Measurement System Analysis: Hidden Factory Evaluation 

What Comprises the Hidden Factory in a Process/Production Area?

• Reprocessed and Scrap materials — First time out of spec, not reworkable
• Over-processed materials — Run higher than target with higher
  than needed utilities or reagents
• Over-analyzed materials — High Capability, but multiple in-process
  samples are run, improper SPC leading to over-control

What Comprises the Hidden Factory in a Laboratory Setting?

• Incapable Measurement Systems — purchased, but are unusable
  due to high repeatability variation and poor discrimination
• Repetitive Analysis — Test that runs with repeats to improve known
  variation or to unsuccessfully deal with overwhelming sampling issues
• Laboratory “Noise” Issues — Lab Tech to Lab Tech Variation, Shift to
  Shift Variation, Machine to Machine Variation, Lab to Lab Variation

Hidden factory Linkage –

• Production Environments generally rely upon in-process sampling for adjustment
• As Processes attain Six Sigma performance they begin to rely less on sampling…