STATISTICS AND
SIX SIGMA
PROCESSES OPTIMISATION
The application of statistical techniques to productive processes
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Statistical Process Control (SPC)
The SPC’s aim is to keep stable the productive process and to evaluate it in relation to the specification’s requirements, which are applicable to finished or semi-finished products. The SPC is essential to guarantee the client’s expectation satisfaction and to reduce the production costs due to the failures created during the different process’ phases. The SPC is a mandatory requirement in the sectors in which there are quality critical conditions (Automotive, Medical, Aerospace, etc.
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Control cards
The control cards are the most suitable instrument to evaluate and keep the productive process stability, and together with the analysis of process capability, are an essential technique in the SPC. The control cards allow to distinguish the cases in which the process variability is due to “special” causes, that need to be removed to avoid the process goes out of control, from the cases in which no interventions are required because the variability is the natural process’ one. To be effective the control cards must be selected according to the to-be-analysable process parameters and their control limits need to be defined in a rigorous way.
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6 Sigma method
The 6 Sigma method is applied both to productive processes, and to services. Its aim is to achieve significant improvements, which are not reachable through common actions, that lead to a gradual improvement. This method involves statistical technique and focused projects, structured in 5 phases: Define, Measure, Analyse, Improve e Control (DMAIC).
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ANOVA
The ANOVA (Analysis of Variance) is a statistical technique able to define if the differences among data groups are casual or substantial, that means due to factors able to affect the data. The ANOVA is a wide-range application: from the analysis of several treatments (chemical, physical, etc.), to the evaluation of productive processes or services.
The application of statistical techniques to productive processes and services allows to minimise the costs and to improve the quality in a systematically and sustainably way. Through the development of specific focused projects, the 6 Sigma program allows important improvements, that means breakthroughs, and optimises the processes and services with noticeable advantages for the efficiency and reduction of waste.
The GESTLABS personnel is Six Sigma Master Black Belt qualified to support the customer in the application of statistical techniques and 6 Sigma improvements projects like:
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Process Capability
The Process capability is the ability to create products in compliance with specification requirements. The Process Capability is measured through specific indicators, CP and CPK, which allow to estimate the product percentage that will be out of the specification limits, and which lead to defects in the short or long term. Together with the control cards, the evaluation of process capability performed by the CP and CPK values calculation, is a crucial instrument for the SPC.
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Sampling plans
The sampling plans define the statistical inference-based criteria through which it is possible to perform the spot checks applicable in every field (approval/evaluation of batches of products or semi-finished products, of productive processes or services) The sampling plans application allows to also evaluate the risks and benefits of every kind of sampling in a rigorous and objective way.
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FMEA
The FMEA (Failure Modes and Effects Analysis) is a technique which allows to analyse a project or a productive process to identify possible weaknesses and, consequently, to perform improvement actions. With the FMEA it is possible to assign the intervention priorities on the project or process through an evaluation developed into a dedicated team. When the FMEA is performed on a project, it is called DFMEA (Design FMEA); while if it is applied to a productive process is called PFMEA (Process FMEA).
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Measurement system analysis (repeatability, reproducibility, R&R gage, accuracy)
The measurement system analysis is performed to determine the measurement error, which has different components. Through the R&R gage analysis is possible to determine the repeatability (that means the variability only due to the error inside the instrument or in the measurement system) and the reproducibility (that means the variability due to factors like the operator, the environmental changes, etc.). Besides these quantities, to determine the whole measurement accuracy, it is necessary to calculate the bias, that is the variance of the measured values average from the real value.
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Statistical Tests
The Statistical Tests allow to evaluate if the differences among data groups concerning batches, samples, productive processes, or services, must be considered casual or due to real variations. Through these tests it is possible to define if the observed trends correspond to improvements, worsening, or “real” or apparent variations in a unique and objective way.
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Design of Experiments
The Design of Experiments (DOE) is a statistical technique able to optimise processes and services according to the required achievable goals through the setting and the statistical analysis of a series of well-structured tests/experiments. The DOE is effectively usable in different fields and applications, both industrial and of different kinds.
RELIABILITY ANALYSIS ON THE PRODUCT
RELIABILITY AND SAFETY
The techniques used by our experts allow to reduce the risk of
releasing products not in compliance with the market expectations
and standards.
The reliability has a crucial role in the client’s satisfaction and deep impacts on the safety of several products released on the market (automotive, medical, etc.)
GESTLABS supports the client by providing with a rigorous and scientific approach, which requires the ability to identify the stress tests and the lab analysis suitable to the identified specific failure mechanisms. Our personnel can support the client in all the phases of the product life cycle, from the design to the prototyping and the production qualifying with the identification and performance of the reliability tests.
Our technicians use the following methods to guarantee that the products released to the clients assure the most reliability.
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Useful Life
The Useful Life is the period when the device works optimally, and it is not affected by wear yet. This period goes usually beyond the warranty period, and it corresponds to the duration expectation by the client. It can be identified through accelerated stress conditions or, in the designing phase of electronic sheets, through specific calculations in compliance with specific standards.
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Qualification Tests
The qualification tests are those on which are based the reliability evaluations of the device (MTTF, MTBF, useful life). They are usually accelerated tests because their aim is to accelerate one or more failure mechanisms. It is particularly essential being able to link the qualification tests to the specific failure mechanisms into which the product runs during its real application by the client. It is also important to set the test parameters to avoid the activation of abnormal failure mechanisms or, on the contrary, to have too low acceleration factors.
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HALT Tests
During the prototyping phase, the use of HALT (Highly Accelerated Life Tests) Tests is suitable. The aim of these tests is to verify the strength of the product subjected to different stress conditions (temperature, humidity, voltage, etc.) They are usually brief but with intensive stress.
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Distributions for reliability
The statistical distributions (chi-squared, Weibull, exponential, etc.) are necessary to accurately perform the reliability predictions starting from the data obtained by the tests. Through these statistical distributions, it is possible to determine the MTTF (Mean Time To Failure) and the MTBF (Mean Time Between Failures) with confidence ranges based on the numerousness of the used sample.
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MTBF Calculation and the failure rate
The MTBF (Mean Time Between Failures) calculation is one of the cornerstones of reliability and it has the aim to predict the failure of a device during it useful life, so that before the wear out. The MTBF and the failure rate, which is the contrary of MTBF, can be determined by the experimental tests or, in case of electronic sheets, by specific standards. The MTBF value is an essential requirement for the customer, and it is necessary in many fields like Automotive, Medical, Aerospace etc.
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Setting of testing plans
The setting of most suitable tests depends on the phase at which the development product is (the product can be a device or a material).
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Accelerated stress tests and acceleration factors
For the reliability predictions it is often necessary not to limit to theoretical calculations, but to perform specific stress tests whose aim is to accelerate specific failure mechanisms. The accelerated tests involve accelerating factors like temperature, humidity, power, voltage, etc. It is mandatory being able to link the most suitable accelerating factors and values to the different failure mechanisms to avoid the activation of abnormal failure mechanisms or to have insufficient acceleration factors. The acceleration factors can be determined by experimental data or specific models coming from experimental tests.
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HASS and Burn-in Tests
During the production, it is often necessary to perform stress tests to identify and remove those products (devices or materials) whose failures will be showed over time and are not identifiable through the common check tests in the production. These products are the weak population, and they can be identified by specific stress tests called HASS (Highly Accelerated Stress Screening) and known as burn-in test in the past.
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Setting of testing plans
The setting of most suitable tests depends on the phase at which the development product is (the product can be a device or a material).
LASER SAFETY
Through a high qualified team guided by the secretary (already president) of the Laser Safety Committee (CT 76 – Laser Equipment) of the CEI – Italian Electrotechnical Committee, GESTLABS can support the client both with a risk check consultation and in the personnel education who works with laser equipment/machines.
The increasing spread of laser applications (mechanics, medical, telecommunications, etc.) makes necessary to carefully evaluate the risk due to laser light, also because of the increasing powers of the different classes allowed by the current regulation.
The GESTLABS Education Centre offers the best experts in Italy to allow your company to safely operate with your LASER equipment in compliance with the current regulations.
LASER SAFETY
The GESTLABS Education Centre offers the best experts in Italy to allow your company to safely operate with your LASER equipment in compliance with the current regulations.
REGULATORY CONSULTING
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Laser Instruments and Systems
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CEI EN 60825-1 Compliance certification
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Equipment classification
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Risks Analysis
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Nominal Ocular Hazard Distance
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Effects and limit values of Laser radiation exposition
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Protective Equipment
Selection and evaluation of:-
Effects and limit values of Laser radiation exposition
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Nominal Ocular Hazard Distance
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The necessity of a qualified Laser Safety Technician for the 3B and 4 classes is a regulation requirement and a warranty which protects the user personnel to possible short or long-term damages.
BASIC TRAINING
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Laser Safety Courses for Operators
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Basic concepts of Laser Risk
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Laser Equipment Classification
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Evaluation of risks associated to every laser class
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Safety Measurements and Behaviour Regulations
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The Personal Protective Equipment and their use
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Certification Release
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In compliance with the required requirements by Law 81/08, also known asUniform law on labor safety for workers under
laser equipment.
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ADVANCED TRAINING
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Laser Safety Courses for Specialists
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Supplementary worksheet on CEI and Law 81/08 regulations
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Laser Safety Advanced Concepts
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Effects of Laser Radiation on fabrics
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Non-Coherent Optical Radiation Risks
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ment and their use
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For:
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H&S (Health&Safety) Managers
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Health Professionals, Researchers, Designers
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Certification Release
Qualification:-
In compliance with required requirements by Law 81/08
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Laser Safety Technician and Laser Safety Officer
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