A detergent production plant used a DMAIC approach to improve the solubility of a new eco-labeled detergent product. In the measure phase, they analyzed test result data and found the process was not stable or capable. The analyze phase identified mixing speed and equipment used as having strong impacts on concentration. A regression model and decision tree uncovered that concentration was too low with low mixing speeds or non-preferred equipment. In the improve phase, they established a benchmark and plan using the preferred equipment. Monitoring then confirmed the improvements reduced defects by 50% as intended.

1. Mark Ellis
Minitab
EMEIA Integrated
Marketing Specialist
The New Minitab Toolkit
for Continuous Improvement
Gillian Groom
Minitab
EMEIA Technical
Training Specialist
Our Presenters

2. © 2019 Minitab, LLC.
2
Who Uses Minitab?

3. © 2019 Minitab, LLC.
Minitab: Your Partner in Your Analytics Journey
Software
Services
Training
Learn first-hand by attending public or
customized trainings in your facilities
according to your requirements.
Statistical
Consulting
Personalized help with statistical
challenges from collecting the right data
to interpreting analysis more.
Support
Assistance with installation,
implementation, version updates and
license management.
Master statistics and Minitab
anywhere with online training
Tools and reporting to ensure
process and product excellence.
Machine Learning and
Predictive Analytics software
Powerful statistical
software everyone can use.
Data Analysis Predictive Modeling Project Oversight Online Stat Training
3

4. © 2019 Minitab, LLC.
Throughout her career, Gillian has been applying
statistical analysis to guide informed management
decisions on business opportunities or problems.
Gillian has a Master's Degree in Probability and Statistics
from Sheffield University.
Meet the Presenter:
Gillian Groom
Technical Training Specialist, Minitab
4

5. The New Minitab Toolkit
for Continuous Improvement

6. © 2019 Minitab, LLC.
Detergent Improvement Project
A detergent production plant needs
• Stabilize the performance of its new dedicated
production line of eco-labeled detergents
• Improve the solubility of this new product.
Using a Classic DMAIC Approach to
Manage The Project

7.  RECORDING: Watch the video online >>
 TALK TO MINITAB: Discuss your specific analytical and CI initiative >>
 FUTURE WEBINARS, EVENTS AND ONLINE RESOURCES:
 Webinars >>
 Events >>
 Tutorial Videos >>
 Datasets >>
 Training Options >>
 Customer Case studies >>
 Articles on Minitab Blog >>
Learn more at Minitab.com >>
Webinar resources:

8. © 2019 Minitab, LLC.
Define Business Understanding
• Document the project in a project charter
• Determine key stakeholders
• Establish initial goals and benefits
• Define resources– IT, Process Engineer, Blackbelt
• Define the project– Determine and address the cause of lack of stability during washing tests
• Establish metrics that measure the success of the project– Defect reduction of 50%
• List assumptions and risk factors– Biggest risk factor was the ability to get the right data

9. © 2019 Minitab, LLC.
Define Map your processes

10. © 2019 Minitab, LLC.
Measure Data Understanding
• Select the variables and records and aggregate and
clean data– Data from different databases, determine
applicable date range
• Note issues with collection methods for the data
• Verify validity and quality of the data
• Characterize the current status of the variable of interest

11. © 2019 Minitab, LLC.
Measure Gage R&R
Gage R&R results are good:
Within the 10% guideline for measurement
fluctuations compared to overall fluctuations

12. © 2019 Minitab, LLC.
Measure Statistical Summary
Data from washing sample test results:
Normally distributed
1st Quartile 86.308
Median 88.088
3rd Quartile 89.636
Maximum 93.780
87.696 88.304
87.805 88.369
2.195 2.627
A-Squared 0.20
P-Value 0.877
Mean 88.000
StDev 2.392
Variance 5.722
Skewness -0.121603
Kurtosis -0.193540
N 240
Minimum 81.139
Anderson-Darling Normality Test
95% Confidence Interval for Mean
95% Confidence Interval for Median
95% Confidence Interval for StDev
94929088868482
Median
Mean
88.488.288.087.887.6
95% Confidence Intervals
Summary Report for Test results

13. © 2019 Minitab, LLC.
Measure Baseline Capability
Soil removal needs to be as uniform as
possible whatever water hardness, type of
washing machine, wash loads …
Capability is poor. Solubility test
results often below the lower spec: 85

14. © 2019 Minitab, LLC.
Measure Baseline Control Chart
Special / Assignable causes impact the
process
These causes need to be identified
Process is not in
control (many out
of control points)
464136312621161161
92
91
90
89
88
87
86
85
84
83
Sample
SampleMean
__
X=88.000
UCL=90.588
LCL=85.412
1
1
1
11
1
1
Xbar Chart of Test results

15. © 2019 Minitab, LLC.
Analyze Modeling/Evaluation
• Explore data and make initial observations about
relationships between variables
• Select modeling technique(s)
• Build model(s)
• Assess model(s)
• Interpret final model
• Discuss model results with key stakeholders
Select modeling
technique(s)
Build model(s)Assess model(s)

16. © 2019 Minitab, LLC.
Analyze Identify Key Input
Use Brainstorming to try to identify key inputs

17. © 2019 Minitab, LLC.
The impact of the concentration on solubility
results after washing cycles is confirmed by
data analysis
Analyze Regression

18. © 2019 Minitab, LLC.
Analyze Root cause identification
Mixing Speeds and using equipment CL have a strong impact on concentration. Concentration is too low
when Mixing speed are low and equipments other than CL are used.

19. © 2019 Minitab, LLC.
Improve Model Deployment
• Establish an improvement plan : benchmark based on CL tool
• Implement the changes
• Validate results with new data
• Establish a monitoring and maintenance plan
• Set schedule to verify that model results have not changed
• Update model when changes occur
• Present project results to key stakeholders
• Close out project

20. © 2019 Minitab, LLC.
Improve Capability Comparison
Compare quality performance before
and after improvement

21. © 2019 Minitab, LLC.
Control Control chart
Monitor mixing speed so that
adjustments can be made when
Mixing speed reaches low values.

22. © 2019 Minitab, LLC.
Detergent Case Study Conclusions
• Companion provided the framework to manage the project
• In the Measure Phase we used Minitab to
 Check data quality
 Provide the baseline to measure any improvements
• Companion provided the tools to document results from brainstorming and C&E Analysis

23. © 2019 Minitab, LLC.
• Minitab and Salford Predictive Modeller used in Analyse Phase
 Regression modelled the relationship between concentration and Solubility
 Data available to identify “best” manufacturing process for our concentration requirements not suited to
regression
 CART decision tree quickly identified the manufacturing settings required. Machine learning tools uncovered
relationships that may have been missed otherwise, due to size and complex relationships in the data
• Minitab Analysis used in Control stage of project
Detergent Case Study Conclusions
Events >>Events >>

24.  RECORDING: Watch the video online >>
 TALK TO MINITAB: Discuss your specific analytical and CI initiative >>
 FUTURE WEBINARS, EVENTS AND ONLINE RESOURCES:
 Webinars >>
 Events >>
 Tutorial Videos >>
 Datasets >>
 Training Options >>
 Customer Case studies >>
 Articles on Minitab Blog >>
Learn more at Minitab.com >>
Webinar resources:

25. THANK YOU!
See you soon!
Minitab.com >>