ENG08037 2019 Metrology & Six Sigma 3 Project

Demonstrate an ability to select a method of inspection for a specific
dimension on a typical injection moulded component

Design & development of a simple fixture to hold a plastic component during
inspection

Use of metrological instrument to develop a measurement routine to inspect a given
dimension on a component.

Assess the suitability of a measurement system for the inspection of a dimension
through the use of Gauge R&R.

Demonstrate an understanding of basic statistics pertinent to the polymer industry.

Identify a problem which needs to be addressed of importance to the organisation.

Utilise an appropriate structured approach to manage the project with realistic, interim and overall project objectives.

Prepare a written report which outlines in detail the background to the project, the methodology used, discussion, conclusions and recommendations.

Present project results with Executive Summary, Conclusions and Recommendations and discuss the approach taken and results achieved.

Metrology

12 hours theory and 24 hour labs (8 x 3 hours)

Six Sigma 3 Project

Six Sigma 3 Project - Students will undertake a formal project, with online  direction and monitoring.

The online teaching and learning strategy will follow the guidelines as developed by Quality Matters: http://www.qmprogram.org/

Unique to the Quality Matters Rubric is the concept of alignment. This occurs when critical course components - Learning Objectives (2), Assessment and Measurement (3), Instructional Materials (4), Learner Interaction and Engagement (5), and Course Technology (6) - work together to ensure students achieve desired learning outcomes.

This is a combined module consisting of Metrology and Six Sigma 3 Project. 

The student much pass both of these elements before they are considered to have passed the module.

Metrology

Continuous assessment 50%

Final Exam 50%

Six Sigma 3 Project

The Project will be assessed by the student preparing interim and final written reports along with a presentation by the student. The project supervisor may also require a log book to be completed regularly by the student.

Project Type A: Six Sigma DMAIC

The Interim Report and Final Report are to be prepared in a structured format using Microsoft Word. The Final report should be at least 3000 words (10 - 12 pages) and contain the following major sections.

• Executive Summary
• Background & Objectives
• Method (DMAIC)
• Results
• Conclusions & Recommendations

The Interim Report should address the 'Background & Objectives' and the 'Method' you plan to utilise to undertake your project.

Six Sigma Projects will be assessed taking into consideration the following:

1. Report Structure & Format

• How clear were the aims and objectives?

• Is the report well structured with logical flow and

• Was supporting data available

• Good use of charts and graphs

2. Students contribution

• Individual Vs Team contribution

• How critical was the student to success of overall project?

3. Problem solving methodology used

• Was methodology appropriate to this project?

• How many tools were used? - Six Sigma, Lean, Project Management, etc.

• Should additional tools have been chosen?

4. Value to the company

• Did the project meet its goals?

• What metrics were improved?

• How much money, time was saved, quality improved?

5. Level of innovation and technical difficulty

• How innovative were the solutions proposed?

• How technically difficult was the project?

• Was the project complex, cross-functional?

Project Type B: Research Project

The Interim Report and Final Report are to be prepared in a structured format using Microsoft Word. The Final report should be at least 3000 words (10 - 12 pages) and contain the following major sections.

• Introduction
• Literature Review
• Method
• Conclusions and Recommendations
• Appendices

Marks should be assigned depending on how well the student has addressed the following and how well the student answers questions during the presentation.

Why am I doing the project?                                                                                               

• Has the problem been adequately defined?
• Has a clear, appropriate and attainable set of aims been identified?

What has been done before?                                                                                               

Has a critical review of the relevant literature been performed? (as a MINIMUM, the student is expected to reference AT LEAST 15-30 appropriate REFEREED publications, though preferably more).

• Has the relationship between the project and the literature been adequately defined

What am I going to do?                                                                                                        

• Has a logical process been developed to meet the aims?
• Has this process been justified?
• Is the methodology appropriate for the scope of the research?

As above

Metrology

Interoperate Drawing: Reading typical injection moulding drawings, applied tolerances, GD&T, Datum Structures

Fixture Development: Location & Clamping; redundancy of location and distortion. Restriction of the 6 degrees of freedom, accommodation of part to part variation.

Instrument Fundamental: Health & Safety, Machine components & operation; Touch Probes, Styli, Change Rack & Camera, Lens, User interfaces; General User Interface (GUI) & Joystick, Directional Control, Zoom Levels, User Verifications & Bracketing, Maintenance and Calibrations; MPE1, 2 & 3, polar & Cartesian coordinate system, efficiency of programing

Tactile Measurement: Strengths & weakness, Manual measurement, Vectoring & Cosin Error, Programming from CAD model, alignment, clearance zones, points, lines, planes, circles, cones, spheres & scanning travel distance, retract distances

Optical Measurement: Strengths & weakness, Picking up the camera probe, Lighting sources; top, bottom, ring light, and colour lighting. Lighting levels; contrast & saturation, edge definition, filtration tools

Extrapolation: Constructing Features; points, midpoints & centre lines, Measuring Distances & Angles, Looping & Arrays, Setting up a template, Reading out to a report.

Measurement System Qualifications: Gauge Repeatability & Reproducibility; Type 1 & Type 2: Objectives, study design, reference standards, acceptance criteria; Cg & Cgk/ %Tolerance & %Contribution, Gauge R&R 6 Pack

Basic Statistics: Introduction to Minitab, Mean, Standard Deviation, Normality, Process Capability; Cp, Cpk, & Pp, Ppk, P-Values & Student t-Test, Regression

Data Integrity: cGMP,21 CFR Part 11, Level 1 & Level 2 Guidance documents

Six Sigma 3 Project

• The student should bring the learning from the subjects covered in the course to conceive, define and agree a project which is relevant to the students course of study.
• Various types of projects may be undertaken depending on whether the student is full time or part time and their course of study.  Examples of these are as follows:

Project Type A: Six Sigma DMAIC

The Six Sigma project will be undertaken by the student and should address a substantive issue in the workplace. The project will test the student's ability to define a real-life problem of concern to the organisation, design a strategy for addressing the problem, gather data, formulate and evaluate options and make recommendations. The project should follow the Six Sigma DMAIC methodology. While it is recommended that the problem is addressed as part of a cross-functional team, it is important that the student makes a significant contribution to the success of the project. A financial saving should be identified. The Green belt is normally expected to contribute annualised savings from €30,000 - €100,000. The amount of savings will depend on the size of the company, sales revenue, number of employees and opportunities for improvements.

The Six Sigma project will also cover the following areas:

1. Project management basics

•· Project charter and problem statement

•· Define and describe elements of a project charter and develop a problem statement, including baseline and improvement goals.

•· Project scope

•· Assist with the development of project definition/scope using Pareto charts, process maps, etc.

•· Assist with the development of primary and consequential metrics (e.g., quality, cycle time, cost) and establish key project metrics that relate to the voice of the customer.

•·  Use project tools such as Gantt charts, critical path method (CPM), and program evaluation and review technique (PERT) charts, etc.

•· Provide input and select the proper vehicle for presenting project documentation (e.g., spreadsheet output, storyboards, etc.) at phase reviews, management reviews and other presentations.

•· Describe the purpose and benefit of project risk analysis, including resources, financials, impact on customers and other stakeholders, etc.

• Describe the objectives achieved and apply the lessons learned to identify additional opportunities.

 2. Team dynamics and performance

•·  Define and describe the stages of team evolution, including forming, storming, norming, performing, adjourning, and recognition. Identify and help resolve negative dynamics such as overbearing, dominant, or reluctant participants, the unquestioned acceptance of opinions as facts, groupthink, feuding, floundering, the rush to accomplishment, attribution, discounts, plops, digressions, tangents,

•· Describe and define the roles and responsibilities of participants on six sigma and other teams, including black belt, master black belt, green belt, champion, executive, coach, facilitator, team member, sponsor, process owner, etc.

•· Define and apply team tools such as brainstorming, nominal group technique, multi-voting, etc.

•· Use effective and appropriate communication techniques for different situations to overcome barriers to project success.

Project Type B: Research Project

Where the student is unable to complete a project in the workplace, a suitable research project may be undertaken by agreement with the project supervisor.  The principal difference between this type of project and Project Type A is that there will be minimal practical work and no requirement to show cost savings for the research project. There will also be a greater emphasis on the students background research and literature review of the chosen topic.

Note: The Research project type is NOT suitable for students wishing to pursue a Six Sigma Green Belt award.