STATISTICAL QUALITY CONTROL & STATISTICAL PROCESS CONTROL

Statistical Process Control

This is a control system which uses statistical techniques for knowing, all the time changes in the process.
It is an effective method in preventing defects and helps continuous quality improvement.

What does S.P.C. mean?

STATISTICAL Statistics are tools used to make predictions on performance.
There are a number of simple methods for analyzing data and, if applied correctly, can lead to predictions with a high degree of accuracy.

What does S.P.C. mean?

PROCESS The process involves people, machines, materials, methods, management and environment working together to produce an output, such as an end product.

What does S.P.C. mean?

CONTROL Controlling a process is guiding it and comparing actual performance against a target.
Then identifying when and what corrective action is necessary to achieve the target .

Benefits of S.P.C.
Assesses the design intent. Achieves a lower cost by providing an early warning system. Monitors performance, preventing defects. Provides a common language for discussing process performance.

Control Charts
Why Use a Control Chart? To monitor, control, and improve process performance over time by studying variation and its source. What Does a Control Chart Do?

Focuses attention on detecting and monitoring process variation over time; Distinguishes special from common causes of variation, as a guide to local or management action;

Control Charts
Serves as a tool for ongoing control of a process; Helps improve a process to perform consistently and predictably for higher quality, lower cost, and higher effective capacity; Provides a common language for discussing process performance.

Control Charts
Types of charts
Attributes
p-chart c-chart

Variables
range (R-chart) mean (x bar chart)

Control Charts

Control Charts
1. no sample points outside limits 2. most points near process average 3. about equal number of points above and below centerline 4. points appear randomly distributed

P Charts

C Charts
UCL = c + zc LCL = c - zc c = c

where

c = number of defects per sample

Control Charts For Variables

Mean chart ( x -Chart )
uses average of a sample

Range chart ( R-Chart )

uses amount of dispersion in a sample

X Charts

Control Charts For Variables

Process Capability

Process limits (The Voice of the Process or The Voice of the Data) - based on natural (common cause) variation

Tolerance limits (The Voice of the Customer) customer requirements

Process Capability A measure of how capable the process is to meet customer requirements; compares process limits to tolerance limits

Process Capability Index

C pk X LTL UTL - X = min or 3 3

where x-bar is the mean of the process, sigma is the standard deviation of the process, UTL is the customers upper tolerance limit (specification), and LTL is the customers lower tolerance limit.

Interpreting Process Capability

Ishikawa diagrams
Ishikawa diagrams (also called fishbone diagrams, cause-and-effect diagrams) are causal diagrams that show the causes of a certain event. Common uses of the Ishikawa diagram are product design and quality defect prevention, to identify potential factors causing an overall effect.

Ishikawa diagrams
The categories typically include: People: Anyone involved with the process Methods: How the process is performed and the specific requirements for doing it, such as policies, procedures, rules, regulations and laws Machines: Any equipment, computers, tools etc. required to accomplish the job Materials: Raw materials, parts, pens, paper, etc. used to produce the final product Measurements: Data generated from the process that are used to evaluate its quality Environment: The conditions, such as location, time, temperature, and culture in which the process operates.

Ishikawa diagrams

Pareto Analysis
Pareto analysis is a statistical technique in decision making that is used for selection of a limited number of tasks that produce significant overall effect. It uses the Pareto principle the idea that by doing 20% of work, 80% of the advantage of doing the entire job can be generated. Or in terms of quality improvement, a large majority of problems (80%) are produced by a few key causes (20%).

Pareto Analysis
Constructing a Pareto Chart First, information must be selected based on types or classifications of defects that occur as a result of a process. The data must be collected and classified into categories. Then a histogram or frequency chart is constructed showing the number of occurrences.

Pareto Analysis

Histogram
A histogram is a graphical representation showing a visual impression of the distribution of data. A histogram consists of tabular frequencies, shown as adjacent rectangles, erected over discrete intervals (bins), with an area equal to the frequency of the observations in the interval.

Histogram
Creating a Histogram
Collect data and sort it into categories. Then label the data as the independent set or the dependent set.
The characteristic you grouped the data by would be the independent variable. The frequency of that set would be the dependent variable.

Each mark on either axis should be in equal increments. For each category, find the related frequency and make the horizontal marks to show that frequency.

Histogram

Check Sheet
The check sheet is a simple document that is used for collecting data in real-time and at the location where the data is generated. The document is typically a blank form that is designed for the quick, easy, and efficient recording of the desired information, which can be either quantitative or qualitative. When the information is quantitative, the check sheet is sometimes called a tally sheet.

Check Sheet

Control Charts
Control charts, also known as Shewhart charts or process-behaviour charts, in statistical process control are tools used to determine whether or not a manufacturing or business process is in a state of statistical control.

Scatter Plot
A scatter plot or scatter graph is a type of mathematical diagram using Cartesian coordinates to display values for two variables for a set of data. The data is displayed as a collection of points, each having the value of one variable determining the position on the horizontal axis and the value of the other variable determining the position on the vertical axis. This is called a scatter diagram or scatter graph.

Scatter Plot

Flow Chart
A flowchart is a type of diagram that represents an algorithm or process, showing the steps as boxes of various kinds, and their order by connecting these with arrows. This diagrammatic representation can give a stepby-step solution to a given problem.

Flow Chart

Made By : Alfred Mathews Harshit Saxena Nitin Chauhan T. Silambarasan Bharat Khanna 02 19 26 40