Statistics & Six Sigma

The application of statistical techniques to production processes

Applying statistical techniques to production processes and services makes it possible to reduce costs and improve quality in a systematic, lasting way. Through the development of specific targeted projects, the 6 Sigma program makes it possible to achieve drastic, “breakthrough” improvements and to optimize processes and services, with significant benefits in efficiency and waste reduction.

Process optimization

GESTLABS personnel are Six Sigma Master Black Belt qualified and support customers in applying statistical techniques and 6 Sigma improvement projects, such as:

Statistical Process Control (SPC)

The aim of Statistical Process Control (SPC) is to keep the production process stable and, at the same time, to evaluate it against specification requirements, whether applicable to finished or semi-finished products. SPC is essential to ensure that products meet customer expectations and, at the same time, to reduce production costs caused by defects generated in the various process phases. SPC is an indispensable requirement in sectors with critical quality requirements (automotive, medical, aerospace, etc.).

Control charts

Control charts are the most suitable tool for evaluating and maintaining the stability of the production process and, together with process capability analysis, they are an essential technique in Statistical Process Control (SPC). Control charts make it possible to distinguish cases where process variability is due to so-called “special” causes — which must be removed to prevent the process from going out of control — from cases where no intervention is needed because the variability is the natural variability of the process. To be effective, control charts must be selected according to the process parameters to be analyzed, and their control limits must be rigorously defined.

Process Capability

Process capability is the ability to build products that comply with specification requirements. It is measured through dedicated indices, Cp and Cpk, which make it possible to estimate the percentage of products that will fall outside specification limits and will therefore result in defects in the short or long term. Together with control charts, the evaluation of process capability through the calculation of Cp and Cpk values is an indispensable tool in Statistical Process Control (SPC).

ANOVA

ANOVA (Analysis of Variance) is a statistical technique for determining whether the differences found between groups of data should be considered random or significant, i.e. due to factors capable of influencing the data. ANOVA has a very wide range of applications, from the analysis of treatments of any kind (chemical, physical, etc.) to the evaluation of production processes or services.

Sampling plans

Sampling plans define the criteria, based on statistical inference, for carrying out sample checks, applicable in any context (acceptance/evaluation of batches of products or semi-finished goods, of production processes or of services). Applying sampling plans also makes it possible to rigorously and objectively evaluate the risks and benefits of each type of sampling.

Design of Experiments

Design of Experiments (DOE) is a statistical technique that optimizes processes and services according to the goals to be achieved, through the setup and statistical analysis of a structured set of tests/experiments. DOE can be used very effectively in the most diverse fields and applications, both industrial and otherwise.

Statistical Tests

Statistical tests make it possible to evaluate whether the differences found between groups of data — relating to batches, samples, production processes or services — should be considered purely random or due to real variations. With these tests it is also possible to establish, unambiguously and objectively, whether the observed trends correspond to real or only apparent improvements, deteriorations or variations.

FMEA

FMEA (Failure Modes and Effects Analysis) is a technique for analyzing a design or a production process to identify potential weaknesses and implement improvement actions. FMEA assigns intervention priorities on the design or process through an evaluation carried out by a dedicated team. When FMEA is performed on a design it is called DFMEA (Design FMEA); when applied to a production process it is called PFMEA (Process FMEA).

Measurement system analysis (repeatability, reproducibility, gage R&R, accuracy)

Measurement system analysis is carried out to determine measurement error, which in turn has several components. The analysis known as gage R&R determines repeatability (i.e. the variability due solely to the intrinsic error of the instrument or measurement system) and reproducibility (i.e. the variability due to factors such as the operator, environmental variations, etc.). In addition to these quantities, to determine the overall accuracy of the measurement, the “bias” must be calculated, i.e. the deviation of the mean of the measured values from the true value.

6 Sigma method

The 6 Sigma methodology applies to both production processes and services, and aims to achieve significant improvements that cannot be obtained through ordinary actions leading to gradual improvement. This methodology relies on statistical techniques and on targeted projects structured in 5 phases: Define, Measure, Analyze, Improve and Control (DMAIC).

Other services

Product reliability analysis

Reliability plays a fundamental role and has a deep impact on the safety of many products released on the market (automotive, medical, etc.).

Laser safety and artificial optical radiations

All materials, equipment, machinery, installations and electrical and electronic systems must be designed and built to professional standards.

LED Technology

Ensuring the reliability of the electronic components of LED-based products means being able to release safe, reliable products.

ESD and MSD Analysis

Ensuring the reliability of the electronic components of LED-based products means being able to release safe, reliable products.

GESTLABS labs

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