Keki Bhote - World Class Quality: Using Design of Experiments to Make It Happen

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World Class Quality Using Design of Experiments to Make it Happen Foreword by Dorian Shainin Keki R. Bhote

Page iv This book is available at a special discount when ordered in bulk quantities. For information, contact Special Sales Department, AMACOM, a division of American Management Association, 1601 Broadway, New York, NY 10019. This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. It is sold with the understanding that the publisher is not engaged in rendering legal, accounting, or other professional service. If legal advice or other expert assistance is required, the services of a competent professional person should be sought. Library of Congress Cataloging-in-Publication Data Bhote, Keki R., 1925 World class quality: using design of experiments to make it happen / Keki R. Bhote. p. cm. Includes index. ISBN 0-8144-5053-9 1. Quality controlStatistical methods. 2. Process control Statistical methods. 3. Experimental design. I. Title. TS156.B5631991 658.562dc20 91-19269 CIP 1991 AMACOM, a division of American Management Association, New York. All rights reserved. Printed in the United States of America. This publication may not be reproduced, stored in a retrieval system, or transmitted in whole or in part, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of AMACOM, a division of American Management Association, 1601 Broadway, New York, NY 10019. Printing number 20 19 18 17 16

Page v To Dorian Shaininan American icon and the world's foremost quality problem solver and To my son, Adi K. Bhote, whose practice of the Design of Experiments is beginning to exceed mine. It is a fond father's greatest reward.

Page vii CONTENTS Foreword ix Part I: Introduction 1 1. The Need for Simple, Powerful Problem-Solving Tools 3 2. The Four Stages of Quality 8 Part II: The Design of Experiments (DOE): Key to the Magic Kingdom of Quality 25 3. The Measurement of Process Capability 27 4. Variation: An Industrial Epidemic 40 5. Three Approaches to DOE: Classical, Taguchi, and Shainin 48 6. Multi-Vari Charts: To Home In on the Red X 58 7. Components Search: Easy, Surefire Clues 66 8. Paired Comparisons: The Detective Method 85 9. Variables Search: The Rolls-Royce of Variation Reduction 89 10. Full Factorials: Ideal for Quantifying Interaction Effects 102 11. B vs. C: A Versatile, Universal Tool 117

Page viii 12. Scatter Plots (Realistic Tolerance Parallelogram Plots): For Optimization and Establishing Realistic Tolerances 132 13. A Case Study Encompassing a Logical Sequence of the Seven DOE Tools 142 Part III: Statistical Process Control (SPC) 159 14. Elementary SPC Tools 161 15. Control Charts vs. Precontrol: Horse and Buggy vs. the Jet Age 171 16. Positrol, Process Certification, and Operator Certification 196 Part IV: The March From Passive Learning to Implementation 203 17. The Management and Practice of Design of Experiments 205 Appendix: An Excerpt From "Better Than Taguchi Orthogonal Tables" by Dorian Shainin and Peter Shainin 211 Index 221

Page ix FOREWORD

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