Process Capability

Copyright 2009 HKRITA. All rights reserved.
Topic: PROCESS CAPABILITY

Development of a Problem Solving Model
for the Hong Kong Textiles and Clothing
Industries Project
HKRITA Ref. No. : RD/PR/001/07
ITC Ref. No. : ITP/033/07TP
Why Study Process Capability
Process Capability Studies provide a baseline for us to
understand how the process is operating relative to the
specifications.
It is the first, thorough look at how variability is affecting
the process, and gives us metrics for quantifying that
variability.
Such studies also provide information regarding what the
process could do under best conditions, and thus gives a
performance target to shoot for.
Process Variation
Process Variation is the inevitable differences among
individual measurements or units produced by a process.
Sources of Variation
within unit (positional variation)
between units (unit-unit variation)
between lots (lot-lot variation)
between lines (line-line variation)
across time (time-time variation)
measurement error (repeatability & reproducibility)
Types of Variation
Inherent or Natural Variation
Due to the cumulative effect of many small
unavoidable causes
A process operating with only chance causes of
variation present is said to be in statistical control
Types of Variation
Special or Assignable Variation
May be due to
a) improperly adjusted machine
b) operator error
c) defective raw material
A process operating in the presence of assignable causes of
variation is said to be out-of-control
Process Capability
Process Capability is the inherent reproducibility of a processs
output. It measures how well the process is currently behaving
with respect to the output specifications. It refers to the uniformity
of the process.
Capability is often thought of in terms of the proportion of output
that will be within product specification tolerances. The frequency
of defectives produced may be measured in
a) percentage (%)
b) parts per million (ppm)
c) parts per billion (ppb)
Process Capability
Process Capability studies can
indicate the consistency of the process output
indicate the degree to which the output meets
specifications
be used for comparison with another process or
competitor
Conventional Use of Distribution Curves
We will use a smooth curve to
represent an actual process
distribution
15 20 25 30
X Dimension
Lower Limit
Upper Limit
Representative
Curve
Process Capability vs Specification Limits
a) b)
c)
a) Process is highly capable
b) Process is marginally capable
c) Process is not capable
Three Types of Limits
Specification Limits (LSL and USL)
created by design engineering in response to customer
requirements to specify the tolerance for a products
characteristic
Process Limits (LPL and UPL)
measures the variation of a process
the natural 6 limits of the measured characteristic
Control Limits (LCL and UCL)
measures the variation of a sample statistic (mean, variance,
proportion, etc)
Three Types of Limits
Distribution of Sample Averages
Distribution of Individual Values
Process Capability Indices
Two measures of process capability
Process Potential
C
p
Process Performance
C
pu
C
pl
C
pk
Process Potential
The C
p
index assesses whether the natural
tolerance (6 ) of a
process is within the specification limits.
=
=
6
LSL USL
Tolerance Natural
Tolerance g Engineerin
C
p
LSL USL
Process Potential
Historically, a C
p
of 1.0 has indicated that a process is
judged to be capable, i.e. if the process is centered
within its engineering tolerance, 0.27% of parts produced
will be beyond specification limits.
C
p
Reject Rate
1.00 0.270 %
1.33 0.007 %
1.50 6.8 ppm
2.00 2.0 ppb
Process Potential
a)
b)
c)
a) Process is highly capable (Cp>2)
b) Process is capable (Cp=1 to 2)
c) Process is not capable (Cp<1)
Process Potential
he C
p
index compares the allowable spread (USL-LSL)
against the process spread (6 ). It fails to take into
account if the process is centered between the
specification limits.
Process is centered Process is not centered
Process Performance
The C
pk
index relates the scaled distance
between the process mean and the nearest
specification limit.

=
3
USL
C
pu

=
3
LSL
C
pl
{ }
pl pu pk
C C Minimum C , =
Process Performance
C
pk
Reject Rate
1.0 0.13 0.27 %
1.1 0.05 0.10 %
1.2 0.02 0.03 %
1.3 48.1 96.2 ppm
1.4 13.4 26.7 ppm
1.5 3.4 6.8 ppm
1.6 794 1589 ppb
1.7 170 340 ppb
1.8 33 67 ppb
1.9 6 12 ppb
2.0 1 2 ppb
Process Performance
a) Process is highly capable (Cpk>1.5)
b) Process is capable (Cpk=1 to 1.5)
c) Process is not capable (Cpk<1)
a)
Cp = 2
Cpk = 2
b)
Cp = 2
Cpk = 1
c)
Cp = 2
Cpk < 1
Example 1
Specification Limits : 4 to 16 g
Machine Mean Std Dev
(a) 10 4
(b) 10 2
(c) 7 2
(d) 13 1
Determine the corresponding C
p
and C
pk
for each
machine.
Example 1A
( )
5 . 0
4 6
4 16
6
LSL USL
C
p
=
=
( ) ( )
5 . 0
4 3
4 10
;
4 3
10 16
Min
3
LSL
;
3
USL
Min C
pk
=

=
Example 1B
( )
0 . 1
2 6
4 16
6
LSL USL
C
p
=
=
( ) ( )
0 . 1
2 3
4 10
;
2 3
10 16
Min
3
LSL
;
3
USL
Min C
pk
=

=
Example 1C
( )
0 . 1
2 6
4 16
6
LSL USL
C
p
=
=
( ) ( )
5 . 0
2 3
4 7
;
2 3
7 16
Min
3
LSL
;
3
USL
Min C
pk
=

=
Example 1D
( )
0 . 2
1 6
4 16
6
LSL USL
C
p
=
=
( ) ( )
0 . 1
1 3
4 13
;
1 3
13 16
Min
3
LSL
;
3
USL
Min C
pk
=

=
Process Potential vs Process Performance
(a) Poor Process Potential (b) Poor Process
Performance
LSL USL LSL USL
Experimental Design
to reduce variation
Experimental Design
to center mean
to reduce variation
Process Potential vs Process Performance
a)
Cp = 2
Cpk = 2
b)
Cp = 2
Cpk = 1
c)
Cp = 2
Cpk < 1
Cp Cpk Missed Opportunity
Process Stability
A process is stable if the distribution of
measurements made on the given feature is
consistent over time.
Time
Stable Process
Time
Unstable
Process
Graphical Representation of
Causes of Variations (Jurans Trilogy)
F
o
c
u
s

o
f

S
i
x

S
i
g
m
a

Common Cause ?
.
UCL
LCL
CL
Special Cause ?

.
UCL
LCL
CL
Steps to Study Process Capability
Select critical parameters for study
Parameters from specifications, contract etc.
Collect Data
Collect 60 data or more as far as possible
Define clearly the precision of each data (no. of significant figures, eg
up to 2 decimal places)
Establish control
Control the input to the process
Analyze the data of the process collected
Assumption : The process performance is a normal distribution
Focus on mean and standard deviation of sample data
Analyze the source of variation
Find the factors that affect the process mean and process spread
(standard deviation)
Establish process monitoring system
Tool Statistical Process Control
Summary on Indexes
Capability
index
Formula Short or
long term
Includes
shift
and drift
Considers the
process
centering
C
p
USL LSL
6
ST
Short term No No
C
pk
Short term
No Yes
P
p
USL LSL
6
LT
Long term Yes No
P
pk
Long term Yes Yes
Example 2 Customer request a metal bar
from 2 suppliers
Customer require 2mm +/- 0.1mm
Supplier B
Supplier A
2 +/- 0.1 mm
Lower Specification Limit
(LSL = 1.9mm)
Upper Specification Limit
(USL = 2.1mm)
Cp = 0.62
Cp = 1.11
Mean
(= 2 mm)
Supplier A
Supplier B
Cp can not reflect the condition of the center shift !!
If the center of distribution was shifted, customer may not happy even receive a high Cp value.
Location Change
Lower SpecificationLimit
(LSL)
Upper SpecificationLimit
(USL)
Mean
()
Out of
specification
Same Cp value
Distribution A
Distribution B
CpK Process Capability Index
A measure of conformance (capability) to
specification
Compares sample mean to nearest specification
against distribution width
CpK can more precisely reflect the capability of distribution.
Example 3
Process Variation on Two Suppliers
LSL = 1.9 mm
USL=2.1mm
Mean
(= 2.0 mm)
= 1.92 mm
CpK = 0.22 CpK = 1.11
= 2.00 mm
Supplier A Supplier B
Remark:
Same SD but different Central
Tendency affects Cpk seriously
but remains same for Cp.
Supplier A
Cp = 1.11
Supplier B
Cp = 1.11
- THE END -

Process Capability

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Copyright 2009 HKRITA. All rights reserved.

Topic: PROCESS CAPABILITY

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