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PROCESS CAPABILITY

A word of caution !

Process capability is defined as 6 0 .


Three ways process capability can be obtained are :
After process is brought under control, estimate
0 by d2 or c4 .
Take a large sample ( n >= 100 if possible) and
calculate 0 .
Take a series of samples (g = 20; n = 4) and calculate R
or s then use = s

A process must be in statistical control before


its capability is measured.
Processes out of control fluctuate and thus are
unpredictable; trying to measure their
capability would lead to misleading
conclusions.

c4

Calculating population standard deviation from a single large sample


0.510
0.510
0.510
0.510
0.510
0.510
0.510
0.510
0.510
0.510
0.510
0.509
0.509
0.509
0.509

Outside diameter of 100 components (inch)


0.509
0.508
0.507
0.507
0.509
0.508
0.507
0.507
0.509
0.508
0.507
0.507
0.509
0.508
0.507
0.507
0.509
0.508
0.507
0.507
0.509
0.508
0.507
0.507
0.509
0.508
0.507
0.506
0.509
0.508
0.507
0.506
0.509
0.508
0.507
0.506
0.509
0.508
0.507
0.506
0.509
0.508
0.507
0.506
0.508
0.508
0.507
0.506
0.508
0.508
0.507
0.506
0.508
0.508
0.507
0.506
0.508
0.507
0.507
0.506

Std. Dev.= 0.002278

Process Cap. = 6 (.002278) =

0.506
0.506
0.506
0.505
0.505
0.505
0.505
0.504
0.504
0.501

Specifications : 0.510 +- 0.005 inches


USL = 0.515 LSL = 0.505
Histogram

LSL = 0.505
25

22
18
15

15

12

11

Frequency

10
5

USL = 0.515

(outside diameter)

20
Frequency

0.516
0.514
0.513
0.513
0.513
0.512
0.512
0.511
0.511
0.511
0.511
0.511
0.511
0.511
0.511

0
0.501

0.503

0.505

0.507

0.509

0.511

0.513

0.515

Diameter (in.)

0.013666

Process Capability Index (Cp)


(Process Potential Index --Text)

Relationship of Process
Capability to Specification Limits
Three situations:
1. 6 0 < USL LSL

Process Capability and the specification limits


(i.e., tolerances) are combined to form a Capability
Index:
USL LSL
Cp =
60

Case I

2.

6 0 = USL LSL

Case II

3.

6 0 > USL LSL

Case III

If C p > 1.00

Case I

If C p = 1.00

Case II

If C p < 1.00

Case III

Process Capability Index (Cp)


The capability index measures whether the
process or machine can produce pieces
which conform to the specifications.
The larger the index, the more likely the
process will generate conforming parts or
pieces provided that the process is centered
at the nominal or target value. (CP >= 1.33)
CAUTION : The capability index does not
indicate process performance in terms of the
nominal or target value.

Nominal = 7 USL = 9 LSL = 5


Suppose X 0 = 4

Cp =

C pl =

LSL = 5

USL = 9

Although Cp > 1.33, the process is not capable. Why not ?


8

Illustration
Nominal = 7

USL = 9 LSL = 5

X0 = 7

This measure takes into account the centering of the process.


We first obtain two one-sided indexes, then select the
minimum of the two.

USL X 0
3 0

USL LSL
95
=
= 4.17
6 0
6 ( 0.16 )

X0 = 4

Another measure of process


capability (Cpk)
(Process Performance Index -- Text)

C pu =

0 = 0.16

0 = 0.33
97
Cpu =
=2
3(0.33)

C pl =

7 5
=2
3(0.33)

C pk = Min (2 , 2) = 2

X 0 LSL
3 0

C pk = Min {C pu , C pl }

X0 = 7

LSL = 5

USL = 9

The process is capable.

10

Illustration contd
If X 0 = 8
Cpu =

98
=1
3(0.33)

C pl =

8 5
=3
3 ( 0.33 )

C pk = Min (1 , 3) = 1
LSL = 5

X0 = 7

USL = 9

The process is capable.


LSL = 5

11

X0 =8

The process is barely capable.

USL = 9

12

Motorolas six sigma concept

LSL = 5

X0 =8

LTL

USL = 9

-6
sigma

+6
sigma

UTL

With the process centered exactly in the middle


(nominal dimension), only 2 defectives out of one billion
are expected.

The process is barely capable.


13

If the process mean shifts 1.5 sigma, the expected


number of defectives will be 3.4 per million.
What is the key to achieving six-sigma capability?

14

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