Is Feature Critical to Product

Performance ORResponsive to

Variation?

Develop Complete List

Screening Study Varying Machine / Material

Designate asKey Feature

Omit From Key Feature Study

Rep

eat f

or

Eac

h F

eatu

re

Yes

No

Are Key ProductFeatures Stable

Study Key ProductFeature

Baseline Current Operating Conditions

Investigate ProcessRelationship

Investigate ProcessVariables

Rep

eat f

or

Eac

h V

aria

ble

Yes

No

Are Key FeaturesCapable

Conduct DesignedExperiments

Develop process / product“Process Window “

Establish SPCCharting

Yes

No

Key Feature CapabilityStudy

Draft OperatorsGuide

Good Cp &Bad Cpk

Can Spec.Change?

ChangeSpec.

Find CenteringCause & Correct

Change ProcessMachine or Material

Yes

Yes

No

No

Does Process Variable

Affect ProductStability

Develop Complete ListBrainstorm & Fishbone

Select Process Variables to Study

Designate asKey Variable

Omit From Variable StudyR

epea

t for

E

ach

Var

iabl

e

Yes

No

Study ProcessVariables

Are process variables stable

Define Source of Instability

Change Process

Slide 1

Slide 4

Slide 2

Slide 3

ManufacturingProcess Improvement

The Big Picture

AEP 10/21/98

1. Select Key Product Features:

Is Feature Critical to Product

Performance ORResponsive to

Variation?

Develop Complete List

Screening Study Varying Machine / Material

Designate asKey Feature

Omit From Key Feature Study

Rep

eat f

or

Eac

h F

eatu

re

Yes

No

To Feature Study

AEP 10/21/98

2. Study Key Features:

Are Key ProductFeatures Stable

Study Key ProductFeature

Baseline Current Operating Conditions

Investigate ProcessRelationship

Investigate ProcessVariables

Rep

eat f

or

Eac

h V

aria

ble

Yes

No

From Key Feature List

To Variable Study

To Process Relationship Study

From ProcessVariable Study

AEP 10/21/98

3. Select Key Process Variables:

Does Process Variable

Affect Stability?

Develop Complete ListBrainstorm & Fishbone

Select Process Variables to Study

Designate asKey Variable

Omit From Variable Study

Rep

eat f

or

Eac

h V

aria

ble

Yes

No

From Unstable Feature Study

Return to Key Feature Study

Are ProcessVariables Stable?

Study ProcessVariables

Change Process

Define Source of Instability

No

YesAEP 10/21/98

4. Investigate Process Relationships:

Are Key FeaturesCapable

Conduct DesignedExperiments

Develop process / product“Process Window “

Establish SPCCharting

Yes

No

Key Feature CapabilityStudy

Draft OperatorsGuide

Good Cp &Bad Cpk

Can Spec.Change?

ChangeSpec.

Find CenteringCause & Correct

Change ProcessMachine or Material

Yes

YesNo

No

From Stable Key Features

AEP 10/21/98