Deming Funnel 7.19

This application provides an insightful perspective on enhancing productivity and minimizing variation through an in-depth understanding of process variation. It employs interactive 3D augmented reality to demonstrate the Deming Funnel (also known as Nelson Funnel) experiments, which are foundational for comprehending process behavior.

The Deming Funnel experiment serves as a fundamental lesson in understanding variation. It illustrates that without comprehensive knowledge of variation, even well-intentioned efforts can inadvertently exacerbate issues. Mastery of Process Behavior Charts (control charts) and the ability to distinguish between assignable causes — also known as special causes — and common causes are crucial skills highlighted through this tool.

APP USAGE

• The user must be standing during operation, as the virtual funnel is approximately one meter in height. The interface allows immediate exploration or initiation via the top right icon labeled “START,” which displays instructions.
• The app supports both manual manipulation of virtual objects and automatic operation modes.
• Four distinct modes are available, each accompanied by multiple real-world examples. For each mode, patterns emerge that are visualized through generated control charts and histograms. Common misconceptions and improper uses of control charts are explicitly demonstrated.
• Camera access is necessary to enable interaction with the virtual objects. The application does not collect any personal data.

TAMPERING AND ITS CONSEQUENCES

The experiments effectively illustrate the negative impacts of various forms of tampering with processes. A well-known example is Mr. Bill Smith, who altered his molding procedures, leading to a process that drifted significantly—up to 1.5 sigma—contributing to the emergence of the Six Sigma methodology. His actions exemplify Mode 2 tampering, emphasizing the importance of proper variation management.

Historically, Professor Deming rescued Ford Motor Company from potential disaster in 1982; however, they subsequently dismissed his teachings and adopted the Six Sigma approach, which, according to extensive studies, resulted in an average of 220,000 defects per million even after purported improvements. This underscores that true quality achievement remains rooted in the principles championed by pioneers like Dr. Shewhart, Professor Deming, and Dr. Wheeler. The Deming Funnel is an introductory step toward achieving superior quality and productivity.

RATIONALE FOR AUGMENTED REALITY

The Deming Funnel experiment is profoundly instructive but challenging to perform in traditional settings due to equipment constraints—such as the need for a perfectly flat surface and precise manual adjustments. Augmented reality technology addresses these limitations, rendering the experience more dynamic and engaging.

This application can be utilized for individual learning or adapted for lectures through screen sharing. A basic understanding of Process Behavior Charts (control charts) is recommended for optimal engagement.