Statistical Process Control

(Reference: Chapter 3 – Process Capability and Statistical

Process Control from Russell & Taylor)
 Basics of Statistical
Process Control
• Statistical Process
Control (SPC)
• monitoring production
process to detect and UCL
prevent poor quality
• Sample
• subset of items
produced to use for LCL
inspection
• Control Charts
• process is within
statistical control limits

..
Variability

• Random • Non-Random
• common causes • special causes
• inherent in a • due to identifiable
process factors
• can be eliminated • can be modified
only through through operator
improvements in or management
the system action

..
SPC in TQM

•SPC
• tool for identifying problems and
make improvements

• contributes to the TQM goal of

continuous improvements

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Quality Measures

• Attribute
• a product characteristic that can be
evaluated with a discrete response (
• good – bad; yes - no

• Variable
• a product characteristic that is
continuous and can be measured
• weight - length

..
Applying SPC to Service

• Nature of defect is different in services

• Service defect is a failure to meet

customer requirements

• Monitor times, customer satisfaction

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Applying SPC to Service
(cont.)
• Hospitals
• timeliness and quickness of care, staff responses to
requests, accuracy of lab tests, cleanliness, courtesy,
accuracy of paperwork, speed of admittance and
checkouts

• Grocery stores
• waiting time to check out, frequency of out-of-stock
items, quality of food items, cleanliness, customer
complaints, checkout register errors

• Airlines
• flight delays, lost luggage and luggage handling,
waiting time at ticket counters and check-in, agent
and flight attendant courtesy, accurate flight
information, passenger cabin cleanliness and
maintenance ..
Applying SPC to Service
(cont.)
• Fast-food restaurants
• waiting time for service, customer complaints,
cleanliness, food quality, order accuracy,
employee courtesy

• Catalogue-order companies
• order accuracy, operator knowledge and
courtesy, packaging, delivery time, phone order
waiting time

• Insurance companies
• billing accuracy, timeliness of claims processing,
agent availability and response time
..
Where to Use Control
Charts
• Process has a tendency to go out of control
• Process is particularly harmful and costly if
it goes out of control

• Examples
• at the beginning of a process because it is a
waste of time and money to begin production
process with bad supplies
• before a costly or irreversible point, after which
product is difficult to rework or correct
• before and after assembly or painting
operations that might cover defects
• before the outgoing final product or service is
delivered
..
Control Charts
• A graph that • Types of charts
establishes control • Attributes
limits of a process • p-chart
• c-chart
• Control limits • Variables
• upper and lower • range (R-chart)
bands of a control • mean (x bar –
chart chart)

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Process Control
Chart
Out of control
Upper
control
limit

Process
average

Lower
control
limit

1 2 3 4 5 6 7 8 9 10
Sample number
..
Normal Distribution

95%
99.74%
-3 -2 -1 =0 1 2 3

..
A Process Is in Control
If …
1. … no sample points outside limits
2. … most points near process average
3. … about equal number of points above
and below centerline
4. … points appear randomly distributed

..
Control Charts for
Attributes
• p-charts
- uses portion defective in a
sample
• c-charts
- uses number of defects in an
item

..
p-Chart

UCL = p + zp
LCL = p - zp
z = number of standard
deviations from process average
p = sample proportion
defective; an estimate of process average
p = standard deviation of sample
proportion
p(1 - p)
p =
n
p-Chart Example

NUMBER OF PROPORTION
SAMPLE DEFECTIVES DEFECTIVE
1 6 .06
2 0 .00
3 4 .04
: : :
: : :
20 18 .18
200

20 samples of 100 pairs of jeans

..
p-Chart Example (cont.)

total defectives
p = total sample observations = 200 / 20(100) = 0.10

p(1 - p) 0.10(1 - 0.10)

UCL = p + z = 0.10 + 3
n 100
UCL = 0.190

p(1 - p) 0.10(1 - 0.10)

LCL = p - z = 0.10 - 3
n 100
LCL = 0.010

..
p-Chart Example (cont.)
0.20

0.18 UCL = 0.190

0.16

0.14
Proportion defective

0.12
p = 0.10
0.10

0.08

0.06

0.04

0.02 LCL = 0.010

2 4 6 8 10 12 14 16 18 20
Sample number
..
c-Chart

UCL = c + zc
c = c
LCL = c - zc

where
c = number of defects per sample

..
c-Chart (cont.)
Number of defects in 15 sample rooms
NUMBER
SAMPLE OF
DEFECTS
190
1 12 c= = 12.67
15
2 8
UCL = c + zc
3 16
= 12.67 + 3 12.67
: : = 23.35
: : LCL = c + zc
15 15
= 12.67 - 3 12.67
190 = 1.99
..
c-Chart
(cont.)
24
UCL = 23.35
21

18
Number of defects

c = 12.67

15

12

3 LCL = 1.99

2 4 6 8 10 12 14 16
Sample number

..
Control Charts for
Variables

• Mean chart ( x -Chart )

- uses average of a sample

• Range chart ( R-Chart )

- uses amount of dispersion in a sample

..
x-bar Chart

= x1 + x2 + ... xk
x=
k
UCL = x= + A2R LCL = x= - A2R

where
=
x = average of sample means

..
 x-bar Chart Example
OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k 1 2 3 4 5
1 5.02 5.01 4.94 4.99 4.96
2 5.01 5.03 5.07 4.95 4.96
3 4.99 5.00 4.93 4.92 4.99
4 5.03 4.91 5.01 4.98 4.89
5 4.95 4.92 5.03 5.05 5.01
6 4.97 5.06 5.06 4.96 5.03
7 5.05 5.01 5.10 4.96 4.99
8 5.09 5.10 5.00 4.99 5.08
9 5.14 5.10 4.99 5.08 5.09
10 5.01 4.98 5.08 5.07 4.99

Example 15.4
..
 x-bar Chart Example

OBSERVATIONS (SLIP- RING DIAMETER, CM)

SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15

Example 15.4
..
x- bar Chart Example (cont.)

= åx 50.09
x= = = 5.01 cm
k 10

=
UCL = x + A2R = 5.01 + (0.58)(0.115) = 5.08
=
LCL = x - A2R = 5.01 - (0.58)(0.115) = 4.94

Retrieve Factor Value A2

..
 5.10 –

5.08 –
UCL = 5.08
5.06 –

5.04 –

5.02 – x= = 5.01
Mean

x- bar
Chart 5.00 –

Examp 4.98 –

le 4.96 –
(cont.) 4.94 –
LCL = 4.94

4.92 –
| | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number

..
R- Chart

UCL = D4R LCL = D3R

åR
R=
k
where
R = range of each sample
k = number of samples

..
 R-Chart Example

OBSERVATIONS (SLIP-RING DIAMETER, CM)

SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15

Example 15.3
..
 R-Chart Example
(cont.)

åR 1.15 UCL = D4R = 2.11(0.115) = 0.243

R= = = 0.115
k 10 LCL = D3R = 0(0.115) = 0

Retrieve Factor Values D3 and D4

Example 15.3
..
R-Chart Example (cont.)
0.28 –
0.24 – UCL = 0.243
0.20 –
Range

0.16 – R = 0.115
0.12 –
0.08 –
0.04 – LCL = 0
| | | | | | | | | |
0–
1 2 3 4 5 6 7 8 9 10
Sample number

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Control Chart Patterns

UCL

UCL

LCL

Sample observations
consistently below the LCL
center line
Sample observations
consistently above the
center line
..
Control Chart Patterns (cont.)

UCL

UCL

LCL

Sample observations
consistently increasing LCL

Sample observations
consistently decreasing

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Zones for Pattern Tests
UCL =
3 sigma = x + A2R
Zone A
=
2 sigma = x + 2 (A2R)
3
Zone B
=
1 sigma = x + 1 (A2R)
3
Zone C
Process =
x
average
Zone C
=
1 sigma = x - 1 (A2R)
3
Zone B
=
2 sigma = x - 2 (A2R)
3
Zone A
=
LCL 3 sigma = x - A2R
| | | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12 13
Sample number
..
Process Capability
Design
Specificati
ons
(a) Natural
variation exceeds
design
specifications;
process is not
capable of
meeting Process
specifications all Design
the time. Specificati
ons
(b) Design
specifications and
natural variation
the same; process
is capable of
meeting
specifications most Process
of the time. ..
Process Capability (cont.)
Design
Specificat
ions
(c) Design
specifications
greater than
natural
variation;
process is Process
capable of Design
always Specificat
conforming to ions
specifications.
(d)
Specifications
greater than
natural
variation, but
process off Process
center; capable ..
but some output
Process Capability
Measures
Process Capability Ratio

tolerance range
Cp =
process range

upper specification limit -

lower specification limit
=
6

..
Computing Cp

Net weight specification = 9.0 oz  0.5 oz

Process mean = 8.80 oz
Process standard deviation = 0.12 oz

upper specification limit -

lower specification limit
Cp =
6

9.5 - 8.5
= = 1.39
6(0.12)

..
Process Capability
Measures

Process Capability Index

=
x - lower specification limit
3
,
Cpk = minimum
=
upper specification limit - x
3

..
Computing Cpk
Net weight specification = 9.0 oz  0.5 oz
Process mean = 8.80 oz
Process standard deviation = 0.12 oz

=
x - lower specification limit
,
Cpk = minimum 3 =
upper specification limit - x
3

8.80 - 8.509.50 - 8.80

= minimum 3(0.12) 3(0.12)
, = 0.83
..
 Appendix:
Determining Control Limits for x-bar
and R-Charts
SAMPLE SIZE FACTOR FOR x-CHART FACTORS FOR R-CHART
n A2 D3 D4

2 1.88 0.00 3.27

Fac 3
4
1.02
0.73
0.00
0.00
2.57
2.28
tors 5
6
0.58
0.48
0.00
0.00
2.11
2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.44 0.18 1.82
10 0.11 0.22 1.78
11 0.99 0.26 1.74
12 0.77 0.28 1.72
13 0.55 0.31 1.69
14 0.44 0.33 1.67
15 0.22 0.35 1.65
16 0.11 0.36 1.64
17 0.00 0.38 1.62
18 0.99 0.39 1.61
19 0.99 Return 0.40 1.61
20 0.88 .. 0.41 1.59
Thank You!

.. 4-42