Process Capability: Detailed Recap
Overview of Process Capability
- Process capability refers to the ability of a process to produce products that meet specifications.
- Key metrics include the **process capability ratio (Cp)** and **process capability index (Cpk)**.
Process Capability Ratios (PCRs)
- **Cp (Potential Capability):** Measures the spread of the process relative to specification limits.
- Formula: Cp = (USL - LSL) / (6 * sigma)
- **Cpk (Actual Capability):** Accounts for the mean's shift relative to the specification limits.
- Formula: Cpk = min(Cpu, Cpl)
- Cpu = (USL - mu) / (3 * sigma)
- Cpl = (mu - LSL) / (3 * sigma)
- **Interpretation:**
- Cp = Cpk when the process is centered.
- Cpk < Cp indicates the process is off-centered.
- A higher Cp or Cpk indicates better process capability.
Six Sigma Capability
- **Six Sigma:** Refers to processes where the probability of defects is extremely low.
- **Characteristics:**
- For a perfectly centered process, Cp and Cpk = 2.
- After accounting for a 1.5 sigma shift, Cpk = 1.5.
- **Defective Rates:**
- 3-sigma: ~2,700 defects per million (ppm).
- 6-sigma: ~0.2 defects per million (ppm).
Attribute Data Metrics
- **Defects per Unit (DPU):** Total defects divided by total units inspected.
- Formula: DPU = Total defects / Total units
- **Defects per Million Opportunities (DPMO):** Accounts for multiple defect opportunities per unit.
- Formula: DPMO = (Total defects / (Total units * Opportunities per unit)) * 10^6
Examples
- **Example 1:**
- Given: LSL = 200 psi, Mean = 264 psi, Sigma = 32 psi
- Calculate Cpl:
- Cpl = (Mean - LSL) / (3 * Sigma) = (264 - 200) / (3 * 32) = 0.67
- **Example 2:**
- For Six Sigma with a 1.5 sigma shift:
- Cp = 2, Cpk = 1.5
- **Example 3:**
- For 50 units, with 7 defects across 4 opportunities per unit:
- DPU = 7 / 50 = 0.14 defects/unit
- DPMO = (7 / (50 * 4)) * 10^6 = 35,000 defects per million opportunities.
