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Measurement Systems Analysis using SigmaXL software

Measurement Systems Analysis using SigmaXL software

Dear friends, many of the viewers had requested for an introductory video on measurement systems analysis (MSA) and Gauge Repeatability and Reproducibility (R&R) Study. We are happy to release this video on MSA! In this video, Hemant Urdhwareshe, Fellow of American Society for Quality, and ASQ Certified Six Sigma Master Black Belt, explains the terminology of measurement systems and also illustrates how to conduct, analyse and interpret the results of a Gauge R&R Study. Hemant has illustrated this with an application example using template from SigmaXL software. Your feedback on the video is welcome!

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Making Sense of Gage R&R Analysis

Making Sense of Gage R&R Analysis

(Originally published in Quality Magazine, October 2025)

The term Measurement Systems Analysis (MSA) refers to a collection of experimental and statistical methods designed to evaluate the error introduced by a measurement system, and the resulting usefulness of that system for a particular application. In manufacturing, measurement system quality directly affects decisions about processes, products, and a manufacturer’s ability to meet their customer’s requirements.

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Weibull Probability Plotting of Right Censored Data on Excel

Weibull Probability Plotting of Right Censored Data on Excel

Dear friends, We are happy to release this 97th video! Many of you have requested to make this video on Weibull Probability Plotting of Right Censored Data. In this video, Hemant Urdhwareshe, Fellow of ASQ, explains how to construct a Weibull Probability Plot when the data is Right Censored!

Hemant has illustrated the complete procedure, step by step, using Microsoft Excel, with an Application Example!

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Reliability Sample Size P3 with failures using Binomial Distribution

Reliability Sample Size P3 with failures using Binomial Distribution

Dear friends, we are very happy to release this video on the first day of the World Quality Month 2023! Some of you have asked the question about how the formula for success run theorem was derived! You should find answer to that question in this video!

Also, the previous video shows the sample size calculation using template! However, in this video, Hemant Urdhwareshe, Fellow of ASQ, explains the mathematics of it and also illustrates how to perform sample size calculations using Microsoft Excel!

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Back to the Basics: Calibration vs. Verification

Back to the Basics: Calibration vs. Verification

In the push toward digital transformation, automated inspection, and AI-enabled quality systems, it’s easy to overlook the fundamentals that quietly hold everything together. Among them are two terms that are frequently confused, even by seasoned professionals: Calibration and Verification

These words live at the core of measurement assurance, and understanding the difference isn’t academic; it shapes risk decisions, audit outcomes, and ultimately, product quality and reliability.

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Sigma Level and Process Capability Indices

Sigma Level and Process Capability Indices

Dear friends, we are happy to release this interesting video to explain and illustrate the relationship between sigma level and process capability indices Cp and Cpk! Hemant Urdhwareshe, ASQ Fellow and Six Sigma Master Black Belt, explains this relationship with animations! We are sure, you will find this video interesting and useful!

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FMEA Quality Objective 9: Design Improvements

FMEA Quality Objective 9: Design Improvements

Progressive improvement beats delayed perfection. Mark Twain

In this article, I will outline how to evaluate an individual Design FMEA or Process FMEA against the FMEA Quality Objective for design improvements.

What is meant by “design improvement”?

An essential part of FMEA procedure is for the FMEA team to recommend and implement actions to reduce risk to an acceptable level. For Design FMEAs, this includes actions to improve the product design. For Process FMEA, this includes actions to improve the design of the manufacturing or assembly process. Of course, there are other types of actions that can be recommended, such as test improvements; but this quality objective is focused on design improvements. [Read more…]

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Sigma Level and PPM Calculation on Excel

Sigma Level and PPM Calculation on Excel

Dear friends, I am glad to release our technical video on the subject of ‘Sigma Level vs Defective Proportion and PPM’! In this video, I have tried to explain the definition of sigma level in the context of the relation between tolerance and standard deviation sigma. Sigma Level assessment is an essential step in Six Sigma projects. In this video, I have explained the logic of 1.5sigma shift as was developed in Motorola. The sigma level vs ppm calculations are explained and illustrated using an Excel screen recording. Hope you find this video interesting!

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DORT: Design of Ongoing Reliability Tests

DORT: Design of Ongoing Reliability Tests

Ongoing Reliability Testing (ORT) is a way to estimate reliability function, as a function of independent variables, primarily age. This is because reliability is “the probability of successful function to specified ages under specified conditions” [O’Connor et al.]. 

Think of planning ORT as a design of an experiment (DoE). A DoE objective is to quantify effects of factors (independent variables) on the dependent variable, the reliability function. (The reliability and failure rate functions contain the same information, because reliability = P[Life > t] = exp[–∫a(u)du], where a(u) denotes the failure rate function and the integral runs from 0 to t.)

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Process Capability Analysis: Cp, Cpk, Sigma Level

Process Capability Analysis: Cp, Cpk, Sigma Level

Dear friends, we are happy to release this video on Process Capability. this is our 93rd video! In this video, Hemant Urdhwareshe, Fellow of ASQ, explains the basic concepts of process capability indices Cp and Cpk with an illustrative example. Hemant has also explained how to validate whether the data is normally distributed with histogram and normal probability plotting. Hemant has further explained the interpretation of the results of study and suggested improvement actions.

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Listening with Intent: The Missing Skill in Design Thinking

Listening with Intent: The Missing Skill in Design Thinking

Of the many constructive soft skills, active listening is surely one of the most helpful in the design thinking process. More than just listening to collect information, active listening is a mindset that fosters empathy for the speaker. In business and engineering, it’s our customer that’s speaking. Active listening seeks to understand not only the other person’s words, but also their attitudes and motivations.

For many people, even the idea of “being a better listener” seems ludicrous. Once you’re listening, how can you listen better? It’s like swallowing better or breathing better. [But the truth is, you can.] Even the best listeners periodically fall into a handful of traps that obstruct their understanding of their employer’s, customer’s, and loved one’s words.

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