Design of Experiments
To further understand why during a process, we have erratic outputs, we follow the concept of Designing Experiments
to detect the source of the process inconsistencies. This event is referred
to as "Design of Experiments" (DOE). Montgomery, D. C. (1991) notes that
"A designed experiment is a test in which some purposeful changes are
made to the input variables of a process or system so that we may observe
and identify the reasons for changes in the output response. ... Experimental
design methods play an important role in process development and process
At Pyramid Consulting, Incorporated
(PCI) our staff will use Factorial Analysis that consist of Software Simulations,
and use of STATISTICA applications when pursuing DOE. This can
all also lead to the following:
- Design for Cost (Cheaper)
- Design for Quality (Better)
- Design for Cycle Time (Faster)
Other applications will consist of geometric
principles to statistical sampling to obtain desired results such as minimizing
the number of experiments necessary to obtain the answer to a problem
or minimizing the variance of estimated coefficients obtained through
With the ever-growing emphasis
on Safety within the workplace, Ergonomics has become an important
topic of discussion within employers as well as employees. With
the implementation of Ergonomics, Pyramid Consulting, Incorporated
(PCI) can help you, the customer improve workstations to better
suit the worker. Some of these Ergonomics solutions can be small,
but in return can have a great effect on the performance and
efficiency of the workplace.
At PCI, our professionals can
develop “Return-to-Work” programs that are cost effective and
efficient. Under our “One-Stop” e-Portal, we are able to team
up with other divisions of PCI to ensure the best solutions to
meet the needs of our customers. Where applicable, PCI will team
up with Chiropractors to ensure the most effective and efficient
At first, PCI would provide an
audit of the workstation. This would be in reference to a
“Design Review”. Where is the disorder and how it came about?
Then our professionals develop a successful ergonomics program to
fit your environment. This environment can consist of a
manufacturing line, a non-office location, or an office location.
We would provide brainstorm sessions with the customer to ensure
that the best possible program is implemented. Sometime this could
consist of just educating the workers on the proper use of the
tools around their workstation.
and Time Case Studies
The purpose of Case Time
Studies is to bring about complete elimination of waste. Which in
return increases profits, reduced cycle time, and even quality
At Pyramid Consulting,
Incorporated (PCI), we would designate a staff just for the
purpose of providing you with such a Motion and Time Study. We
would begin with an Audit of the process line you wish to achieve
complete “Elimination of Waste” and “Improvement” on. This
audit would consist of actual Stopwatch readings of each process
and at the same time, videotape if approved. The entire “Case
Study” would consist of the following:
- Methodology (Flowchart)
Statistical Process Control (SPC)
What exactly is Statistical Process
Control (SPC)? SPC is a method that reduces your production costs and
gives your company even better control over striving quality standards.
As a company, SPC can help you:
- Keep track of your process, and make adjustments before
defective parts are produced
- Detect or identify causes of defects
There are many benefits to using SPC,
some of which have a direct, positive impact on you. Generally, SPC means:
- Less cost to make a product
- Less reworking of the product, and less need for inspection
- Less scrap and waste
- Detect or identify causes of defects.
- Higher quality, yields, and productivity
- Satisfied customers (whether they be the consumer, or
the next person down the manufacturing line from you)
But, equally importantly, SPC gives
- More of a sense of control over the process, and your
- A more interesting and challenging job
- An expanded role in the making of a product
- Guideline towards Six-Sigma
How is Six Sigma associated with SPC?
Well in order to achieve Six Sigma, you need to use statistical methodologies.
The primary tool implementing “Six Sigma” is the use of the “Control Chart”.
In general a control chart is a tool of SPC. In a control chart you have
reference lines, called control limits, which are calculated based on
the data in the chart, in such a way that very few points will fall outside
the control limits as long as the process is producing consistent results.
Six Sigma technically means a failure
rate of 3.4 parts per million; however, the term in practice is used to
denote more than simply counting defects. With Continuous Improvement
an ongoing quest for a vast number of companies, we at Pyramid Consulting,
Inc. (PCI) strive to be your “One-Stop” e-portal to fulfill that quest.
Without implementing SPC and eventually
striving towards Six Sigma, the goal for virtually defect free processes
is extinct. As a matter of fact, Six Sigma is so important now than ever,
that Motorola has developed the Six Sigma Black Belt level of expertise.
The Six Sigma implementation projects
can cost on the average of $85,000 to $185,000 in value through the improvement
of cycle time, reduction of defects, cost reductions, etc.
Since PCI is an official WonderwareTM
Systems Integrator, we can develop the proper SPC guidelines to fit your
needs along with the proper software packages. Our staff utilizes the
PCI “One-Stop E-portalTM” concept to implement
the best strategy for you to ensure that highest results.