Awareness Module
Statistical Process Control
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Prerequisite Knowledge
Are you aware of the following? :-
Knowledge of Seven QC tools e.g.
1. Check sheet
2. Pareto
3. Histogram
4. Graphs & Control Charts
5. Stratification
6. Scatter
7. Cause & Effect Diagram
Basic of Problem solving should be clear to the participants.
What is Problem?
Team building.
Objectives.
Analysis vs Action.
Verification & Validation of the causes.
Effectiveness of the action taken.
Monitoring the trends.
Thanks to the team
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Objective Awareness Module
To make participants understand about the concept
and benefits of SPC (Statistical Process Control).
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Training Agenda
• Process
• Process Data
• Attribute vs. Variable Data
• Variation
• Source of Variations
• Effects of Variations
• SPC
• Role of SPC
• SPC at A Glance
• Basic Concepts of SPC
• Normal Distribution
• Control Charts
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Process
Defining A Process:
What exactly is a process ?
A process is a transformation of inputs into outputs.
Example:
• Reaching to Office
• To make a cup of Tea Explained in next slides
• Assy of A Pen
Inputs PROCESS Outputs
Basic Process illustration:
- Man
Feedback Loop is a process - Machine Transformation of Inputs - Product
- Material or
which relates information - Service
- Method
about outputs back to the input - Measurement
stage, so that an analysis of - Enviornment
the transformation process Feedback Loop
can be made. Information / Response on Product or Service
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Process Example : 1 Awareness Module
Reaching to Office
Input PROCESS Output
Self Vehicle Vehicle Readiness Travelling / Driving
Starting Time Office = 9:30 AM
Other Belongings
or
DATA
9:00 am
Public Start Time 9:15 am
Transport Waiting Time at Stop 9:25 am
Distance 9:30 am
Metro Card 9:40 am
Money in Change Condition 9:45 am
Other Belongings
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Process Example : 2 Awareness Module
A Cup of Tea
Input PROCESS Output
Water,
Basic Recipe / Tea Leaf,
Tea
Ingredients Sugar &
Milk Boiling & Filter
Ginger DATA
or
Optional Tea Masala Temperature ( Hot / Cold )
or Taste
( if Flavour Tea / Lemon
Masala Tea is
required )
Some process data is observed in Example 1 & 2, What is this Data ?
( Explained in next slide)
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Process Data
What is Process Data ?
• Process Data is the measurement / count result of Inputs and Outputs.
• Data are two Types :
• Attribute Type : This data is count based information.
for example; GO / NO GO Plug Gauge, OK / NG, Visual Defects ( dent, blow
holes).
• Variable Type : This data is measurement based information.
for example ; Shaft Diameter (12.0 mm ), Temperature (20º C), Height (10 m )etc.
Example 1 is taken again to in next slide to explain Attribute vs. Variable Data.
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Attribute vs. Variable Data
Reaching to Office
Attribute Data (Discrete)
Variable Data (Continuous)
Nov-11 (Attendance)
30
25
Days
20
Working Days
15 On Time
Late
10
0
1
SPC Tools for Attribute SPC Tools for Variable
• Pareto • Histogram
• Bar Chart • Control Chart Advantage :
• Pie Chart • Process Capability
• P-Chart More Information about the Variation
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Variation
What is Variation?
• Two product can not be produced similar from a process, in terms of dimension. This gap is known as
variation.
Why Variation ?
• This is normal phenomenon due to variation in process inputs ( 5M + 1E ).
There are Two Causes responsible for the Variation:
1.) Chance ( Common ) causes
Many sources of little variation within a process that has a stable an repeatable distribution over time
(inherent variation)
The process output is predictable
Resolution of these causes usually requires action on the system
2.) Special ( Assignable ) causes
Single source causing high variation that makes the process distribution change .
The process output is unpredictable
Resolution of theses causes usually requires local action especially during the early process improvement
efforts
Examples:-
Material Variation
Poor Maintenance
Electrical Power surge
New Methods/Procedures
Untrained Operator
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10 / 36
Source of Variations
- Skilled
MAN
- Maintenance.
MACHINE
- Dimension
MATERIAL - Physical Condition
(Dent / Rust etc)
- Manual / Auto
METHOD - Single pc flow etc
-Gauge / Instruments ,
MEASUREMENT 0 1 2 3 4 5 - Type (Digital /
Analogue )
- Ambient Condition ( As
ENVIORNMENT Controlled requirement
of Temp In std Room )
Fish Bone Diagram is a QC Tool to understand about the Variation in 5M + 1 E
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Effect of Variation
Effect of Variation ?
S.N. Business (Process) Parameter Effect Why ?
1 Rejection and Rework Increase
2 Process Cost More
3 Profit Reduce
4 Customer Unsatisfied
Note :
Overall negative impact reflects on the Business if Variations are not controlled in a permissible limit.
To improve and Control these Variations SPC technique is used. Explained in next slides.
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SPC Awareness Module
What is SPC ?
SPC is data based technique to monitor, improve and control the
process performance ( Main objective is to reduce & control the Variation ).
Note : Above chart is showing that diameter of 5th shaft is going out of control
limit. Process need to reset and to be analyze for the cause of variation.
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Role of SPC
Continuous improvement is the most important Role of SPC. This is
done under PDCA approach. Also known as Deming cycle.
PDCA:
P - Plan (A Plan is developed)
D - Do (The Plan is tested on a trial Basis)
A P
C - Check (The effects of the test plan are monitored) C D
A - Act (And appropriate corrective actions are taken on the process)
Process (Quality) Improvement
1. Collection 2. Control 3. Analysis & Improvement
• Calculate Control Limit
• Gather Data from Process Data • Quantify Common Cause of Variation.
• Plot on a Chart • Identify Special Causes • Take Action to Reduce it
of Variation and act upon those
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SPC AT A GLANCE
Practical Traditional
Problem Approach
Statistical
Problem
Statistical
Statistical Approach Solution
Practical
Solution
Benefits :
• Systematic
• Structured
• Data Driven
• Focused on significant
Root Causes & Solutions
• Effectiveness for Long Term
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Basic concepts of Statistics
Five Basic Concepts of Statistics are :
1. Variation (No two things are exactly same)
2. Control (Controlling the common & assignable cause)
3. Capability (When voice of process meets customer requirements)
4. Stability (Capability over a period of time)
5. Over adjustment (Taking action when not necessary & failing
to take action when necessary)
Before understand above terms it is important to know Normal Distribution, Explained in next slide.
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Basic concepts of Statistics
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Normal Distribution
Central Tendency
Count / Frequency
Spread
-4 -3 - 2 -1 0 +1 +2 +3 +4
Dimension
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Properties of Normal Distribution
Symmetric,
Bell Shaped.
Shape of Curve depends on population mean µ (miu) and standard
deviation sigma).
Center of distribution µ .
Spread is determined by sigma
In the family of Normal distribution curve smaller the standard
deviation, higher will be the peak.
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Normal Distribution curve
The Normal Curve
99.73%
+/-3 sigma
95.45%
+/- 2 sigma
68.26%
+/- 1 sigma
2.14% 13.6% 34.13% 34.13% 13.6% 2.14%
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Control Chart
CONTROL CHART
What:
Control Charts are used to monitor and evaluate a process.
A control chart consist of a central line, a pair of control limits, one each, allocated
above and below the central line, and characteristic values plotted on the chart which
represent the state of a process.
If all these values are plotted within the control limit without any particular tendency,
the process is regarded as being in the controlled state.
Why:
•To separate common causes from special causes of variation.
•To help assign causes of variation.
When :
Measuring control characteristics.
Where:
At the earliest possible point in the manufacturing process.
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CONTROL CHART……Contd.
Phases are
– Collection (Gather data and plot on a chart)
– Control ( Calculate trial control limits from process data
and Identify special causes of variation and act upon them)
– Analysis and improvement (Quantify common cause of
variation; take action to reduce it)
– These three phases are repeated for continual process improvement
Type of Control Charts
Variable charts Attribute Charts:
np Chart Number of Defective
X bar- R charts (average and range)
p Chart Fraction Defective
X bar-S chart (average and STD deviation)
X - MR chart (individuals and moving range) c Chart No. of Defects on a fixed sized Product
u Chart No. of Defects on a varying sized product
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Benefits of Control charts
Benefits:-
• Help to understand the process variation
• Indicate when action should be taken or not
• Show evidence that the process is in control condition or not.
• Are part of the improvement process
• Communicate unbiased & common information.
• Indicate the extent of common causes of variation (but the causes
themselves need more detailed analysis to isolate)
• Detect special causes of variation.
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