7/4/2021
Process Capability Index and
Six Sigma
Dr. Abdul Shakoor
What is a Process Capability Study?
Process capability study is a scientific
and a systematic procedure that uses
control charts to detect and eliminate
the unnatural causes of variation until a
state of statistical control is reached.
When the study is completed, you will
identify the natural variability of the
process.
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Process Capability
Process capability represents the performance
of a process in a state of statistical control.
It measures how well the process is currently
behaving w.r.t the output or customer
specifications.
Process capability is also the ability of the
combination of people, machine, methods,
material, and measurements to produce a
product that will consistently meet the design
requirements or customer expectation.
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Why Process Capability is So
Important
Because it allows one how well a process can
produce an acceptable product. As a result a
manager or engineer can prioritize needed process
improvements and identify those processes that don’t
need process improvements.
If the process is capable then conventional
acceptance methods can be eliminated or reduced.
This not only yield great cost saving in eliminating
non value added inspection but it will also eliminate
rework, reject, and increased customer inspection.
When the process is not capable then 100 %
inspection need to be carried out.
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Procedure for Process
Capability
Procedure (s – method)
1. Take subgroup size 4 for 25 subgroups
2. Calculate sample s.d., s, for each subgroup
3. Calculate avg. sample s.d. s = s/g
4. Calculate est. population s.d. 0 = s/C4
C4 is from table B and is 0.9213 for n = 4
1. Calculate Process Capability = 6 0
R - method
1. Same as 1. above
2. Calculate R for each subgroup
3. Calculate avg. Range, = R/g
4. Calculate 0 = R/d2
d2 is from table B and is 2.059 for n = 4
1. Calculate 6 0
Process Capability Indices
Cp is the ratio of the tolerance width to
the spread of the process
Cp= Tolerance Width/Process spread
Cp = USL-LSL/ 6б
Where Cp is Capability index
USL-LSL = Tolerance
6б = Process Capability
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Process Capability (6) And
Tolerance
Cp - Capability Index
T = USL-LSL
Cp = 1 Case II 6 = T
Cp > 1 Case I 6 < T
Cp < 1 Case III 6 > T
Few conclusions
a) Process is highly
capable (Cp>2)
b) Process is capable
(Cp=1 to 2)
c) Process is not
capable (Cp< 1)
Cpk?
Cpk is the ratio of the
measured distance LSL USL
between the overall
mean of the process
and the closest
specification limits to
the half of the total
process spread.
Cpk considers the avg
centering of the process
where as Cp doesn't.
Min (USL - avg, avg - LSL)
Cpk =
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3ST
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Comments On Cp, Cpk
Cp does not change when process center (avg.) changes
Cp = Cpk when process is centered
Cpk Cp always this situation
Cpk = 1.00 de facto standard. It indicates that the process
is producing products that confirms to the specifications.
Cpk < 1.00 process producing rejects
Cp < 1.00 process not capable
Cpk = 0 process center is at one of spec. limit (U or L)
Cpk < 0 i.e. – ve value, avg outside of limits
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Within and Overall Capability
Within (Short Overall (Long
Term) Term)
Sample size 25 Subgroups ≥ 100 subgroups
No of lots Single lot Several lots
Period of time Hours or days Weeks or months
No of operators Single operator Different operator
Process Potential Cp Pp
Process Cpk Ppk
Performance
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Six Sigma Defined (Low-Level)
A Process in which the Specification
Limits are Six Standard Deviations above
and below the Process Mean
Two Approaches:
•Move the Specification Limits Farther Apart
•Reduce the Standard Deviation
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Approach #1
Ask the Customer to Move the
Specification Limits Farther Apart.
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2-sigma Process Spec Limits
Cp = 0.667
Cpk = 0.667
45,500 ppm
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3-sigma Process Spec Limits
Cp = 1.0
Cpk = 1.0
2,700 ppm
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4-sigma Process Spec Limits
Cp = 1.333
Cpk = 1.333
63 ppm
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5-sigma Process Spec Limits
Cp = 1.667
Cpk = 1.667
0.57 ppm
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6-sigma Process Spec Limits
Cp = 2.0
Cpk = 2.0
0.002 ppm
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Approach #2
Reduce the Standard Deviation.
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2-sigma Process Spec Limits
Cp = 0.667
Cpk = 0.667
45,500 ppm
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3-sigma Process Spec Limits
Cp = 1.0
Cpk = 1.0
2,700 ppm
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4-sigma Process Spec Limits
Cp = 1.333
Cpk = 1.333
63 ppm
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5-sigma Process Spec Limits
Cp = 1.667
Cpk = 1.667
0.57 ppm
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6-sigma Process Spec Limits
Cp = 2.0
Cpk = 2.0
0.002 ppm
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Process Drift
What Happens when the Process
Mean Is Not Centered between
the Specification Limits?
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3-sigma Process Spec Limits
(centered)
Cp = 1.0
Cpk = 1.0
2,700 ppm
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3-sigma Process Spec Limits
(shifted 0.5 std. dev.)
Cp = 1.0
Cpk = 0.833
ppm = 6,442
(about 2.72-sigma)
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3-sigma Process Spec Limits
(shifted 1.0 std. dev.)
Cp = 1.0
Cpk = 0.667
ppm = 22,782
(about 2.28-sigma)
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3-sigma Process Spec Limits
(shifted 1.5 std. dev.)
Cp = 1.0
Cpk = 0.5
ppm = 66,811
(about 1.83-sigma)
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Six Sigma: Many Meanings
A Symbol
A Measure
A Benchmark or Goal
A Philosophy
A Method
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Six Sigma: A Symbol
is a Statistical Symbol for
Standard Deviation
Standard Deviation is a Measure
of Dispersion, Volatility, or
Variability
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Six Sigma: A Measure
The ―Sigma Level‖ of a process
can be used to express its
capability — how well it performs
with respect to customer
requirements.
Percent Defects, Cp, Cpk, PPM
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Six Sigma: A Benchmark or Goal
The specific value of 6 Sigma (as
opposed to 5 or 4 Sigma) is a
benchmark for process excellence.
Adopted by leading organizations as a
goal for process capability.
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Six Sigma: A Philosophy
A vision of process performance
Tantamount to ―zero defects‖
A ―Management Mantra‖
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Six Sigma: A Method
Really a Collection of Methods:
Product/Service Design
Quality Control
Quality Improvement
Strategic Planning
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Where Does ―3.4 PPM‖ Come From?
Six Sigma is commonly defined to be
equivalent to 3.4 defective parts per
million.
Juran says that a Six Sigma process will
produce only 0.002 defective parts per
million.
What gives?
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Normal Curve Probabilities
±1 Sigma 68.3% of Data
±2 Sigmas 95.4%
±3 Sigmas 99.73%
±4 Sigmas 99.994%
±5 Sigmas 99.99994%
±6 Sigmas 99.9999998%
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68.3% of Data Fall within 1 Standard Deviation of the Mean
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95.4% of Data Fall within 2 Standard Deviations of the Mean
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99.73% of Data Fall within 3 Standard Deviations of the Mean
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99.9999998% of Data Fall within 6 Standard Deviations of the Mean
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Process Centered
between Spec Limits
Sigma Level Cp Cpk PPM
1 0.333 0.333 317,310
2 0.667 0.667 45,500
3 1.000 1.000 2,700
4 1.333 1.333 63.4
5 1.667 1.667 0.57
6 2.000 2.000 0.002
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The End
Questions
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