[go: up one dir, main page]
Scribd
Upload
47 views3 pages

Variability Reduction

This document discusses variability reduction, which aims to reduce product variation and make products more robust. There are three main sources of variation: manufacturing variation, environmental/deterioration variation, and usage variation. Design of experiments can be used to understand which factors most influence variation and determine designs that minimize it. Additional techniques to reduce manufacturing and usage variation include process capability analysis, statistical process control, process optimization, and mistake-proofing. The overall goal of variability reduction is to develop robust product and process designs that balance customer needs with sources of potential variation.

Uploaded by

vijayakum ar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
47 views3 pages

Variability Reduction

This document discusses variability reduction, which aims to reduce product variation and make products more robust. There are three main sources of variation: manufacturing variation, environmental/deterioration variation, and usage variation. Design of experiments can be used to understand which factors most influence variation and determine designs that minimize it. Additional techniques to reduce manufacturing and usage variation include process capability analysis, statistical process control, process optimization, and mistake-proofing. The overall goal of variability reduction is to develop robust product and process designs that balance customer needs with sources of potential variation.

Uploaded by

vijayakum ar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 3

Variability Reduction is a multi-part strategy to reduce product variation and make a product more

robust or fit to use, e.g., meet its performance requirements regardless of variation.
Broadly speaking, there are three sources of variation: manufacturing variation,
environmental/deterioration variation and usage variation. To the extent we are aware of these
potential sources of variation, we can take steps to design a product to counter these sources of
variation.

This is the concept of robust design. It is achieved primarily by the use of design of experiments to
determine which factors (product and process parameters) are most sensitive to variation or noise
and which factor level settings (parameter values) minimize the variability in the desired performance
parameter.
Design of Experiments (DOE) can be used to counter all three sources of variation. In addition, other
steps can be taken to counter manufacturing variation and usage variation. First, understanding the
statistical capability of a process (process capability) can help to either design within the capability of
that process or determine when an improved capability is required (e.g., new equipment,
outsourcing, etc.). Second, by using SPC, special cause variation can be identified and attacked.
Third, over the longer term, process variability from common causes can be systematically reduced
through process optimization, operator training, preventative maintenance, tool monitoring,
standardization of machine settings, climate control, power conditioning, etc. Fourth, variability in
usage can be countered by mistake-proofing (see design for manufacturability guidelines), warning
labels, easy-to-understand operating manuals and controls, etc.

Variability reduction involves understanding customer needs and developing a product and process
design that balances these needs with process capabilities and potential sources of variation. Thus
variability reduction is broader than SPC and DOE individually and more proactive than SPC. The
following diagram represents an overall framework for variability reduction or quality engineering.
One source for further information is a book titled OPTIMIZATION AND VARIATION REDUCTION
IN QUALITY by Wayne Taylor, 1991, McGraw Hill, ISBN 0-07-063255-3.

ypes of Variation
There are two basic types that can occur in a process:

 common cause
 special cause

Common Cause

Common cause variation happens in standard operating conditions. Think


about the factory we mentioned before. Fluctuations might occur due to the
following:

 temperature
 humidity
 metal quality
 machine wear and tear.

Common cause variation has a trend that you can chart. In the factory
mentioned before, product differences might be caused by air humidity. You
can chart those differences over time. Then you can compare that chart to
weather bureau humidity data.

Special Cause

Conversely, special cause variation occurs in nonstandard operating


conditions. Let’s go back to the example factory mentioned before. Disparities
could occur if:

 a substandard metal was delivered.


 one of the machines broke down.
 a worker forgot the process and made a lot of unusual mistakes.

This type of variation does not have a trend that can be charted. Imagine a


supplier delivers a substandard material once in a three-month period.
Subsequently, you won’t see a trend in a chart. Instead, you’ll see
a departure from a trend.

You might also like