Process variation hinders organizational potential.
Process Variation in Lean Six Sigma
Uncontrolled output differences harm efficiency & quality across manufacturing & healthcare industries.
1. Common Cause Variation:
Sources of Process variation
Natural variability inherent in any process over time.
Expected fluctuations even with stable inputs and methods.
2. Special Cause Variation
Examples include raw material problems, operator errors, equipment failures.
Unusual changes traced back to specific circumstances.
3. Assignable Variation
Preventable variability due to issues like substandard inputs.
4. Random Variability
Natural variation in stable processes despite controls in place.
Types of Process Variation
Variability in Outputs -
1. Dimension Variation:
Manufacturing faces quality issues due to dimensional variation.
2. Defect Rates:
Defect rates reflect product flaws per total output, indicating process stability.
3. Cycle Times:
Cycle time variation affects scheduling and on-time performance.
Variability in Inputs -
1. Raw material properties:
Product components vary in size, purity, and mechanical specs.
2. Environmental Conditions
Environmental factors impact process dynamics and output consistency.
3. Measurement System Variation
Input tools introduce variability, mitigated by calibration and confirmation.
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