Process Capability
Module 6 – Quality Control
TMA@2008
Learning Outcomes
After completing this module, you will be able to:
Understand the concep of process capability and its
importance for quality control
Measure and analysis the process capability of a given
process
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Introduction
Variability in the process
is a measure of the uniformity
of output
Two ways to think of this variability:
1.Natural or inherent variability in a
critical-to-quality characteristic at a
specified time (instantaneous)
2.Variability in a critical-to-quality
characteristic over time
Process capability
refers to the uniformity of the
process
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It is customary to take the six-sigma spread in the
distribution of the product quality characteristics as a
measure for process capability
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Process capability analysis is an engineering
study to estimate process capability.
In the form of probability distribution (shape)
Center (mean)
Spread (standard deviation)
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Uses of process capability data:
Predicting how well the process will hold the tolerances.
Assisting product developers/designers in selecting or
modifying a process.
Assisting in Establishing an interval between sampling for
process monitoring.
Specifying performance requirements for new equipment.
Selecting between competing vendors.
Planning the sequence of production processes when there is
an interactive effect of processes on tolerances.
Reducing the variability in a manufacturing process.
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Techniques used in process
capability analysis
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Histogram Plot
The histogram along with the sample mean and
sample standard deviation provides information
about process capability.
The process capability can be estimated as:
x 3s
The shape of the histogram can be determined
(such as if it follows a normal distribution)
Histograms provide immediate, visual
impression of process performance.
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Example
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x 264.06
s 32.02
Process capability:
264.06 + 3(32.06) 264 + 96
It means that approximately 99.73% of the bottle
manufactured by this process will burst between
168 to 360 psi
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Process Capability Ratio
A convenient, simple and qualitative way to express
process capability
If USL = Upper Specification Limit
LSL = Lower Specification Limit
Then, process capability ratio is:
USL LSL
Cp
6
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If the standard deviation is not known; it can be
estimated by calculating
̂ S or R / d2
The process capability ratio
USL LSL
Ĉ p
6ˆ
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Example
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Process Capability Ratio:
USL LSL
Ĉ p
6ˆ
ˆ 2.00 1.00
Cp 1.192
6(0.1398)
Useful practical interpretation:
1 1
P
C
100
P 100 83.8
p 1.192
Percentage of specification used up by the process:
83.8%
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One-sided Process Capability
Ratio
For one-sided specification (upper or lower
specification limit only):
USL
C pu
3
LSL
C pl
3
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Interpretation of PCR
The greater the
value of Cp the
process getting
more capable
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Assumptions for Interpretation
If any of these
assumptions
are violated,
the resulting
quantities may
be in error
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Recommendations
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Process Capability Ratio and Off-
Center Process
Cp does not take process
centering into account
It is a measure of
potential capability, not
actual capability
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A Measure of Actual Process
Capability
A process capability ratio that does take into account
centering is Cpk defined as:
Cpk = min(Cpu, Cpl)
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Interpretations of Cpk
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Cpk alone is still an inadequate measure of process
centering
Cpk must be compared to Cp.
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Example
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Example
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The Use of Control Chart and Cpk
It is recommended to use the control chart and
calculate the process Cpk for better understanding of
the process and to able to control the process properly
On every sample, calculate standard deviation and
then mean of the sample. Use it for control chart.
Calculate Cpk
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LSL Spec USL
Capable and centered
Capable, but not centered
Not capable, and
not centered
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Example
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• Since LSL = 200
Process in control but not capable
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Normal Assumption
The normal distribution of the process output is an
important assumption
If the distribution of the process output is not normal
then the formula cannot be used
Other process capability indices must be employed
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