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STATISTICAL PROCESS
CONTROL (SPC)
A statistical process control involves testing a random
sample of output from a process to determine whether
the process is producing items within a pre-selected
range
SPC uses statistical tools to observe the performance
of the production process in order to detect significant
variations before they result in the production of a substandard article.
SPC is about monitoring consistency and repeatability
of a process
MAJOR OBJECTIVES
OF SPC
Quickly detect the occurrence of assignable
causes of process so that investigation of the
process and corrective action may be undertaken
before non-conforming units are manufactured
Reducing variability in the process
STATISTICAL PROCESS
CONTROL TOOLS (SPC)
Variation in output is due to:
Common causes (also known as natural variation)
Inherent variation present in every process
Variations are created by combined influences of
countless minor factors
Causes may difficult to distinguish or wholly
unidentifiable
Resulting degree of variation is minor
Assignable causes (known as special variation)
Variations due to specific causes
A process subject to assignable variation is out of control
STATISTICAL PROCESS
CONTROL TOOLS (SPC)
Control (or in control or stable)
A process that exhibits only common cause
variation is said to be in control or stable
A process is said to be out of control when it
exhibits assignable variation
Examples: less experienced worker has replaced
an experienced worker, machine malfunctioning,
change of machine settings
CONTROL CHARTS
A control chart is a time ordered plot of sample statistics
If the process is in control, all sample points will fall between them
CONTROL CHARTS
If all the points plot inside the limits, but
behave in a nonrandom manner
indication that process is out of control and
needs investigation
A CONTROL CHART
IN STATISTICAL CONTROL
A process that is operating with only
chance cause of variation present is said
to be in statistical control
If the process is in control, all the plotted
points should have an essentially
random pattern
STATISTICAL PROCESS
CONTROL TOOLS
Control Charts for variables (Characteristics that are expressed on a
numerical scale: density, weight, diameter, resistance, length, time,
volume)
X-bar Chart and R-Chart
X-bar chart for process average
R-chart for process variability
Control Charts for attributes (characteristic that cant be measured
on a numerical scale: smell of cologne acceptable or not
acceptable, color of a fabric acceptable or not)
p-chart and c-chart
p-charts for percent defective in a sample
c-charts for counts (e.g. # of defects)
SPC TOOLS
Control Charts for variables (X-chart, R-Chart)
Variables data are measured on continuous scale
Length, width, weight
Temperature
Voltage
Viscosity
Amount of time needed to complete a task
R-CHART CONTROL
LIMITS
Sample Size
X-bar chart
R-chart
R-chart
n
2
3
4
5
6
7
8
9
10
A2
1.880
1.023
0.729
0.577
0.483
0.419
0.373
0.337
0.308
D3
0
0
0
0
0
0.076
0.136
0.184
0.223
D4
3.267
2.574
2.282
2.114
2.004
1.924
1.864
1.816
1.777
ZONES FOR
IDENTIFICATION OF
NONRANDOM PATTERN
CONTROL CHART
PATTERNS
CONTROL CHART
PATTERNS
PATTERN RECOGNITION
IN CONTROL CHARTS
Recognizing non-random patterns on the
control chart
One point plots outside 3 limits
Two or three consecutive points plot beyond 2 limits
Four out of 5 consecutive points plot at a distance of 1 or
beyond from the centre line
Eight consecutive points on one side of centre line
P-CHART
Control charts for attributes
p-chart measures % defective items or proportion defective
items in a sample
P-CHART LIMITS
C-CHART
Appropriate when number of defects are counted
because not possible to compute proportion
defective
Examples
Number of accidents per day
Number of crimes committed in a month
Blemishes on a desk
Complaints in a day
Typo errors in a chapter of the text book
# customer invoice errors
C-CHART LIMITS
PROCESS CAPABILITY
Specifications: A range of values imposed by
designers of the product or service based on
customer requirements
Control limits and based on production process,
and they reflect process variability due to
randomness alone
Process variability: Natural or inherent variability
in a process due to randomness
Process capability: The inherent variability of
process output relative to the variation allowed by
the design specifications
MEASURES OF
PROCESS CAPABILITY
Measures of Process Capability
Process Capability Ratio
Process Capability Index
PROCESS CAPABILITY
RATIO
Cp = (Upper Spec Lower Spec) / 6
If Cp < 1, process range > tolerance range
PROCESS CAPABILITY
PROCESS CAPABILITY
PROCESS CAPABILITY
Cp does not take into account where
the process mean is located relative
to the specifications
Cp simply measures the spread of the
specifications relative to the six sigma
spread in the process
PROCESS CAPABILITY
INDEX
Cpk measures if the process mean has shifted away from the design target, and which
Direction it has shifted --- that is, if it is off center. Ideally, Cpk = 1.33
PROCESS CAPABILITY
INDEX
Cpk = 1, indicates the process variation is
within the upper and lower control limits
Cpk>1, process is capable of meeting
design specifications
Cpk<1, process has moved closer to one of
the upper or lower design specifications,
and it generate defects
When, Cpk = Cp, process mean is centered
on the design target
PROCESS CAPABILITY
(SEQUENTIAL STEPS)
1.
2.