Chapter 3
Statistical Process Control
Lecture Outline
Basics of Statistical Process Control Control Charts Control Charts for Attributes Control Charts for Variables Control Chart Patterns SPC with Excel and OM Tools Process Capability
Copyright 2011 John Wiley & Sons, Inc.
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Statistical Process Control (SPC)
Statistical Process Control
monitoring production process to detect and prevent poor quality
UCL
Sample
subset of items produced to use for inspection
LCL
Control Charts
process is within statistical control limits
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Process Variability
Random
inherent in a process depends on equipment and machinery, engineering, operator, and system of measurement natural occurrences
Non-Random
special causes identifiable and correctable include equipment out of adjustment, defective materials, changes in parts or materials, broken machinery or equipment, operator fatigue or poor work methods, or errors due to lack of training
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SPC in Quality Management
SPC uses Is the process in control? Identify problems in order to make improvements Contribute to the TQM goal of continuous improvement
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Quality Measures: Attributes and Variables
Attribute A characteristic which is evaluated with a discrete response good/bad; yes/no; correct/incorrect Variable measure A characteristic that is continuous and can be measured Weight, length, voltage, volume
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SPC Applied to Services
Nature of defects is different in services Service defect is a failure to meet customer requirements Monitor time and customer satisfaction
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SPC Applied to Services
Hospitals
timeliness & quickness of care, staff responses to requests, accuracy of lab tests, cleanliness, courtesy, accuracy of paperwork, speed of admittance & checkouts
Grocery stores
waiting time to check out, frequency of out-of-stock items, quality of food items, cleanliness, customer complaints, checkout register errors
Airlines
flight delays, lost luggage & luggage handling, waiting time at ticket counters & check-in, agent & flight attendant courtesy, accurate flight information, cabin cleanliness & maintenance
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SPC Applied to Services
Fast-food restaurants
waiting time for service, customer complaints, cleanliness, food quality, order accuracy, employee courtesy
Catalogue-order companies
order accuracy, operator knowledge & courtesy, packaging, delivery time, phone order waiting time
Insurance companies
billing accuracy, timeliness of claims processing, agent availability & response time
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Where to Use Control Charts
Process
Has a tendency to go out of control Is particularly harmful and costly if it goes out of control
Examples
At beginning of process because of waste to begin production process with bad supplies Before a costly or irreversible point, after which product is difficult to rework or correct Before and after assembly or painting operations that might cover defects Before the outgoing final product or service is delivered
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Control Charts
A graph that monitors process quality Control limits
upper and lower bands of a control chart
Attributes chart
p-chart c-chart
Variables chart
mean (x bar chart) range (R-chart)
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Process Control Chart
Out of control
Upper control limit Process average Lower control limit
10
Sample number
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Normal Distribution
Probabilities for Z= 2.00 and Z = 3.00
95% 99.74%
-3
-2
-1
=0
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A Process Is in Control If
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
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Control Charts for Attributes
p-chart
uses portion defective in a sample
c-chart
uses number of defects (non-conformities) in a sample
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p-Chart
UCL = p + zp LCL = p - zp
z = number of standard deviations from process average p = sample proportion defective; estimates process mean p = standard deviation of sample proportion
p = p(1 - p) n
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Construction of p-Chart
SAMPLE # NUMBER OF DEFECTIVES PROPORTION DEFECTIVE
1 2 3 : : 20
6 0 4 : : 18 200
.06 .00 .04 : : .18
20 samples of 100 pairs of jeans
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Construction of p-Chart
p=
total defectives total sample observations = 200 / 20(100) = 0.10 0.10(1 - 0.10) 100
UCL = p + z UCL = 0.190 LCL = p - z LCL = 0.010
p(1 - p) = 0.10 + 3 n
p(1 - p) = 0.10 - 3 n
0.10(1 - 0.10) 100
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Construction of p-Chart
0.20 0.18 0.16 Proportion defective 0.14 0.12 0.10 0.08 0.06 0.04 0.02 2 LCL = 0.010 4 6 8 10 12 Sample number 14 16 18 20 p = 0.10 UCL = 0.190
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p-Chart in Excel
Click on Insert then Charts to construct control chart
I4 + 3*SQRT(I4*(1-I4)/100) I4 - 3*SQRT(I4*(1-I4)/100)
Column values copied from I5 and I6
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c-Chart
UCL = c + zc LCL = c - zc
where c = number of defects per sample
c =
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c-Chart
Number of defects in 15 sample rooms
SAMPLE NUMBER OF DEFECTS
1 2 3
12 8 16
190 c= = 12.67 15 UCL = c + zc = 12.67 + 3 = 23.35 12.67
: :
15
: :
15 190
LCL = c - zc = 12.67 - 3 = 1.99
12.67
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c-Chart
24
UCL = 23.35
21
18 15 12 9 6 3
Number of defects
c = 12.67
LCL = 1.99
10
12
14
16
Sample number
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Control Charts for Variables
Range chart ( R-Chart )
Plot sample range (variability)
Mean chart ( x -Chart )
Plot sample averages
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x-bar Chart: Known
UCL = = + z x x LCL = = - z x x
Where x1 + x2 + ... + xk = X= k
= process standard deviation x = standard deviation of sample means =/ n k = number of samples (subgroups) n = sample size (number of observations)
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x-bar Chart Example: Known
Observations(Slip-Ring Diameter, cm) n Sample k 1 2 3 4 5
We know = .08
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x-bar Chart Example: Known
= 50.09 X = _____ = 5.01 10 = UCL = x + z x = 5.01 + 3(.08 / 10) = 5.09 LCL = = - z x x = 5.01 - 3(.08 / 10) = 4.93
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x-bar Chart Example: Unknown
UCL = = + A2R x
where _
LCL = = - A2R x
= x = average of the sample means _ R = average range value
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Control Chart Factors
Sample Size n 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Factor for X-chart A2 1.880 1.023 0.729 0.577 0.483 0.419 0.373 0.337 0.308 0.285 0.266 0.249 0.235 0.223 0.212 0.203 0.194 0.187 0.180 0.173 0.167 0.162 0.157 0.153
Factors for R-chart D3 0.000 0.000 0.000 0.000 0.000 0.076 0.136 0.184 0.223 0.256 0.283 0.307 0.328 0.347 0.363 0.378 0.391 0.404 0.415 0.425 0.435 0.443 0.452 0.459 D4 3.267 2.575 2.282 2.114 2.004 1.924 1.864 1.816 1.777 1.744 1.717 1.693 1.672 1.653 1.637 1.622 1.609 1.596 1.585 1.575 1.565 1.557 1.548 1.541
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x-bar Chart Example: Unknown
OBSERVATIONS (SLIP- RING DIAMETER, CM) SAMPLE k 1 2 3 4 5 6 7 8 9 10 1 5.02 5.01 4.99 5.03 4.95 4.97 5.05 5.09 5.14 5.01 2 5.01 5.03 5.00 4.91 4.92 5.06 5.01 5.10 5.10 4.98 3 4.94 5.07 4.93 5.01 5.03 5.06 5.10 5.00 4.99 5.08 4 4.99 4.95 4.92 4.98 5.05 4.96 4.96 4.99 5.08 5.07 5 4.96 4.96 4.99 4.89 5.01 5.03 4.99 5.08 5.09 4.99 x 4.98 5.00 4.97 4.96 4.99 5.01 5.02 5.05 5.08 5.03 R 0.08 0.12 0.08 0.14 0.13 0.10 0.14 0.11 0.15 0.10 1.15
Totals 50.09
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x-bar Chart Example: Unknown
_ R= R ____ = k 1.15 ____ 10 = 0.115
x 50.09 = = ___ = _____ = 5.01 cm x 10 k _ = UCL = x + A2R = 5.01 + (0.58)(0.115) = 5.08 = LCL = x - A2R = 5.01 - (0.58)(0.115) = 4.94 _
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x- bar Chart Example
Mean
5.10 5.08 UCL = 5.08 5.06 5.04 5.02 5.00 4.98 4.96 4.94 4.92 | 1 | 2 | 3 | | | | 4 5 6 7 Sample number | 8 | 9 | 10 LCL = 4.94 = = 5.01 x
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R- Chart
UCL = D4R R= R k LCL = D3R
Where R = range of each sample k = number of samples (sub groups)
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R-Chart Example
OBSERVATIONS (SLIP- RING DIAMETER, CM) SAMPLE k 1 2 3 4 5 6 7 8 9 10 1 5.02 5.01 4.99 5.03 4.95 4.97 5.05 5.09 5.14 5.01 2 5.01 5.03 5.00 4.91 4.92 5.06 5.01 5.10 5.10 4.98 3 4.94 5.07 4.93 5.01 5.03 5.06 5.10 5.00 4.99 5.08 4 4.99 4.95 4.92 4.98 5.05 4.96 4.96 4.99 5.08 5.07 5 4.96 4.96 4.99 4.89 5.01 5.03 4.99 5.08 5.09 4.99 x 4.98 5.00 4.97 4.96 4.99 5.01 5.02 5.05 5.08 5.03 R 0.08 0.12 0.08 0.14 0.13 0.10 0.14 0.11 0.15 0.10 1.15
Totals 50.09
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R-Chart Example
_ UCL = D4R = 2.11(0.115) = 0.243
_ LCL = D3R = 0(0.115) = 0 Retrieve chart factors D3 and D4
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R-Chart Example
0.28
0.24 0.20 0.16 0.12 0.08 0.04 0 LCL = 0 | | | 1 2 3 | | | | 4 5 6 7 Sample number | 8 | 9 | 10 UCL = 0.243 R = 0.115
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Range
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X-bar and R charts Excel & OM Tools
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Using x- bar and R-Charts Together
Process average and process variability must be in control Samples can have very narrow ranges, but sample averages might be beyond control limits Or, sample averages may be in control, but ranges might be out of control An R-chart might show a distinct downward trend, suggesting some nonrandom cause is reducing variation
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Control Chart Patterns
Run
sequence of sample values that display same characteristic
Pattern test
determines if observations within limits of a control chart display a nonrandom pattern
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Control Chart Patterns
To identify a pattern look for:
8 consecutive points on one side of the center line 8 consecutive points up or down 14 points alternating up or down 2 out of 3 consecutive points in zone A (on one side of center line) 4 out of 5 consecutive points in zone A or B (on one side of center line)
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Control Chart Patterns
UCL UCL
LCL Sample observations consistently below the center line
LCL Sample observations consistently above the center line
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Control Chart Patterns
UCL UCL
LCL Sample observations consistently increasing
LCL Sample observations consistently decreasing
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Zones for Pattern Tests
UCL Zone A
= 2 2 sigma = x + 3 (A2R) = 3 sigma = x + A2R
Zone B
= 1 1 sigma = x + 3 (A2R)
Process average
Zone C Zone C
= x
= 1 sigma = x - 1 (A2R) 3
Zone B
= 2 sigma = x - 2 (A2R) 3
Zone A
LCL
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13
= 3 sigma = x - A2R
Sample number
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Performing a Pattern Test
SAMPLE 1 2 3 4 5 6 7 8 9 10 x 4.98 5.00 4.95 4.96 4.99 5.01 5.02 5.05 5.08 5.03 ABOVE/BELOW B B B B B A A A A UP/DOWN U D D U U U U U D ZONE B C A A C C C B A B
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Sample Size Determination
Attribute charts require larger sample sizes 50 to 100 parts in a sample Variable charts require smaller samples 2 to 10 parts in a sample
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Process Capability
Compare natural variability to design variability Natural variability What we measure with control charts Process mean = 8.80 oz, Std dev. = 0.12 oz Tolerances Design specifications reflecting product requirements Net weight = 9.0 oz 0.5 oz Tolerances are 0.5 oz
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Process Capability
Design Specifications (a) Natural variation exceeds design specifications; process is not capable of meeting specifications all the time. Process Design Specifications (b) Design specifications and natural variation the same; process is capable of meeting specifications most of the time. Process
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Process Capability
Design Specifications (c) Design specifications greater than natural variation; process is capable of always conforming to specifications. Process
Design Specifications
(d) Specifications greater than natural variation, but process off center; capable but some output will not meet upper specification. Process
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Process Capability Ratio
tolerance range process range upper spec limit - lower spec limit 6
Cp =
=
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Computing Cp
Net weight specification = 9.0 oz 0.5 oz Process mean = 8.80 oz Process standard deviation = 0.12 oz upper specification limit lower specification limit Cp = 6 9.5 - 8.5 = = 1.39 6(0.12)
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Process Capability Index
= x - lower specification limit 3
Cpk = minimum
= upper specification limit - x 3
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Computing Cpk
Net weight specification = 9.0 oz 0.5 oz Process mean = 8.80 oz Process standard deviation = 0.12 oz
= x - lower specification limit , 3 = upper specification limit - x 3 8.80 - 8.50 9.50 - 8.80 , = 0.83 3(0.12) 3(0.12)
Cpk = minimum
= minimum
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Process Capability With Excel
=(D6-D7)/(6*D8)
See formula bar
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Process Capability With OM Tools
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