Process capability analysis
Process capability is a measure of how well a process
can produce output within specified limits (tolerances)
set by the customer or standards.
Control Limits
Control limits indicate the
behavior of the process and
whether the process is in
control.
Specification Limits
Specification limits are used to determine process capability and sigma value. You
can define Upper Specification Limits (USL) and Lower Specification Limits (LSL)
for each chart. Control limits are limits or averages that are calculated based on
previous history.
Scenario 1: Specification Limits Within Control
Limits
What it shows: The specification limits (red lines:
LSL and USL) are narrower than the control limits
(blue lines: LCL and UCL).
Meaning: The process is too variable. Even if the
process is statistically in control (within control
limits), many products will fall outside customer
requirements.
Implication: The process needs improvement—
reduce variation to meet quality standards.
Scenario 2: Specification Limits Equal to
Control Limits
What it shows: The specification limits and
control limits match exactly.
Meaning: The process is just capable of
meeting specifications if everything stays in
control.
Implication: This is a borderline case. Even a
small shift in the process could lead to defects.
It's risky and not robust.
Scenario 3: Specification Limits Exceed
Control Limits
What it shows: The specification limits are
wider than the control limits.
Meaning: The process is very stable and well-
controlled. All or nearly all output falls well
within customer requirements.
Implication: This is an ideal scenario. The
process is capable and consistent—high
quality is ensured.
What Is a Process Capability Index?
This index is indicated as Cpk, which measures process capability to show
how close a particular process can deliver the results to the required
specifications.
Another term you will need to know to understand process capability
meaning is Cp, which measures the process’s potential capability to meet
specifications.
The Difference Between Cp and Cpk
While the difference between Cp and Cpk is subtle, it’s crucial. Cp assesses
the process spread relative to tolerances, assuming the process is
centered on the target. Cpk considers the spread and centering,
determining the capability to meet specifications even if the process could
be more perfectly centered. This helps uncover the actual capability.
Advantages of a Capable Process
Cost reductions: Less waste and reworked
Operational efficiency: Less time monitoring and troubleshooting
processes.
Reduced risk: Reduces risk for poor quality, delays, or failure to
meet customer expectations.
Standardization: Capable processes help develop standard
procedures to improve quality
What is Cpk?
The Parking a Car in the Garage Analogy
Think of the walls of your garage - where you have to fit your car - they
become the customer specification limits. If you go past those limits,
you will crash, and the customer will not be happy!
The Cp has 2 subdivisions
Cp upper that is Cpu
Cp lower that is Cpl
Cpu = Mean – LSL / 3 X SD
Cpl = USL – Mean / (3 X SD)
you must compare the value of Cp and Cpk to determine process
capability. The higher the value, the better the capability.
1.Cp or Cpk < 1: Process is incapable and requires improvement.
2.Cp > 1 or Cpk > 1.33: The process is conditionally capable. However,
improvements are likely necessary to ensure consistency.
3.Cp or Cpk > 1.33: The process is considered capable and meets
quality requirements.
If the Cp and Cpk are close, the process is well-centered to achieve
the target value. If Cpk is lower than Cp, the process could be better
centered.
What is Pp?
Process Capability Pp measures the process spread vs. the
specification spread. In other words, how distributed the outcome of
your process is vs. what the requirements are
Process Spread vs. Specification Spread
Think of the Specification Spread as the sides of your garage – those are
static, they are not moving, and it is important that your process puts
values inside those bounds. The Process Spread is the size of the car you
are trying to fit in.
Process Performance Indices
The process performance indices are Pp and Ppl. They are similar to
Cp and Cpk but have key differences. While Cp and Cpk evaluate the
process’s ability to meet specifications, Pp and Ppk offer a snapshot
of current performance. In other words, Cp and Cpk measure
potential over the long term, while Pp and Ppk measure actual
process performance and stability during a defined period.
Process Meets Specifications:
Good Potential Performance
This is what happens when your
process spread does not match
Process Does NOT Meet
your specification spread!
Specifications: Bad Potential
Performance
Short Term Capability
Potential performance of a process, under control at a
point in time. Calculated from data taken over a short
period of time such that there is no external influence on
the process (i.e. temperature change, shift change,
operator change etc.). Short term capability represents
the true process capability. Short term capability
indicates the technology of the process.
Long Term Capability
The actual performance of a process over a period of time.
Calculated from data taken over a period of time long enough
such that external factors can influence the process. Long term
capability represents both the Technological capability
combined with the controls that you exercise.
How to Measure and Calculate Process Capability
1. Data collection
2. Identify specifications
3. Calculate process mean
4. Calculate the standard deviation
5.Calculate Cp
6.Calculate Cpk
7.Interpreting the Capability Index
Process Capability Example 1: The ice cream that must be served in an ice cream
parlor has to be between -15 degrees Celsius and -35 degrees Celsius. The
process of refrigeration that keeps the temperature has a standard deviation (SD)
of 2 degrees Celsius. And the mean value of this temperature is -25 degrees
Celsius. Using these inputs obtain the process capability index (PCI) for this
process?
Note – In this section do not bother about any technical terms just understand
how to use the formula. Later you will find details.
Answer:-
USL = -15
LSL = -35
SD = 2,
Mean = -25
Formula
Cpu = Mean – LSL / 3 X SD
Cpl = USL – Mean / (3 X SD)
Cpk = Min (Cpl, Cpu)
Substitute the values in the formula
Cpu = (-15-(-25))/ (3*2) = -10/6 = -1.667
Cpl = (-25+35)/ (3*2) = 10/6 = 1.667
We know that Cpk is a minimum of [Cpu, Cpl] and hence a minimum of [1.667,- 1.667] is
-1.667. Therefore the upper limit seems to suit best for this condition.
Example 2: - The training room temperature during the training must
be kept between 18 degrees Celsius and 26 degrees Celsius. The
process of maintaining this temperature has a standard deviation of 2
degrees Celsius. If the mean temperature is 21 degrees Celsius, find
the PCI.
Answer; -
Here USL is 26 and LSL is 18 and the Standard deviation is 2, and the
mean is 21.
Cpu= (26 - 21)/ (3 * 2) = 5/6 = 0.8334
Cpl = (21 - 18)/ (3 * 2) = 3/6 = 0.5
Cpk = Minimum of [ Cpl, Cpu]
That is Cpk = minimum of [0.5, 0.8334]
The process capability index Cpk is 0.5
Case study
Abstract:
The primary objective of this investigation is to conduct an analysis of process
capability within filling operations.
A process capability index serves as a tool for evaluating the conformity of a
process with engineering specifications, commonly referred to as capability or
performance indices. These indices are extensively utilized across various
industries.
The aim of this study is to perform a process capability analysis specifically
tailored to filling operations. An industrial case study is provided to exemplify
the monitoring of filling processes using process capability analysis. The findings
underscore the efficacy of process capability analysis in overseeing the quality of
filling processes.
Introduction:
Assessing process capability involves determining how effectively the process
can adhere to specifications and maintain the required level of control. It also
reflects the extent to which machinery, materials, personnel, and methods can
be integrated to consistently produce products meeting engineering standards.
Methods such as histograms, probability plots, and control charts are employed
for process capability analysis, which serves as an effective means of
monitoring. Ensuring the process is under statistical quality control is essential
before evaluating capability. Once process stability is confirmed, normality tests
are conducted on the data using histograms and probability plots. Capability
indices, including CP, Cpk, pp and ppk are commonly used in manufacturing
industries to assess the process's ability to meet engineering specifications and
evaluate performance.
MATERIALS AND METHODS
1. Theoretical Analysis:
Statistical methods optimize manufacturing output quality by selecting the best
procedures. Computational formulas for control charts and process capability
indices are detailed.
2. Control Chart:
A graphical display of quality characteristics measured against sample number. It
includes a center line (CL) for average value and upper (UCL) and lower (LCL) control
limits. When the process is in control, all sample points fall within these limits.
3. The mean (X) chart:
To create a mean chart, which is based on the average of samples from the
processbeing analyzed, we begin by establishing the center line (CL) of the chart.
This line is calculated as the mean of all the means within the sample
4. The Range (R) chart:
The R-chart is constructed in a manner is similar to x̄ bar chart. The centre line of the
control chart is the average
range of R bar and the upper and lower control limits are computed as following:
5:Process Capability Indices:
These indices gauge a process's ability to meet engineering limits and are significant
only when the process is
under control. Widely utilized in industries, common indices include Cp, Cpk, Cpm,
and Cpmk. Analysis
techniques involve probability plots and control charts to ascertain process
performance and statistical control.
6: Work at industry:
Process capability in a industry involves assessing the ability of a
process to consistently produce products or
services that meet customer requirements. Here's how it generally
works
1. *Define Specifications:* The first step is to define the specifications or
requirements that the product or service
must meet. These specifications are typically based on customer
expectations and industry standards.
2. *Collect Data:* Data on the process output or performance is collected
over time. This data may include
measurements of key characteristics or parameters related to the product
or service.
3. *Calculate Process Capability Indices:* Various process capability
indices, such as Cp, Cpk, Cpm, and Cpmk, are
calculated based on the collected data. These indices provide quantitative
measures of how well the process is capable of meeting the specifications.
4. *Interpret Results:* The calculated indices are then interpreted to assess the capability
of the process. A process
may be deemed capable if the indices indicate that the process output is well within the
specifications and variation is
minimal. Conversely, if the indices suggest that the process output is not consistently
meeting specifications or there
is excessive variation, further analysis and improvement efforts may be needed.
5. *Continuous Monitoring and Improvement:* Process capability analysis is an ongoing
process. Companies
continuously monitor the performance of their processes and make improvements as
needed to ensure that products
or services consistently meet customer requirements and standards.
By implementing process capability analysis, companies can identify areas for
improvement, reduce defects and
waste, enhance product quality, and ultimately improve customer satisfaction.
CONCLUSION
1. The investigation was carried out within the filling industry, utilizing CP, Cpk,
Cpm, and Cpmk indices to
showcase the significance of process capability analysis in overseeing and
guaranteeing product quality to meet
customer demands.
2. Before assessing the process capability, it's essential to validate the control
state of the process and confirm the
normal distribution of the quality attribute.
3. The process capability index Cpmk offers greater assurance regarding
process yield and loss to customers
compared to the other two indices, Cpk and Cpm.
Thank you
