SIRWILL FBM TOOLS® SPC / EPC / Six Sigma Module

Version 6.0 for Windows ’98 and above

Copyright © 2009 – 2028 Sirwill Software (P) Ltd., India.

WEB DOWNLOAD / CD-ROM

Fact-Based Management Software for Statistical Process Control (SPC) Engineering Process Control (EPC) Six Sigma Metrics

USER MANUAL (LITE / STANDARD)

Developed and Marketed by:

SIRWILL SOFTWARE (P) LTD. ‘Anjali’, T.C-5/674, Trivandrum, Kerala, India - 695005. Tech. Support: +91 9830481675 E-Mail : [email protected] , [email protected] Web: www.GlobalQualityVillage.com

Software Edition Restrictions LITE Can analyse up to a maximum of 25 records only. Also some menus are disabled. STANDARD Can analyse up to a maximum of 10000 records. All menus are enabled. ® Sirwill FBM Tools - SPC Module USER MANUAL

Table of contents

Chapter Title Page No. 1 Introduction 3-4 2 Installation Process 5-6 3 First Screen 7 4 File Menu 8-10 5 Reports Menu 11 6 Graphics Menu 12 7 Help Menu 13 8 Step-by-step : Control Charts 14-19

Page: 2 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 1

INTRODUCTION

Welcome to the world of Statistical Process Control (SPC), Engineering Process Control (EPC) and Six Sigma Metrics.

Sirwill FBM Tools® - SPC / EPC / Six Sigma module is designed for the quality conscious engineers and managers who wish to improve quality of their products / processes / services.

This software supports analysis of a variety of Statistical Process Control data that one encounters in industrial and business situations. You will also find advanced statistical analysis of chart patterns such as run analysis included in this software. Apart from traditional SPC charts, there is provision for using user-specified control limits to monitor the processes once they attain stable condition.

Pareto Analysis and Scatter Plots are also included as additional tools, which are very useful in quality improvement studies.

Engineering Process Control (EPC) tools such as Correlogram and Prediction Chart may be used only after the process attains stability.

Six Sigma Metrics such as Defects per Million (DPM), Sigma Quality Level, and Yield (%) can be computed for both homogenised and unhomogenised (raw) data. However, we recommend the use of these statistics computed from homogenised data only.

The following table gives a summary of SPC tools and analysis supported by this software.

Data Type 3-Sigma Control Charts Other Charts Analysis

Variable ! X-Moving Range ! Run Chart ! Basic Statistics (measurable) ! Xbar-Range ! Histogram ! 3-Sigma limits ! Xbar-Sigma ! Process Capability ! Normal Distribution Indices (Cp,Cpk) (with Six Sigma Metrics) ! Run Analysis

! Correlogram (EPC) ! Prediction Chart (EPC)

Attribute ! Fraction Defectives (p) ! Poisson Distribution ! Basic Statistics (countable) ! Total defectives (Np) (with Six Sigma Metrics) ! 3-Sigma limits ! Defects per Item ( c ) ! Run Analysis ! Defects per unit (u)

Variable / ! Pareto Diagram Attribute

Variable ! Scatter Diagram and Linear Regression * Some items are not supported by the LITE edition, and those menu’s appear ‘greyed’ when you run the software.

Page: 3 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Data Input All data files to be analysed by this software must be in a specific format (*.fts) recognized by the software. If you wish to create *.fts data files and key-in the data afresh, you can use the data editing facility. There is also provision for importing data from existing MS-Access, dBase IV or Excel files. Statistical Output Statistical analysis reports (in textual form) can be displayed on the screen, stored in a user-specified output file, or diverted to printer for hard copy. Graphical output such as charts and diagrams can be displayed on the screen or printed through any Windows ’98 compatible printer. On-line Help On-line pop-up help feature provides context-sensitive help while running the software. Just click open the On-line Help from the menu-pad once, and press F1 key thereafter.

Computer Requirements This software can run on Windows ’98 and above. Recommended configuration of computer is: P-III machine with 64 MB RAM, 200 MB free disk space, Colour monitor with 800x600 resolution, Colour Inkjet printer.

Page: 4 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 2

INSTALLATION PROCESS

Step - 1: SPC Software Installation

Open the downloaded zip file using WinZip utility and unzip (extract) all files into a temporary folder on the desktop. Sub-folders would be created automatically and the files get placed in the appropriate sub-folders. (If you are installing the software from a CD, please skip this step and load the CD in the CD-ROM).

Then open the folder (or explore the CD) and double-click on the file named MDAC_TYP.EXE to install the Microsoft data access components on your computer. This is required for the SPC software to have proper access to database files. If it is already installed on your computer, the windows system would flash a message (and you may skip this step)

After that, locate a file named 'setup.exe' in the folder. Run this file by double-clicking on the icon.

Now, the software installation process begins. Please follow the instructions displayed by the setup program. If any error message is displayed, click on the 'Ignore' button.

On successful completion of setup, the software will be installed on the Windows system.

You may now re-boot the computer.

Step - 2 : Starting the SPC Software for the first time after installation

Please go to the windows menu bar and click on the appropriate menu item to run the software.

The software asks for the first key string which is exactly 45 letters (characters) long. You may type in all the 45 individual letters or copy the first key string (exclude the leading and trailing spaces) from our email / key string file (a text file kept in the folder containing the setup.exe file) and paste in the input box.

Then enter the second key string which is exactly 40 letters (characters) long.

Next, you need to enter the third key string which is exactly 35 letters (characters) long.

If all the three key strings are correct and genuine (received from us against a purchase), the software gets launched. Otherwise, you will be given four chances more so that you can enter the correct key strings and check whether they are genuine.

If all the five trials are un-successful, then you need to re-start the software and try to authenticate the key strings all over again.

Read the user manual and explore the software.

Notes: a) SPC software uses activeX components which are supported by Windows '98. So you ideally need Windows '98 Second Edition or higher. Older versions of Windows-XP might require 'service pack' to be downloaded and installed from http://www.microsoft.com (For this, please select the 'Windows Update' option in the Windows menubar and download the necessary files from internet). b) If you are using Windows 2000 or Windows XP, please change your user account to ‘Local Administrator’ and re-start the computer before attempting to install the SPC software. These versions of Windows do not allow ordinary users to install any software on the Windows system. Page: 5 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

c) In some computers, setup program may report registry access errors while installing some activeX components. Please select "Ignore" option if such error messages appear on the screen. d) Select the option "Keep existing file" when the setup reports copying of an older version of the file into the windows directory. e) Setup program may not work properly if any memory resident programs such as anti-virus software is active. Please close down such programs before running setup.exe (Press Ctrl+Alt+Del keys to open the 'shut down window' and select such programs and press 'End Task' button). f) Softcopy of user manual is already available as a menu item as well as in the WinZip file. Please refer the manual for detailed help. Alternatively, you can use the online-help by selecting the 'On-line Help Menu' when the SPC software is running. g) If you face any problem in installation/running of the software, please send an email to our Technical Support Team at [email protected] / [email protected] or call our 24x7 support telephone number +91 9830481675 at any time on any day of the year. h) To un-install the program, please goto the Windows "Control Panel", open the "Add/Remove Programs" menu, select the program from the list and press the "Add/Remove" button. (Merely deleting the installation directory from the hard disk will not un-install the program from windows system.)

Wish you a nice time with our software.

Page: 6 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 3

FIRST SCREEN

When the program starts, you find the default screen with the following items only.

1) A menu bar at the top and

2) A status line at the bottom.

Menu bar at the top contains the following pull-down menus:

File Reports Graphics Help

File menu contains option for creating new files or opening existing files, data import and export facilities, data printing facility, defining project details and starting data analysis, registering the user key, and exiting from the software.

Reports menu gives statistical analysis reports such as SPC report and Run analysis, once the data is read in through ‘Start

Graphics menu gives various graphics displays such as run chart, 3-sigma control charts, histogram, Pareto diagram and scatter plot, once the data is read-in.

Help menu contains information on legal user, product serial number, and our contact address for technical support. This menu also contains option for invoking On-line Help facility.

Status line at the bottom displays the name of authorised user and status of data processing.

Various menu options are explained in detail in the following sections.

Page: 7 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 4

FILE MENU

The sub-menu options are…

New Data File Open Data File Print Data Import Data " Export Data " Start Data Analysis " Exit

New Data File

Sirwill FBM Tools – SPC software uses its own data file format (*.fts).

The user has to either create a fresh data file in this specific format or import data from other file formats such as MS-Access (*.mdb), Dbase IV (*.dbf), Excel (*.xls) etc. (For data import, please click the Import Data option.).

To create new file in *.fts format, please specify the following:

! Number of columns needed. (This cannot be increased at a later stage. So, you may opt for more number of columns at the time of file creation). ! Number of rows needed. (Rows get automatically added as you keep entering data. So, you may opt for some tentative, say 50, number of rows at the time of file creation.) ! File name. You can press the ‘Browse’ button to explore the directory tree to locate the data directory and enter the file name. You need to key-in the file name only. The ‘fts’ extension will be added automatically.

Open Data File

In case you wish to open an existing data file (in the ‘fts’ format) and edit (change existing records / add new records), please choose this option.

Print Data

If you want to take a hard copy of the data, you can do so by choosing this menu item.

Import Data

The following sub-menu is available under this option: From MS-Access file From dBase IV File From Excel 8.0 File

Page: 8 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

If you already have the data in a different file format such as MS-Access, dBase III, dBase IV, Excel 5.0, Excel 8.0 etc, you need to first copy the data into an ‘fts’ file before analysis.

Your original file will remain intact. Only the selected records get copied to a new file with ‘fts’ extension.

For importing from Microsoft Access (Versions 3.0 and above) please choose the Import ‘From MS- Access’ menu.

For importing from any X-Base DOS file (dBase III, dBase IV, Foxpro 2.0, Foxpro 2.5) please choose the Import ‘From Dbase IV’ menu.

For importing from Microsoft Excel, please choose the Import ‘From Excel 8.0’ menu.

Important Notes on data import from Excel: Please add a column (say ‘Record ID’) to your Excel file and enter the row numbers as alpha-numeric serial number. Say, R00001, R00002, R00003,… before importing the data. This helps the SPC software to correctly locate the required rows in your Excel file and import the data. Also, if you are using a later version of Excel (above 8.0), then save your file as an Excel 8.0 file before attempting to import data to the .fts format.

Export Data The following sub-menu is available under this option:

To MS-Access file To dBase IV file To Excel 8.0 file

Suppose you wish to copy the data from an ‘fts’ file into a dBase / Excel file, you can do so with the Export Data feature. That way, you don’t have to manually re-enter the data in dBase/Excel file when you need to share the data with another person who doesn’t have this software in his computer. For exporting to a MS-Access file, please choose the Export ‘To MS-Access’ menu. For exporting to a dBase IV file, please choose the Export ‘To dBase IV’ menu. For exporting to a Microsoft Excel file, please choose the Export ‘To Excel 8.0’ menu.

Start Data Analysis Once the data file (in ‘fts’ format) is ready, you can start the analysis. The following sub-menu is available under this option:

Control Charts Pareto Analysis Scatter and Regression

Sirwill FBM Tools-SPC allows you to maintain a database of information regarding various control charts, Pareto diagrams, and scatter plots in routine use. So, you need not key-in the headers, specification, analysis options etc every time.

Page: 9 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Please select one of the three sub-menus (namely, control charts, pareto analysis, and, scatter and regression.) according to the purpose of data analysis. For preserving database integrity, separate screens are provided for each of these tools. After filling in the details of a particular project / process, please do not forget to save the record. When you want to do the analysis, please browse the database (using the horizontal scroll bar at the bottom) to bring up the record, and, press the ‘Start Analysis Now’ button. When you press ‘Start Analysis Now’ button, the software starts data processing. The following actions take place. a) Checking the field selections b) Reading data from the data file. c) Applying the data evaluation (e.g., Homogenization) rules, and d) Computing the statistics. Time required for data processing depends on the amount of data, type of analytical tool chosen, RAM (memory) in the computer, and the CPU speed. Normally it takes a few seconds only. In case your computer is slow / low on memory, it may take a few minutes. Please watch the vertical progress indicator near the right edge of the project book window. Once the data processing is over, you can see the reports and graphs by clicking the various report / Graphics options. Important Note: If you modify the data file or change the selections, you must re-start the analysis (i.e., you must press ‘Start Analysis Now’ button once again).

Exit

Click this option to close the application. Please make it a habit to use this option to exit the software.

Page: 10 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 5

REPORTS MENU

The following sub-menu is available under this option:

Summary Statistics Run Analysis

Once data processing is over, it is time to see the reports.

Summary Statistics

This report gives the basic statistics, result of data homogenisation, control limits of 3-sigma charts, and, process capability analysis. (Applicable for Control Chart data only)

Run Analysis

Our software uses a sophisticated algorithm to identify statistically significant cyclic variations in the sample average (process mean).

(Applicable for Control Chart data only)

Please click the appropriate report menu and view the report.

Page: 11 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 6

GRAPHICS MENU

The following sub-menu is available under this option:

Run Chart 3-Sigma Control Chart Histogram and Frequency Table Pareto Diagram Scatter and Regression Six Sigma Metrics and Probability Distributions " Engineering Process Control (EPC) "

Graphs are very essential for SPC. After data processing is completed, you may view the various graphs generated by this software.

This software provides Run Charts, 3-Sigma Control Charts, Histogram and Frequency Table, Pareto Diagram and Pareto Analysis Table, Scatter Diagram and Linear Regression Line, Normal / Poisson Distributions, Correlogram, and EPC Prediction chart.

Please click the appropriate chart option from the menu.

When you press the ‘Print’ button on graph, only the graph will be printed (option buttons not printed). Please select ‘Landscape’ as the print-orientation of all charts for better look of hard copy.

Notes:

1. To enable colour banded control charts, please tick the checkbox on the project information screen. 2. If you have selected ‘Monitoring Mode’ of analysis, your Control charts show the user-defined control limits only (labeled as LCL*, CL*, UCL* etc.). 3. Graphs and reports are displayed only if active data is available. Please ensure that data file is correctly read-in before viewing the graphs and reports.

Page: 12 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 7

HELP MENU

The following sub-menu is available under this option:

About FBM Tools - SPC Module On-line Help

About FBM Tools-SPC

It gives information about the software version, developers’ contact address, technical support number, name of authorised user, and product serial number. Please mention your product serial number in all your future communications for better and faster support.

On-line Help

This option takes you to the on-line help system. You can also press ‘F1’ key for context sensitive help.

Page: 13 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Chapter 8

STEP BY STEP: CONTROL CHARTS

This chapter gives you step by step instructions to enter data and get the analysis for control charts. Procedure is exactly similar (and intuitive) for Pareto and Scatter Plots.

Let us consider the following example:

Chart to be used : Xbar-Range

Specifications limits: USL = 10.5 % Target value = 10.0 % LSL = 9.5 %

Data Table: Sample No: Obs-01 Obs-02 Obs-03 Obs-04 Obs-05 1 9.99 9.6 9.8 10.05 9.91 2 10.14 10.43 10.24 10.24 10.14 3 10.34 10.43 10.24 10.43 10.34 4 9.8 10.14 10.24 9.99 10.24 5 10.27 10.21 10.44 10.39 10.39 6 9.63 9.75 9.99 9.87 9.75 7 9.86 9.77 9.77 9.96 9.96 8 9.97 10.16 10.16 10.07 10.26 9 9.88 10.39 9.68 10.14 10.05 10 9.88 9.78 9.78 9.98 9.98 11 9.68 10.42 10.23 9.86 9.77 12 10.35 10.12 10.23 9.99 10.35 13 10.23 9.99 10.12 10.35 10.35 14 9.87 10.12 10.23 9.99 10.12 15 9.90 9.96 10.08 10.14 10.02 16 9.72 9.84 9.78 10.02 10.08 17 9.96 10.07 10.02 10.17 10.12 18 9.81 9.95 10.10 9.9 10.2 19 10.05 9.9 9.85 10.05 10.15 20 10.29 10.10 10.00 10.05 10.05 21 9.90 10.05 9.81 9.95 10.00 22 10.10 9.96 10.25 9.86 10.06 23 9.81 10.16 9.91 10.10 10.06 24 9.96 10.01 10.21 9.91 10.02 25 10.3 10.21 9.96 10.16 10.02

Step 1: Data input – prepare a data file.

Go to 'File' menu and click the 'New Data File' option. Now, a dialog box appears on the screen, asking for size and name of the data file to be created.

Page: 14 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

A new file named BHC.fts shall be created and displayed like a spreadsheet as shown below. Now enter the data in the cells as shown below. Once data entry is over, click the 'Save/Update' button and then click the 'Close' button.

Step 2: Specify the project details and data file for analysis. Now go to 'File' menu, select 'Start Analysis Now' submenu, and click 'Control Charts' option.

Click 'New Record' button to add a new blank record. Then fill-up the details of the project as below, and, save the record. If you wish to analyse the data, please click the 'Start Analysis Now' button.

Page: 15 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Step 3: Reports and Graphs Now go to 'Reports' menu, and click 'Summary Statistics' option. You can view the first report on the screen. To take a print out, please click the printer icon on the top left corner of the report viewer.

To view run analysis report, please click 'Run Analysis' option in the 'Reports' menu.

To view the graphs, please click the appropriate option in the 'Graphics' menu. For control charts data, you can view Run Chart, 3-Sigma control charts, and Histogram.

Note:

If you have read-in pareto data, then please click the 'Pareto Diagram' option in the 'Graphics' menu.

Similarly, if you have read-in scatter plot data, then please click the 'Scatter and Regression' option in the 'Graphics' menu.

To take print out of graphs, please click the 'Print' button on the graphs. In case of Histogram and Pareto diagram, you can also view (and print) the data summary tables.

Page: 16 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Page: 17 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Page: 18 of 19 ® Sirwill FBM Tools - SPC Module USER MANUAL

Thank You. Page: 19 of 19