Statistical Process Control

Variability in Process
Process that produce goods and services usually exhibit some
variation in their output

It is generally accepted that as variation is reduced, quality is

improved.
 Random  Non-Random
 common causes  special causes
 inherent in a process  due to identifiable
 can be eliminated only factors
through improvements  can be modified
in the system through operator or
management action
Basics of Statistical Process Control

 It is a technique used to evaluate conformance quality of a

product.

 It involves monitoring production process to detect and prevent

poor quality

 Its objective is to check whether currently produced items are

meeting design specifications or not.

 It involves testing a random sample of output from a process to

determine whether process is producing items within
preselected range.
Statistical Process Control
(SPC) Charts UCL

Normal Behavior

LCL

UCL = Upper Control Limits 1 2 3 4 5 6 Samples

over time
LCL = Lower Control Limits

UCL

Possible problem, investigate

LCL

1 2 3 4 5 6 Samples
over time
 Quality Measures
 Attribute
 a product characteristic that are classified as either
conforming or not conforming to the specifications.
 E.g. good or bad; functioning or malfunctioning

 Variable
 a product characteristic that can be measured
 E.g. weight - length
 Where to Use Control Charts
 Process is particularly harmful and costly if it goes
out of control
 Examples
 at the beginning of a process because it is a waste of
time and money 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
Control Charts
 It visually shows if a sample is within control or not.
 A graph that establishes control limits of a process
 Control limits
 upper and lower bands of a control chart

 Types of charts
 Attributes
 p-chart
 c-chart

 Variables
 range (R-chart)
 mean (x bar – chart)
 Process Control Chart

Out of control
Upper
control
limit

Process
average

Lower
control
limit

1 2 3 4 5 6 7 8 9 10
Sample number
 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
 Control Charts for Attributes

 p-charts
 uses proportion of defective in a sample

 c-charts
 uses number of defects per item in a sample
 p-Chart
It uses proportion of defective items in a sample as the sample
Statistics.
total defectives UCL = p + zp
p= total sample observations LCL = p - zp

z = number of standard deviations from

process average
p = sample proportion defective; an estimate
of process average
p = standard deviation of sample proportion
p(1 - p)
p = n
Normal values of z = 2.00 (95% probability)
= 3.00 (99.74 % probability)
Normal Distribution

95%
99.74%
-3 -2 -1 =0 1 2 3
Example of Constructing a p-chart: Step 1

Sample n Defectives p
1 100 4 0.04
1. Calculate the sample 2 100 2 0.02
proportions, p for each 3 100 5 0.05
sample. 4 100 3 0.03
5 100 6 0.06
6 100 4 0.04
7 100 3 0.03
8 100 7 0.07
9 100 1 0.01
10 100 2 0.02
11 100 3 0.03
12 100 2 0.02
13 100 2 0.02
14 100 8 0.08
15 100 3 0.03
Example of Constructing a p-chart: Steps 2&3

2. Calculate the average of the sample proportions.

55
p = = 0.036
1500

3. Calculate the standard deviation of the sample proportion

p (1 - p) .036(1 - .036)
p = = = .0188
n 100
Example of Constructing a p-chart: Step 4

4. Calculate the control limits.

UCL = p + z  p

LCL = p - z  p

.036  3(.0188)

UCL = 0.0924
LCL = -0.0204 (or 0)
Example of Constructing a p-Chart: Step 5
5. Plot the individual sample proportions, the average
of the proportions, and the control limits

0.16
0.14
0.12

p 0.1
UCL
0.08
0.06
0.04
p
0.02
0
1 2 3 4 5 6 7 8
Observation
9 10 11 12 13 14 LCL
15
 p-Chart Example
 The western Company produces denim jeans. The company
wants to establish a p-chart to monitor the production
process.
 The company believes that approximately 99.74% of the
variation in the production process is random and should be
within control limits.

 The company has taken 20 samples , each of 100 pairs of

jeans and inspected them for defects, which is shown in
table

 Construct p-chart to determine whether the process is in

control or not.
 Sample Number of Defectives
p-Chart
1 6
Example 2 0
3 4
4 10
5 6
6 4
7 12
8 10
9 8
10 10
11 12
12 10
13 14
14 8
15 6
16 16
17 12
18 14
19 20
20 18
 Number of Proportion
Sample
Defectives Defectives
1 6 0.06
p-Chart 2
3
0
4
0
0.04
Example 4 10 0.1
5 6 0.06
6 4 0.04
7 12 0.12
8 10 0.1
9 8 0.08
10 10 0.1
11 12 0.12
12 10 0.1
13 14 0.14
14 8 0.08
15 6 0.06
16 16 0.16
17 12 0.12
18 14 0.14
19 20 0.2
20 18 0.18
Total 200
p-Chart Example (cont.)

total defectives
p= = 200 / 20(100) = 0.10
total sample observations

p(1 - p) 0.10(1 - 0.10)

UCL = p + z = 0.10 + 3
n 100
UCL = 0.190

p(1 - p) 0.10(1 - 0.10)

LCL = p - z = 0.10 - 3
n 100
LCL = 0.010
p-Chart Example (cont.)
0.20

0.18 UCL = 0.190

0.16

0.14
Proportion defective

0.12
p = 0.10
0.10

0.08

0.06

0.04

0.02 LCL = 0.010

2 4 6 8 10 12 14 16 18 20
Sample number
 c-Chart
It is used when it is not possible to compute proportion
defective, so we use actual number of defects to compute
average and control limits.

UCL = c + zc
c = c
LCL = c - zc

where
c = number of defects per sample
 c-Chart example
 Ritz Hotel has 240 rooms. Individual Housekeeper is
responsible for cleaning & maintenance of 20 rooms.

 During an Inspection , one room from each Housekeeper is

selected and number of mistakes are counted .

 Following table shows results from 15 samples conducted

during one month.

 Use z value corresponding to 99 % variation.

c-Chart example
Sample Number of Defects

1 12
2 8
3 16
4 14
5 10
6 11
7 9
8 14
9 13
10 15
11 12
12 10
13 14
14 17
15 15
c-Chart (cont.)

190
c= = 12.67
15
UCL = c + zc
= 12.67 + 3 12.67
= 23.35

LCL = c + zc
= 12.67 - 3 12.67
= 1.99
c-Chart (cont.)

24
UCL = 23.35
21

18
Number of defects

c = 12.67

15

12

3 LCL = 1.99

2 4 6 8 10 12 14 16
Sample number
 Control Charts for Variables

 Mean chart ( x -Chart )

 It is a plot of the means of the samples taken from a
process

 Range chart ( R-Chart )

 It is a plot of the range for the samples taken from a
process
 Range is the difference between highest and lowest
values in the sample.
 x-bar Chart
Mean of each sample is computed & plotted

Sample Mean : X

= x 1 + x 2 + ... x k
x= k
= =
UCL = x + A2R LCL = x - A2R

where
=
x = average of sample means
k = no. of samples
 x-bar Chart Example
Following table shows the data of 10 samples about diameter of
slip-ring bearings.

OBSERVATIONS (SLIP- RING DIAMETER, CM)

SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15 R
x- bar Chart Example
(cont.)

= x 50.09
x= = = 5.01 cm
k 10

=
UCL = x + A2R = 5.01 + (0.58)(0.115) = 5.08

LCL = =
x - A2R = 5.01 - (0.58)(0.115) = 4.94

Retrieve Factor Value A2

 5.10 –

5.08 –
UCL = 5.08
5.06 –

5.04 –

5.02 –
x= = 5.01
Mean

5.00 –

4.98 –
x- bar
Chart 4.96 –

Example 4.94 – LCL = 4.94

(cont.) 4.92 –
| | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number
R- Chart
It is a plot of range within each sample.
Range reflects the process variability instead of the tendency
toward a mean value
R
R=
k
UCL = D4R LCL = D3R

Where
R = range of each sample
R = Average of range of samples
k = number of samples
D3 &D4 are table values
 R-Chart Example

OBSERVATIONS (SLIP-RING DIAMETER, CM)

SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15 R
 R-Chart Example (cont.)

R 1.15 UCL = D4R = 2.11(0.115) = 0.243

R= = = 0.115
k 10 LCL = D3R = 0(0.115) = 0

Retrieve Factor Values D3 and D4

R-Chart Example (cont.)

0.28 –
0.24 –
UCL = 0.243
0.20 –
0.16 –
Range

R = 0.115
0.12 –
0.08 –
0.04 – LCL = 0
0– | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number
Using x- bar and R-Charts Together
 Process average and process variability must be in control.

 It is possible for samples to have very narrow ranges, but

their averages is beyond control limits.

 It is possible for sample averages to be in control, but

ranges might be very large.

 The use of both control charts provide a more complete

picture of overall process variability.
 Control Chart Patterns

UCL

UCL

LCL

Sample observations
consistently below the LCL
center line
Sample observations
consistently above the
center line
 Control Chart Patterns (cont.)

UCL

UCL

LCL

Sample observations
consistently increasing LCL

Sample observations
consistently decreasing