STATS Manufacturing Project - Lovell Levelers, Inc.

Instructions
You need to understand how to send your assignments (deliverables) to your instructor. The tabs (bottom of each sheet) in this document contain all of the deliverables expected of you.
If you need help along the way, look for these special cells that have a red indicator Read me
in the corner. It looks like the "Read me" box to the right:
Simply slide your cursor over the red-cornered cell and you will get more information.
The format for all of the deliverables is the same:
The 'assignment objective' is in black font.
The next segment is in green font. These are your instructions for that assignment.
The blue font is the data (where applicable) for completing each the assignment.

Software
We are using Excel software for the projects. You may use other software to complete your projects, but please 'report' your answers in the Excel format described below.
You may complete your assignments with any version of Excel software.
All assignments can easily be completed with a basic copy of Excel.
There is also an Add-In feature which is available for Excel that can be helpful, although it is not required. The Add-In feature comes free with each Excel package, although it may not be currently loaded into your copy.
Following are the simple instruction for loading the Excel Add-ins for both Excel 2003 and Excel 2007. (Slide your cursor over the red-cornered cells to read)

Excel 2003

Excel 2007

Excel Novice - Please read

Project Timeline
Deliverables include:
Project charter (target week 3 or sooner)
Baseline sigma (week 4 or sooner)
Histogram (week 5 or sooner)
Expected variation (week 6 or sooner)
t test ( week 7 or sooner)
Chi square (week 9 or sooner)
ANOVA (week 11 or sooner)
DOE (week 12 or sooner)
Scatter diagram (week 13 or sooner)
Control chart (XmR) (14 or sooner)
Pp Ppk (week 15 or sooner )

How to submit an Assignment
In response to customers like you, we have added a peach-colored box for each deliverable. We have done this to make it clear (and consistent) the areas of the project that will be reviewed to your instructor.
Project:
Deliverable:
Student last name:

Manufacturing Project
Improve phase - gen. sol.
Johnson

What is the control chart telling you?
There is a point out of control at
subgroup #15. I would try to figure
out why that happened. We would
also recalculate the control limits
because there is evidence the
process has changed.

of
Example ble
a
r
a delive

What is the average of subgroup 1?
What is the average of subgroup 2?
What is the average of subgroup 3?
What is the average of subgroup 4?
What is the average of subgroup 5?
What is the average of subgroup 6?
What is the average of subgroup 7?
What is the average of subgroup 8?

22
34
23
22
25
23
29
27

Read this!
To send each assignment to your instructor:
Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the
peach-colored box, then while holding down on that button, drag to
the LOWER-RIGHT corner of the box. This will highlight the entire
peach-colored box. Release the mouse button. Do a CTRL-C. This will
copy what has been highlighted.
Go to your Villanova website and follow this sequence:
1. COMMUNICATE
2. CLASS ROSTER
3. Click on your instructor's email envelope icon
4. Type "Check My Work - Specific assignment" in the SUBJECT box.
5. Click once inside of the message box
6. Do a CTRL-V. This will paste your deliverable into this box.
Don't be concerned if after you paste it, the appearance of the text is out of
alignment. It will straighten out after you hit SEND.
7. SEND Check your SENT ITEMS folder afterward to see how it straightened out.
Please 'hand-in' your assignments throughout the course.
DO NOT SAVE THEM FOR THE END.
Procrastinators: The deadline for completing all project deliverables
is 7 days prior to the end of the course.

Read this!

This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your Excel software.
If you see Data Analysis already listed under the Tools tab, you are set. If you do not see Data Analysis
follow the instructions in the Green tab.
Excel 2003 instructions

Excel 2003 or earlier versions of Excel example

This spreadsheet tab provides illustrations of adding the DATA ANALYSIS capability to your 2007 Excel software.
If you see Data Analysis already listed under the DATA tab, you are set. If you do not see Data Analysis
follow the instructions in the Green tab.
Excel 2007 instructions

Excel 2007 example

Manufacturing Project
Lovell Levelers, Inc. is a major provider of specialized parts
for the automotive industry. LLIs biggest customer, Specific Motors
was not a delighted customer this month. In fact, last
Monday, the executive vice president of Specific Motors headquarters,
Phyllis Kendall was diverted from a return trip from Singapore
to drop in unexpectedly at the LLI plant. There was nothing
routine about this visit. She made it explicitly clear that
Specific Motors was disappointed with the level of quality relative
to the leveler plates. In particular, she was disappointed with the
current average of rejects at the rate of 1,350 defects per million
opportunities (DPMO), and at LLI's cost of poor quality of just over $256,000
per quarter. She said the industry standard is <50 DPMO and
if we do not get the level of quality to the industry standard (as a
minimum) within the next six months, LLI should not expect
to keep the business next year.
The student will be a Black Belt working for LLI. The specifics about their company:
CEO
Bill Lovell
GM
Mary Nichols
Sponsor
John Hopps
Finance
Cindy Jenkins
Process owner
Leroy Miller
Master BB
Dennis Kens
Manufacturing
Mitch Freese
Design Engineer
Al Nelson
Quality
Debbie Judson
The deadline for completing all project deliverables is 7 days prior to the end of the course

Objective:
The Black Belt team did a pareto analysis of the data and determined that three factors were causing
over 95% of the problem with the leveler plates. Those factors are,
the length of the plates, the width of the plates, and the thickness of the plates.
You need to know if the data from these three 'product parameters' are normally distributed.

Instructions for you:
1. Construct three (3) histograms for the three data sets.
2. Interpret each of the histograms to determine whether the variables are random or normally
distributed.

Data:
Length
10.67
10.74
10.68
10.72
10.66
10.69
10.70
10.72
10.69
10.68
10.72
10.70
10.70
10.73
10.75
10.73
10.69
10.68
10.70
10.77
10.72
10.69
10.66
10.69
10.63
10.68
10.73
10.74
10.65
10.69
10.70
10.72
10.75
10.71
10.72
Upper Spec
Lower Spec
Target

Width

11
10.5
10.75

7.66
7.45
7.55

7.51
7.57
7.55
7.53
7.53
7.56
7.52
7.58
7.55
7.53
7.56
7.58
7.55
7.55
7.54
7.57
7.54
7.55
7.55
7.56
7.54
7.56
7.56
7.55
7.54
7.55
7.56
7.57
7.54
7.55
7.54
7.55
7.53
7.54
7.55

Thickness
0.551
0.546
0.546
0.554
0.546
0.542
0.545
0.538
0.552
0.547
0.546
0.545
0.546
0.548
0.546
0.543
0.548
0.545
0.553
0.539
0.549
0.541
0.543
0.545
0.549
0.546
0.545
0.540
0.541
0.545
0.547
0.543
0.545
0.546
0.547

Histograms in Excel 2003
Histograms in Excel 2007
More on Bin Ranges

0.56
0.54
0.55

How to submit an Assignment
Target Assignment Date - Submit in Week 5 or earlier
YOU DO NOT NEED TO SEND THE ACTUAL HISTOGRAMS
Project:
Manufacturing
Deliverable:
Histogram
Student last name:
Merriweather
Is 'length' normally distributed?
Is 'width' normally distributed?
Is 'thickness' normally distributed?

Yes
Yes
No

YOU DO NOT NEED TO SEND THE ACTUAL HISTOGRAMS
To send each assignment to your instructor:
Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the
peach-colored box, then while holding down on that button, drag to
the LOWER-RIGHT corner of the box. This will highlight the entire
peach-colored box. Release the mouse button. Do a CTRL-C. This will
copy what has been highlighted.
Go to your Villanova website and follow this sequence:
1. COMMUNICATE
2. CLASS ROSTER
3. Click on your instructor's email envelope icon
4. Type "Check My Work - HISTOGRAM" in the SUBJECT box.
5. Click once inside of the message box
6. Do a CTRL-V. This will paste your deliverable into this box.
Don't be concerned if after you paste it, the appearance of the text is out of
alignment. It will straighten out after you hit SEND.
7. SEND Check your SENT ITEMS folder afterward to see how it straightened out.
Please 'hand-in' your assignments throughout the course.
DO NOT SAVE THEM FOR THE END.
Procrastinators: The deadline for completing all project deliverables
is 7 days prior to the end of the course.

Objective:
Although many things have been learned to this point and we have made progress, but we are not quite there.
Earlier in the project the team determined that thickness was the main problem relating to the high level
defects in the leveler plates. The analysis has been completed. Now, we want to IMPROVE the process.
You recommend using a design of experiments approach to hopefully realize a breakthrough improvement.
The team brainstorms a long list of possible reasons why the thickness is not capable. From that list, the
team has reduced it down to five factors they want to include in an experiment. They suspect
interactions, so they conclude a full factorial will be required. They refer to the resolution matrix (found in your
reading materials and in the Fractional Factorial Designs Lecture) and they find they can
learn about the effects of those five factors in 32 experiments.
The factors for the experiment were Depth, Temp, Pressure, R.P.M. and Time.

Instructions for you:
From the factorial experiment (below) calculate the interactions to determine confounding.
1. Fill in the interaction columns. (shaded in peach color) You will need to do
this to answer #1 in the peach-colored area below.
2. Is the design below a resolution III, IV, V or Full Factorial (no resolution)?
3. The design below is a design that an consultant is recommending. Unfortunately, you learn some bad news.
Your management has set your budget only allowing for 8 runs because the trials cost $600 a piece.
The team has determined it cannot live with main factors being confounded with other main factors or with
two-factor interactions.
What would you recommend? Big Hint: One of the factors MAY
be dropped from the study - for economic reasons. (please provide
your answer in the peach-colored area below) You do not have to determine which factor to drop.
4. Using the resolution matrix found in your online textbook,
what resolution would your recommendation be?
5. Based on your new recommendation, what are you giving up? Explain (briefly in the peach area)

"I'm lost"

Data:
Factor
Depth
Temp
Pressure
R.P.M.
Time

(-)
85
140
850
4400
30

(+)
150
155
2500
4800
45
I try to enter + or - and it does not work.

Trial
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Factor Factor Factor Factor Factor A X B A X C A X D A X E B X C B X D B X E C X D C X E D X E
C
A
B
D
E
+
+
+
+
Entering +
+
or - does
+
+
not work
How to submit an Assignment
Target Assignment Date - Submit in Week 12 or earlier
YOU DO NOT NEED TO SUBMIT THE DESIGNED EXPERIMENT
Project:
Manufacturing
Deliverable:
DOE Design Choice
Student last name:
Merriweather
1. What is the sign (+ or -) for the AxC interaction for the 4th trial?
2. What is the resolution as shown above? (III, IV, or V, or Full):::

"I'm lost"
III

3. What is your recommendation?
Your recommendation here

4. What would the new resolution be? (III, IV, or V) :::
5. What would you be giving up?
What confounding will you see?

V

Please describe what you would be giving up based
upon your recommendation.

YOU DO NOT NEED TO SUBMIT THE DESIGNED EXPERIMENT
To send each assignment to your instructor:
Click-and-hold the LEFT mouse button at the TOP-LEFT corner of the
peach-colored box, then while holding down on that button, drag to
the LOWER-RIGHT corner of the box. This will highlight the entire
peach-colored box. Release the mouse button. Do a CTRL-C. This will
copy what has been highlighted.
Go to your Villanova website and follow this sequence:
1. COMMUNICATE
2. CLASS ROSTER
3. Click on your instructor's email envelope icon
4. Type "Check My Work - DOE" in the SUBJECT box.
5. Click once inside of the message box
6. Do a CTRL-V. This will paste your deliverable into this box.
Don't be concerned if after you paste it, the appearance of the text is out of
alignment. It will straighten out after you hit SEND.
7. SEND Check your SENT ITEMS folder afterward to see how it straightened out.
Please 'hand-in' your assignments throughout the course.
DO NOT SAVE THEM FOR THE END.
Procrastinators: The deadline for completing all project deliverables
is 7 days prior to the end of the course.