Process Capability

1, Jatco Requirements 2, Cmk, Cpk, Ppk Explanation 3, Control Charts and Capability Ratio`s

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SPC Jatco Requirements

When calculating process capability Jatco requires a 90% confidence level.
Achievement target PpK Characteristics of Critical Parts Special Characteristic (S Characteristic) Characteristic in QA List General Characteristics 1.67 or higher 1.67 or higher 1.67 or higher 1.33 or higher Cpk 1.67 or higher SPC 1.67 or higher 90% 1.33 or higher 1.33 or higher SPC Check sheet, etc. Confidence Level Control Method

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Process Capability
Capability Studies A process capability study is performed for a new or changed production process (including assembly) in order to verify the (preliminary) process capability or performance and to obtain additional inputs for controlling the process.

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Process Capability
Machine Capability Study The machine capability study is a short-term study with the sole aim of discovering the machine-specific effects on the production process. Process Capability Study The process capability study is a longer-term study. In addition to variation arising from the machine, all other external factors that influence the production process over a longer operating time must be taken into account.
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Process Capability
Stable Process A stable (in statistical control) process is only subject to random influences. In particular, the location and variation of the product characteristic are stable over time. Quality-Capable Process A process is quality-capable when it can meet all the specified requirements without exception.

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Process Capability
Capability Indices Cmk, Cpk and Performance Index Ppk
The term Cpk must only be used for a stable process. A process is stable if the following synonymous statements apply to it: Mean and variance are constant. No systematic variations of the mean such as trend, batch-tobatch variation, etc., occur. There is no significant difference between sample variation and total variation. Every sample represents the location and variation of the total process.
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Process Capability
If the process is not stable, one speaks of process performance, and the index is called the process performance index, Ppk . This applies to all processes with systematic variation of the mean such as trend or batch-to-batch variation. It is, therefore, the process behaviour which determines whether the index is named Cpk or Ppk .
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Process Capability
In a machine capability study (initial process study or short term study ), the index is always called Cmk , Cmk is understood to be an index for a short-term capability study. Only when sufficient data has been collected over a longer term (e.g., as the result of a process capability study, preproduction run with at least 125 values or evaluation of several control charts) it is possible to calculate and distinguish between Cpk and Ppk on the basis of the process behaviour.
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Process Capability
Flow Chart for Machine and Process Capability Study

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Process Capability
Flow Chart for Machine Capability
Manual Calculation Procedure If no special software is available, m C and Cmk also can be calculated as follows. The mean x and the overall standard deviation s total are calculated from the n measured values x i :

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Process Capability
Machine Capability Study with Reduced Expense As specified at least fifty ( n = 50 ) parts should be manufactured for a machine capability study, but use of one hundred ( n =100 ) parts is preferred. In practice, capability studies often incur high costs due to expensive measurements. In such cases, the following, two-stage procedure may be used to minimize cost: 1. Of the 50 parts produced consecutively, begin the study by measuring only every second part, i.e., parts 2, 4, 6, ..., 50. This step yields 25 measured values per characteristic. The machine is considered capable if the capability index calculated from the 25 values is Cmk 2.0 . Supplier Quality Assurance and Management Department
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Process Capability
Machine Capability Study with Reduced Expense
Simplified Machine Capability

Manuafcture 50 parts in sequance and number them in the order they where manufactured. Measure every 2nd part i.e. parts # 2,4,6,.....50 Document the measurements and

Problem analysis make improvements

yes

Cmk 2.0

Measure the parts # 1,3,5,....49 and add the measurement values to the excisting documented results (# 2,4,6,....50)

no

yes

Cmk 1.67

Machine is capable

2. If 1.67 < Cmk < 2.0 , the remaining 25 parts must also be measured. These results are combined with the original 25 measurements and the capability index is re-calculated. The machine is considered capable if a capability index Cmk 1.67 is achieved using all 50 values.

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Process Capability
Machine Capability Study with Reduced Expense In special cases, it may be unavoidable to reduce the sample size even further (regardless of the capability requirement). This may be the case if the measurement procedure is very expensive or the test is destructive. Naturally, the smaller the sample size, the less accurate the conclusions (larger confidence interval of the characteristic calculated from the sample). The Jatco SQA engineer must be consulted before the sample size is reduced. In such cases, the machine or process parameters should be given priority instead of the product parameters.

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Process Capability
Process Capability Study The process capability study is a long-term study that is conducted over an extended operating time and includes sources of variation external to a machine. These sources are typically summarized under the headings of Man, Machine, Material, Method and Environment.

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Process Capability
Process Capability Study A process capability study includes the following steps: Select parts from series production in rational samples (not sorted); at least 25 subgroups should be evaluated. The preferred sample size is n = 5. Overall, at least 125 parts should be examined. Measure part characteristics and record the results along with production sequence. Statistical evaluation of the data: Evaluate temporal stability and statistical distribution. Calculate capability indices. Supplier Quality Assurance and Management Department
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Process Capability
Process Capability Study

Note: In special cases, use of fewer than 125 parts may be unavoidable due to time or cost of making the necessary measurements, or if the test is destructive. Smaller sample sizes lead to larger confidence intervals of the characteristic(s) being studied. In turn, this reduces the accuracy of the conclusions that may be drawn from the data. The Jatco SQA Engineer must be consulted before the sample size is reduced.
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Process Capability
Process Capability Study The random samples shall be taken from on-going production under standard production conditions (i.e. with machine broken in and cycle time and machine adjusting parameter values as in standard production) at regular intervals in the same size each time. In this case, in contrast to the MCS, all effects that result from changes in machine parameter values, tooling changes and machine malfunctions shall be taken into consideration. However, the measurements that are necessary for machine setup or for a corrective measure are not taken into consideration in the PCS Supplier Quality Assurance and Management Department
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Process Capability
Process Capability Study When taking random samples, the measurement of the parts should be carried out as promptly as possible. However, if an accumulation of several random samples before the measurement recording cannot be prevented, an assignment of the parts to the random samples in their time sequence is to be made possible. In contrast, the sampling sequence of the individual parts of a random sample does not have to be considered. The form of sampling sometimes carried out in practice, in which each nth part, e.g. each 10th part, is taken from the on-going standard production, is not suitable for the process capability investigation. Supplier Quality Assurance and Management Department
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Process Capability
Process Capability Study The random sample size n must be at least 3 (recommended size n = 5) The random sample quantity m must be at least 6 The total random sample size should generally be m n

>125.

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Process Capability
Process Capability Study If this random sample size is difficult to obtain for economic or technical reasons, a smaller one is also permissible. Then the corresponding higher limit values calculated using a 90% confidence level using the equation below must be complied with. However, the effective total random sample size (without outliers) must be at least 30.

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Process Capability
Process Capability Study

The random sample frequency must be high enough so that at least once, a sampling of the specified size n is carried out within a time interval in which no systematic influences on the process are expected, i.e. at least one random sample per
shift and employee change of the machine parameter values tool life and material batch

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Process Capability
Process Capability Study The testing period, over which the sampling of the m random samples extends, must contain at least the following influences (recommended period 1 to 2 weeks): 3 changes of shift 3 changes of employees a change of the tooling or change of the machine parameter values and a change of the material batch

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Process Capability
Process Capability Study Studying the Process Stability

For the stability test, control limits based on the normal distribution are calculated for the means and the standard deviations
If the control limits for the means are exceeded, this shows that the process is not stable and that its position has changed systematically. i.e. Make a control chart with the data and confirm stability.

If the process can be shown as stable then use Cp/Cpk if the process cannot be shown to be stable then use Pp/Ppk .
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Process Capability
Process Capability Study Studying the Statistical Distribution A qualitative evaluation can be made and a distribution assigned using graphic representations such as an individual value plot, a histogram, probability plots etc. Calculating the shape parameters (skewness, kurtosis) or performing distribution tests can act as quantitative methods.

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Process Capability
Process Capability Study
Calculating Process Capability Indices If no special software is available, capability and performance values can also be calculated as follows. Normal distribution:

Estimating the process average.

Total Mean ( Mean of the sample means) Mean of a sample with size n (e.g. n=5)

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Process Capability
Process Capability Study
Estimating the standard deviation of the process.

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Process Capability
Process Capability Study
If the Process Cannot be Shown to be Stable: From the n measured values x i , the total mean x and the overall standard deviation s total are calculated:

and with T = USL - LSL finally

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Process Capability
Process Capability Study
6.1 Relation Between Capability Index and Fraction Nonconforming Most of the literature on process capability shows that there is a direct relation between a calculated Cpk value and a fraction nonconforming, e.g.: Cpk =1.33 corresponds to 32 ppm (one-sided). This relation is based on the normal distribution model. If the real characteristic distribution deviates from the normal distribution, different fractions nonconforming normally arise. Supplier Quality Assurance and Management Department
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Process Capability
Process Capability Study
6.1 Relation Between Capability Index and Fraction Nonconforming Most of the literature on process capability shows that there is a direct relation between a calculated Cpk value and a fraction nonconforming, e.g.: Cpk =1.33 corresponds to 32 ppm (one-sided). This relation is based on the normal distribution model. If the real characteristic distribution deviates from the normal distribution, different fractions nonconforming normally arise. Supplier Quality Assurance and Management Department
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Process Capability
Process Capability Study

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Process Capability
Process Capability Study
Effect of the Measurement System

The measuring device and measuring procedure used to measure the parts in the random sample are very important for evaluating the process later on. If the measuring device is not accurate enough or if the measuring procedure is unsuitable, the tolerance for the production process is reduced unnecessarily. A large %GRR value will impair the machine and process capability indices.
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Process Capability
Process Capability Study
Capability ratios are statistics. All statistics will vary from sample to sample, even when the underlying process doesn't change. We will use the data in Table below to illustrate the manner in which capability ratios vary over time.

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Process Capability
For the data of Table 1, the grand average is 10.084, and the average range is 4.11. Thus, the limits for an average and range chart for these data would be: For subgroup averages: X= A2 R- = 10.084 (0.577)(4.11) = 7.71 to 12.46 For subgroup ranges: D4 R- = (2.114)(4.11) = 8.69 As may be seen in graph below the data displays a reasonable degree of statistical control. There are no indications of anything other than routine, common-cause variation.

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Process Capability
The Specifications are 3 to 17.
With these specification limits and the summary statistics from the control chart, the capability ratio for this bead board process would be: Cp = (USL-LSL)/6Sigma(X) = (17-3)/(6.0)(1.767) = 1.32 With a grand average of 10.084, the centered capability ratio is: Cpk = (USL-X=)/3Sigma(X) = (17-10.084)/(3.0)(1.767) = 1.30 Today, many customers ask for Cpk of 1.33 or greater. While this process is close, it does not quite meet this magic value. Supplier Quality Assurance and Management Department
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Process Capability
The calculations were are based on 500 data, and we seldom wait until we have so much data to compute the capability ratios. In most cases, capabilities are computed occasionally, or periodically, using 50 or fewer values. So we shall divide our 100 subgroups into blocks of 10 subgroups each and compute the Cpk value for each block.

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Process Capability
Subgroups 1 to 10: Grand average = 10.08, average range = 4.0, and Sigma(X) = 4.0/2.326 = 1.720 The centered capability ratio is: Cpk = (17.0-10.08)/(3.0)(1.720) = 1.34 A good capability ratio -- our customer will be pleased with this.

Subgroups 11 to 20: Grand average = 9.98, average range = 3.9, and Sigma(X) = 3.9/2.326 = 1.677 The centered capability ratio is: Cpk = (9.98-3.0)/(3.0)(1.677) = 1.39
Congratulations, the capability ratio got better. Supplier Quality Assurance and Management Department
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Process Capability
Subgroups 21 to 30: Grand average = 10.12, average range = 4.5, and Sigma(X) = 4.5/2.326 = 1.935 The centered capability ratio is: Cpk = (17.0-10.12)/(3.0)(1.935) = 1.19 What happened to cause the capability ratio to drop? Subgroups 31 to 40: Grand average = 10.24, average range = 4.2, and Sigma(X) = 4.2/2.326 = 1.806 The centered capability ratio is: Cpk = (17.0-10.24)/(3.0)(1.806) = 1.25

This capability ratio is still not good enough -- we must do better.

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Process Capability
Subgroups 41 to 50: Grand average = 10.10, average range = 4.9, and Sigma(X) = 4.9/2.326 = 2.107 The centered capability ratio is: Cpk = (17.0-10.10)/(3.0)(2.107) = 1.09 This is worse than before. Subgroups 51 to 60: Grand average = 10.42, average range = 3.9, and Sigma(X) = 3.9/2.326 = 1.677 The centered capability ratio is: Cpk = (17.0-10.42)/(3.0)(1.677) = 1.31

Well, this is better, but our customer is asking for 1.33 or greater.
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Process Capability
Subgroups 61 to 70: Grand average = 10.30, average range = 4.7, and Sigma(X) = 4.7/2.326 = 2.021 The centered capability ratio is: Cpk = (17.0-10.30)/(3.0)(2.021) = 1.11 You were supposed to be improving -- what is going on here? Subgroups 71 to 80: Grand average = 10.06, average range = 3.8, and Sigma(X) = 3.8/2.326 = 1.634 The centered capability ratio is: Cpk = (17.0-10.06)/(3.0)(1.634) = 1.42

At last we`ll send this data to our customer.

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Process Capability
Subgroups 81 to 90: Grand average = 9.88, average range = 3.5, and Sigma(X) = 3.5/2.326 = 1.505 The centered capability ratio is: Cpk = (9.88-3.0)/(3.0)(1.505) = 1.52
Excellent capability ratio. Good work. Subgroups 91 to 100: Grand average = 9.66, average range = 3.7, and Sigma(X) = 3.7/2.326 = 1.591 The centered capability ratio is: Cpk = (9.66-3.0)/(3.0)(1.591) = 1.40 Why is this value slipping? Supplier Quality Assurance and Management Department
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Process Capability
Of course, the real answer is that we are not slipping. The process was not getting worse, nor was it getting better. But our statistics were changing from block to block even though the process remained the same, and these changes were reflected in the centered capability ratio values computed. If we placed these 10 centered capability ratios on an XmR chart.

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Process Capability
Figure 2 shows that the routine amount of variation in capability ratios, based upon 50 values each, will allow them to go as low as 0.88 or as high as 1.72, while the process is unchanging with an average capability ratio of 1.30. So how can you make sense of the capability ratios? Put them on a control chart. If this chart is out of control, you can be sure that your process is also out of control. However, the converse is not true -your process can be out of control and still yield a control chart for capability ratios that is in control.

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Why SPC

Data Driven Decision Making

However it is not always practical to have the amount of data that will allow us to have this in depth analysis of the process capability before SOP Therefore this analysis needs to be done after we have enough data over a reasonable time period. The Jatco Safe Launch Plan allows us to make this analysis.
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