Hub
Training ModeLevel 1: Quality Awareness
Do You Know Your Numbers?
Cp
Process Potential
Even if your car can do 300km/h (High Cp), if you drive on a cliff edge, it's unsafe.
Width of Spec / Width of Process
Cpk
Process Capability
This is your actual driving. It considers if you are centered or drifting.
Min (Cpu, Cpl)
Sigma (σ)
Variation (Noise)
Smaller σ = Thinner curve = Consistent product. σ is the enemy.
Standard Deviation
The 1-10-100 Rule
Why 'Do It Right The First Time' is cheapest?
COST MAGNITUDE
$1
$10
$100
StationFactoryCustomer
Stage 1: Prevention / At Station
If you catch the defect AT the station (Self-Check), it costs $1 to fix (seconds of time).
The PDCA Wheel
Quality rolls back without a wedge. Only 'Standardization' prevents backsliding.
PDCA
Standard (SD)
Quality Level
Basic
Push Quality Higher:
P
Plan
D
Do
C
Check
A
Act
Click button to start cycle...
5S Management: Sort (Seiri)
Step 1: Distinguish 'Needed' vs 'Not Needed'. Remove the trash.
Workbench
Mission Instructions
This workbench is a mess. Click on all **TRASH (Red)** to remove it. Do NOT click useful tools!
Trash (Click to Remove)
Tool (Keep)
The 5 Whys Detective
Don't be a 'Band-Aid' doctor. Find the Root Cause.
1
There is an oil puddle on the floor.
2
The machine is leaking oil.
3
The seal has failed (broken).
4
The seal quality was poor (Cheap part).
5
Because Purchasing wanted to save cost on this SKU.
6
ROOT CAUSE: No 'Spare Part Spec', only Price.
There is an oil puddle on the floor.
What do you do?
Anatomy of the Formula
Why Cpk = Min(Cpu, Cpl)?
Upper Capability (Cpu)
( USL - Mean )/3σ
How far are you from the Right cliff (USL)?
Lower Capability (Cpl)
( Mean - LSL )/3σ
How far are you from the Left cliff (LSL)?
VS
Cpk always takes the WORST value (Smaller distance). Because the weakest link determines your risk.