Quality: Production line- Tea Infuse TeamMa Chi FaiShi Cai Tao LiXiang Ji Rui Lin D M A I C Everything starts with a question Q: How often do you change the tea leaf? A: No idea, but it doesnt matter so Why dont we try to answer the question ourselves? A improvement driven direction formed D M A I C Definite of the projects Target Obtain infused tea with similar level of Tea Polyphenol Balance between tea polyphenol and cost D D M A I C Demonstrate SIPOC analysis and simulation Heater session SupplierInputProcess Time of tea be infused Volume of water (100L ) Water temp. (90 C) Amount of Tea leave Type of tea Concentrated of Tea Polyphenol 2g of tea leave per unit, 6 units Tea leave Infuse for 10 minutes Compress with high pressure for rotation 90 C Water 750 ml 4 minutes WaterInfuse time OutputCustomer Dilution session Remark Technician cannot provide the amount for tea leave for the production line Shake with hands in metallic container SIPOC: Production line simulation D Action D M A I C Methodology-Testing solution D D M A I C Control solutions Sample solutions Control solutions Sample solutions D D M A I C Methodology Testing solution Operated by the same person at each role Stir tea sample before used Filter tea sample before used with filter paper Cooled the sample tea to room temperature (about 26 C ) for 50 minutes D D M A I C Measurement Given in advance M D M A I C Measurement - Design of Experiment Factors studied Times of tea be infused 1, 2, 3, Type of tea Non quantifiable The difference of the first factors impact on different type of tea Response variable concentration of Tea Polyphenols( )X Y M D M A I C Measurement - Design of Experiment Measurement System Variation Analysis Variation due to Gage A machine is used for measuring the concentration in the experiment. Chemical reagent might change over time. Variation due to Operators Certain procedures are performed by the same operator through one block. M D M A I C Measurement - Design of Experiment Other DOE Principles considerations Randomization No subjective bias since we are using the machine to test the ingredient. Replication vs. Repetition Standard procedures Aiming at insight Blocking A fixed group of members for each different type of tea M D M A I C Measurement - Design of Experiment Statistical Modeling considerations Discrete variables. Our main target of the experiment is to test our hypothesis. It doesnt really mater that how larger the difference can be after the difference is large enough to cause a critical failure in performance. To sum up, a statistical model using ANOVA or something else is not of much meaning in our case. We give the regression line for showing the noticeable decreasing trend. M D M A I C Improvement I D M A I C Results of Jasmine tea Infuse #Tea Polyphenols A Tea Polyphenols decrease with infuse # D M A I C Analysis result Infuse #Tea Polyphenols Different type of tea, different shape of curves Tea Polyphenols decrease with infuse # Decrease rate varies with kind of tea leave A D M A I C When to change tea leave? Suggestion 1: Observation Change tea leave based on observation 1st2nd3rd4th5th6th Infuse # Add transparent glass layer to the container for observation Pu-erh tea Challenge Label the 1 st and 6 th infuse tea From previous data, darkness is proportional to the number of Tea Polyphenol Infuse #Tea Polyphenols A D M A I C Concern: suggestion 1: Observation Change tea leave based on observation Lets see the number of Tea Polyphenol of Jasmine tea Jasmine tea Challenge Label the 1 st and 6 th infuse tea A D M A I C Analysis result Infuse #Tea Polyphenols A Tea Polyphenols cannot be determined by darkness (color) Common quality problem Why 3 types of tea? Misleading if just investigate the Tieh-Kuan-Yin Tea and Pu-erh tea Drawing a wrong solutions D M A I C Original Changing stragty Similar color Tieh-Kuan-Yin Tea Color difference Infuse #Tea Polyphenols Pu-erh Tea Jasmine Tea Infuse #Tea Polyphenols Infuse #Tea Polyphenols Original method cannot provide uniform tea polyphenols, we need to change A D M A I C Proposed idea Infus e Ball1Ball2Ball3Ball4Ball5Ball6Ball7Ball8Ball9Ball Change: Throw in next infuse Change: Add in next infuse Number inside Refer to Infuse # to that box Record D M A I C Analysis result A D M A I C Analysis - PCA Process Capability Analysis U-L Pu-erh tea Jasmine Tea Tieh-Kuan-Yin Tea A D M A I C Control C D M A I C Equipment-a device that can solve the problem I D M A I C I D M A I C Equipment-inside view I D M A I C Conclusion We should chance the tea leave every time Apply 6 boxes designed Solve costly problem Maintain the relatively stable level of tea Polyphenol D M A I C Some discussions The definition of our quality is the variance of Tea Polyphenols concentration only in our work. Further study can be focused on how many blocks we should have in the device we designed so that the level of Tea Polyphenols can meet the standards, which is too time consuming for us considering the experiment we already made. Our study is a very practical one, not so theoretical.