = D4*R-bar",{"$nulls":3},3,"0       2.575"]
[{"$nulls":4},4,"0       2.282"]
["Lower Control Limit (LCL) = D3*R-bar",{"$nulls":3},5,"0       2.115"]
[{"$nulls":4},6,"0       2.004"]
["Is the Range under control",null,null,"Yes / No"]
["Note: If the Range chart is not under control, homogenize the data by eliminating points going out of control limits. Rule for this is, one can eliminate max 15% of the total points in the Range."]
[]
["Enter the Revised values of R-bar, UCL and LCL after Homogenization in the cells below"]
["Revised Average Range (R-bar)"]
[]
["Revised Upper Control Limit (UCL) = D4*R-bar"]
[]
["Revised Lower Control Limit (LCL) = D3*R-bar"]
[]
["Is the Range Chart plotted",null,null,"Yes/No"]
[]
["Are the Stratification levels more than 3",null,null,"Yes/No"]
[]
["If No, STOP HERE, Your Measurement System is not capable for capturing the Variations. Analyze the Measurement System and Correct the problem with the Measurement System."]
[]
["Are there 7 consequtive points increasing, decreasing and one side of the Mean range",null,null,"Yes / No","If yes write causes if possible"]
[]
[]
["If the Process is not stable even after Homogenization, STOP HERE. Do not proceed further in the analysis. Identify the sources of variations for the instability and correct it."]
[]
[]
[]
["Sigma Calculation"]
["Sigma = R-bar/d2",{"$nulls":3},"Sample","d2"]
[{"$nulls":4},2,1.128]
["6 * Sigma",{"$nulls":3},3,1.693]
[{"$nulls":4},4,2.059]
["Overall Average",{"$nulls":3},5,2.326]
[{"$nulls":4},6,2.534]
["Construction of Histogram"]
["Number of Groups = Sqrt (Number of data points)"]
["Range = Maximum Value - Minimum Value"]
["Class Interval (C.1) = Range/Number of groups"]
["Class Interval (C.1) after rounding off to the nearest multiple of the Least count"]
[]
["Draw the Histogram here"]
{"$rows_empty":15}
["Does the Overall Average lie in the group having maximum frequency",null,null,"Yes/No"]
[]
["Is there a gradual decreasing trend in frequency on both sides of the group having the maximum frequency",null,null,"Yes/No"]
[]
["Are there two Modes (Two groups having maximum frequency ) & both the groups are distinctly seperated",null,null,"Yes/No"]
[]
["Based on the above analysis, can you conclude that the histogram is Normal",null,null,"Yes/No"]
[]
["Note: If the Histogram is non-normal do not proceed further for analysis"]
[]
[]
[]
["Rejection Analysis Using Sigma (Only for Normal distributions)"]
[]
["Average",null,"Z(USL) = (USL - Average)/Sigma"]
[]
["Sigma",null,"Z(LSL) = (Average - LSL)/Sigma"]
[]
["6 * Sigma",null,"Projected Rejection to above USL (Based on the Normal table)"]
[]
["USL",null,"Projected Rejection to below LSL (Based on the Normal table)"]
[]
[]
["LSL",null,"Cpk = Min (Zusl,Zlsl)/3"]
[]
["Tolerance",null,"Cp = Tolerance/6*Sigma"]
[]
["Process Centering Drift analysis (Average Chart)"]
["Average",{"$nulls":3},"Sample","A2"]
[{"$nulls":4},2,1.88]
["UCL = Average + A2*R-bar",{"$nulls":3},3,1.023]
[{"$nulls":4},4,0.729]
["LCL = Average - A2*R-bar",{"$nulls":3},5,0.577]
[{"$nulls":4},6,0.483]
["Average Chart (Process Center) analysis"]
["Is the Average Chart plotted",{"$nulls":3},"Yes/No","Comments if any"]
["1) No points outside the Control limits (Indicates that the variation in the process centering is consistent with the inherent sources of variation)"]
[]
["2) Seven consequitive points increasing or decreasing (Indicates that the Process center is gradually getting drifted may be because of tool wear)"]
[]
["3) Seven consequitie points on one side of the Central line (Indicates that the Process center has changed from one position to another position)"]
[]
["4) Shift from one end to other end (Indicates shift in the process center suddenly)"]
[]
["5) Patterns and Cyclical Variations"]
[]
["Six Sigma Analysis"]
["6 Sigma < Tolerance"]
["6 Sigma = Tolerance"]
["6 Sigma > Tolerance"]
["Actions decided based on Six Sigma Analysis"]
["6 Sigma < Tolerance",null,"6 Sigma = Tolerance",null,"6 Sigma > Tolerance"]
["1. Continue to use Control chart to monitor the Process using the control limits evaluated",null,"1. Continue to use Control chart to monitor the Process using the Control limits evaluated. Make sure that the Process is set at the Target.",null,"1. Use DOE tools to reduce variation"]
[]
[]
[]
["2. Modify the Control Limits so that the control limits are not based on the Tolerance",null,"2. Question the basis of Tolerancing and relax if it saves money and at the same time does not affect functionally.",null,"2. Fundamentally change the process or method of manufacturing"]
[]
[]
[]
["3. Tighten the Tolerance if it will save money and improve the function",null,"3. Use DOE tools to reduce 6 Sigma",null,"3. Do 100% inspection till the variation is reduced"]
[]
[]
["4. Discontinue 100% inspection if it is currenctly done for the characteristic",null,"4. Do 100% inspection till the variation is reduced"]
[]
[]
["5. Change the procedure"]
[]
[]
["Note: If the 6Sigma = Tolerance or 6Sigma > Tolerance, all the actions from the above list should be selected"]
[]
["Modified Average Control Limits (If this is selected as action) and Setup lomits calculation"]
[]
[]
[]
["Sigma value selected to relax the control limits (Generally 4 is selected as default) = k",null,null,"Upper Setup Limit (Average+((UCL-LCL)/6))"]
[]
[]
["Modified Average Lower Control Limit (USL-(k*Sigma-3* (Sigma/sqrt(n)))",null,null,"Lower Setup Limit (Average-((UCL-LCL)/6))"]
[]
[]
["Modified Average Lower Control Limit (LSL + (k*Sigma-3* (Sigma/sqrt(n)))",null,null,"Target value"]
[]
[]
["DOE Tools selected for Process Improvement"]
["Multi-Vari Analysis"]
["Concentration Chart "]
["Paired Comparison"]
["Component Search"]
["Product/Process Search"]
["Variable Search"]
["Full Factorial"]
["B Vs C Test"]
["Scatter plot for Process optimization"]
["EVOP (Evolutionary Operations) for Process Optimization"]
[]
["For Ongoing monitoring and control of the characteristic, use the Control limits identified with Bold Underline and Italics"]
[]
["Analysis Completed by",null,"Reviewed and Approved by ",null,"Date"]
[]
[]
[]
[]
["Notes on Scale selection for Range chart:"]
[]
["1. Leave the first two blocks free (This is to ensure that the out of control points are plotted if it comes)"]
["2. Start the Lower value with 0"]
["3. Divide the Range into equal intervals and fix the scale"]
[]
["Notes on Scale selection for Average chart:"]
[]
["1. Leave the top two and bottom two blocks free (This is to ensure that the out of control points are plotted if it comes) "]
["2. Find out the difference between the UCL and LCL"]
["3. Divide this difference into equal intervals and fix the scale"]

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