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2001 Prentice-Hall
Chapter Overview
Statistical Fundamentals
Process Control Charts
Some Control Chart Concepts
Process Capability
Other Statistical Techniques in Quality
Management
Statistical Thinking
Is a decision-making skill demonstrated by the
ability to draw to conclusions based on data.
Intuitive decisions are sometimes biased and
wrong-headed.
As a result, decisions are sometimes made that
satisfy the few but irritate the many.
Process Stability
Means that the variation we observe in the
process is random variation and nor
nonrandom variation. To determine process
stability we use process charts.
Process charts are graphs designed to signal
process workers when nonrandom variation is
occurring in a process.
Sampling Methods
To ensure that processes are stable, data are
gathered in samples.
For the most part, sampling methods have
been preferred to the alternative of 100%
inspection.
Sampling Methods
-- The reasons for sampling are well established.
. Samples are
- cheaper,
- take less time,
- less intrusive,
- allow the user to frame the sample, and
- destructive testing, when 100% inspection is
impossible.
2001 Prentice-Hall Transparency 12-24
Statistical Fundamentals
100% inspection
-- Recent experience has shown that 100%
inspection can be effective in certain instances.
-- 100% samples are also known as screening
samples, sorting samples, rectifying samples, or
detailing samples.
-- Another example of 100% inspection is used
when performing in-process inspection.
-- We should clarify that in-process inspection also
can be performed on a sampling basis.
2001 Prentice-Hall Transparency 12-25
Statistical Fundamentals
Sampling Methods
-- Random samples. Randomization is useful because it
ensures independence among observations. To
randomize means to sample is such a way that every
piece of product has an equal chance of being selected
for inspection.
-- Random samples are often the preferred form of
sampling and yet often the most difficult to achieve.
-- This is especially true in process industries were
multiple products are made by the same machines,
workers, and processes in sequence.
Sampling Methods
-- Systematic samples. Systematic samples have
some of the benefits of random samples
without the difficulty of randomizing.
-- Samples can be systematic according to time or
according to sequence.
Sampling Methods
Sampling by Rational Subgroup. A rational
subgroup is a group of data that is logically
homogenous; variation within the data can
provide a yardstick for setting limits on the
standard variation between subgroups.
If variation among different subgroups is not
accounted for, then an unwanted source of
nonrandom variation is being introduced.
Process Charts
SPC charts are tools for monitoring process
variation.
Figure 12.3 shows a process control chart. It
has an upper limit, a center line, and a lower
limit.
There is a generalized process for
implementing all types of process charts.
Variables Attributes
X (process population average) P (proportion defective)
X-bar (mean for average) np (number defective)
R (range) C (number conforming)
MR (moving range) U (number nonconforming)
S (standard deviation)
g and h Charts
A g chart is used when data are geometrically
distributed, and h charts are useful when data
are hyper-geometrically distributed.
Figure 12.12 presents pictures of geometric
and hyper-geometric distributions. If you
develop a histogram of your data, and it
appears like either of these distributions, you
may want to use either an h or a g chart
instead of an X chart.
2001 Prentice-Hall Transparency 12-64
Process Control Charts
Slide 22 of 37
np Charts
The np chart is a graph of the number of
defectives (or nonconforming units) in a
subgroup. The np chart requires that the
sample size of each subgroup be the same each
time a sample is drawn.
When subgroup sizes are equal, either the p or
np chart can be used. They are essentially the
same chart.
2001 Prentice-Hall Transparency 12-76
Process Control Charts
Slide 26 of 37
np Charts (continued)
Some people find the np chart easier to use
because it reflects integer numbers rather
than proportions. The uses for the np chart
are essentially the same as the uses for the p
chart.
c and u Charts
The c chart is a graph of the number of defects
(nonconformities) per unit. The units must be of
the same sample space; this includes size, height,
length, volume and so on. This means that the
area of opportunity for finding defects must
be the same for each unit. Several individual
unites can comprise the sample but they will be
grouped as if they are one unit of a larger size.
The control limits for the c chart are computed
based on the Poisson distribution.
2001 Prentice-Hall Transparency 12-80
Process Control Charts
Slide 28 of 37
Six-Sigma Quality
-- If a process average is on the center line, a six-
sigma process will result in an average of only 3.4
defect per million units produced.
-- The Taguchi method ( see chapter 7S) is a
valuable tool for achieving six-sigma quality by
helping to develop robust designs that are
insensitive to variation.
Capability Studies
-- There are two purposes for performing
process capability studies:
1. To determine whether a process consistently
results in product that meet specifications.
2. To determine whether a process is in need of
monitoring through the use of permanent process
charts.