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2. Types of variation. Common causeAlways presentInherent in processCan predict performance with a range of variationCannot tell what specifically causes variation. Special causeAbnormal, unexpectedDue to causes not inherent in processCan be identified (e.g., change in shift, weather, process).
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1. 1 Colorado 5M WebExVariation, Run Charts, and Control ChartsBeth A. Katzenberg, EdM, MBA, CPHQDirector, Corporate Quality & ComplianceColorado Foundation for Medical Care
2. 2 Types of variation Common cause
Always present
Inherent in process
Can predict performance with a range of variation
Cannot tell what specifically causes variation
Special cause
Abnormal, unexpected
Due to causes not inherent in process
Can be identified (e.g., change in shift, weather, process)
3. 3 You must understand the type of variation that is occurring as this will determine how you address the problem.
4. 4 Variation
5. 5 Pitfalls If only common cause variation and treat as special cause (tampering), leads to greater variation, mistakes, defects
If common cause and special cause, and change the process, leads to wasted resources because the change won’t work
6. 6 Tools to identify variation
7. 7 Run charts
8. 8 Run chart
9. 9 Run chart analysis: Common cause variation only
10. 10 Run chart analysis: Runs Run = one or more consecutive data points on the same side of the median
Excludes data points on the median
11. 11 Expected number of runs
12. 12 High probability of special cause variation:Too few runsToo many runs
13. 13 Run chart analysis: Run length
14. 14 Run chart analysis: Trends
15. 15 Run chart analysis: Freaks
16. 16 Run chart analysis: Cycling
17. 17 Run charts tips How many data points?
15-20 minimum is preferable
Median = 50%/50% split point
Precisely half of the data set will be above the median and half below it
18. 18 Control charts
19. 19 Control chart
20. 20 Dividing control chart into zones
21. 21 Identifying special causes Apply independently to each side of the center line:
1 point outside the 3 sigma limit
2 out of 3 consecutive points in zone A or beyond
4 out of 5 consecutive points in zone B or beyond
<20 total data points: 7 consecutive points in zone C or beyond on one side of center line
20+ total data points: 8 consecutive points in zone C or beyond on one side of center line
(continued)
22. 22 Identifying special causes, cont. Apply this test to entire chart:
<21 total data points: 6 or more points in a row steadily increasing or decreasing
21+ total data points: 7 or more points in a row steadily increasing or decreasing
14 consecutive points alternating up and down in saw-tooth pattern
15 consecutive points in zone C (above and below center line)
23. 23 Deciding which control chart to use
24. 24
25. 25 Control chart example 1
26. 26 Control chart example 2
27. 27 Control chart example 3
28. 28 Control chart example 4
29. 29 Just because a process is under control (common cause variation only), it does not mean that the process is meeting expectations.
It just means that the process is predictable and you are getting consistent performance.
30. 30 Control charts tips Control limits are not specifications limits (specification limits related to customer requirements)
After removing special causes and recalculating chart, continue to plot new data on this chart, without recalculating control limits.
Recalculate control limits only when a permanent, desired change has occurred in the process and only using data after the change occurred
31. 31 Share the data Team meetings
Post in break-rooms
Newsletters
Intranet
32. 32 Examples of Software QI Macros www.qimacros.com
StatSoft www.statsoft.com
Minitab www.minitab.com
33. 33 References Carey, R.G. & Lloyd, R.C. Measuring Quality Improvement in Healthcare: A Guide to Statistical Process Control Applications, Quality Resources, 1995.
Pyzdek, R. The Six Sigma Handbook: A Complete Guide for Green Belts, Black Belts, and Managers at All Levels, 2003.
The Six Sigma Memory Jogger II, GOAL/QPC, 2002.
34. 34 Beth Katzenberg, EdM, MBA, CPHQ
Director, Corporate quality & compliance
Colorado Foundation for Medical Care
bkatzenberg@cfmc.org