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ECET-462
Application of Computers in Process Control

Purdue University Calumet

[LABORATORY 11]
Statistical Process Control using Microsoft Office Excel
Statistical Process Control using Microsoft Office Excel
LAB -11
Objectives:
Demonstration of the use of Microsoft Office Excel 2007 for evaluating the values for Statistical
Process Control system.
Software Required: Microsoft Office Excel 2007
Data:
Thickness of PCB coming out of a PCB making machine/process is measured over a period of a
time and the following samples were taken by a person in operation.

Bare PCB thickness in Mils (1Mil = 1/1000 inch)
PCB samples were collected from a manufacturer
Table 1
Sample# Thickness in Mil Sample#
1 62.90 63.60 64.00 1
2 63.00 63.10 62.20 2
3 62.20 62.80 63.10 3
4 63.30 63.40 63.00 4
5 63.10 61.90 62.80 5
6 63.00 61.30 62.90 6
7 63.40 63.00 63.90 7
8 62.50 62.80 62.60 8
9 62.20 62.30 63.30 9
10 63.10 63.10 63.30 10
11 63.50 63.00 63.80 11
12 62.30 63.00 63.00 12
13 63.50 64.00 63.00 13
14 64.50 63.10 61.90 14
15 64.40 63.20 61.60 15
16 62.70 63.00 62.30 16
17 63.10 63.00 63.00 17
18 62.60 63.60 63.10 18
19 62.90 64.00 63.50 19
20 62.90 62.80 62.50 20
21 61.60 61.50 62.50 21
22 61.90 63.00 63.20 22
23 63.00 63.50 62.90 23
24 63.50 62.30 62.90 24
25 62.30 62.90 63.00 25
i. Find Mean, X , of each Sample
ii. Find Range of each Sample
iii. Find Mean of Samples, X .
iv. Find average of Range, R, of Samples
v. Find the Control Limits UCL, LCL
vi. Find Standard Deviation, o, of the Samples using the equation o = R /d
2

vii. What percentage of PCB thickness will be within
USP LSP
64.8129 61.0511
64.1860 61.6780

Procedure:

1) Go to Start All programsMicrosoft OfficeMicrosoft Office Excel 2007. Save the file
in your storage device.
2) Insert the above values in the excel file. We shall discuss the formula commands for the
perticular example given above.
3) To find X , of each Sample use the formula for finding mean in the formula bar:






4) Find Range of each Sample use the following formula:
=MAX(B6:D6)-MIN(B6:D6)


5) To find Mean of Samples, X (X-bar-bar) sum up all the means from X and divide it by
total number of samples. Use the following formula:
=SUM(F6:F30)/25

6) To find average Range R(R-Bar), of samples sum up all the values in range column
(which is G column) and divide them by total number of samples:
=SUM(G6:G30)/25

7) Control Limits:

Find the values of control limits using the following formulas:

Control Limits for X Charts:
R A X UCL
2
+ =
LCL X A R =
2

Control Limits for R Charts:
UCL D R =
4
LCL D R =
3

Values of A
2 ,
D
3 ,
D
4
can be found from the following table:

Table 2
n D
3
D
4
A
2
d
2
2 0 3.27 1.88 1.13
3 0 2.57 1.02 1.69
4 0 2.28 0.73 2.06
5 0 2.11 0.58 2.33
6 0 2.00 0.48 2.53
7 0.08 1.92 0.42 2.70
8 0.14 1.86 0.37 2.85
9 0.18 1.82 0.34 2.97
10 0.22 1.78 0.31 3.08

n number of data in a sample

8) To find the standard deviation of the sample use:
=STDEVP(B6:D30)
This formula will calculate standard deviation for the samples based on entire population.

In order to calculate estimated standard deviation (o ), use the following formula:
Standard Deviation,
2
d
R
= o

Where, d
2
can be found from the Table 2. And the formula you have to write in excel file
for this particular program is:
=SUM(I7/1.69)



9) The percentage of the product that will be within the target limits can be calculated from
the cumulative normal distribution defined by the following formula.

dx e a F
x
a
2
2
1
2
1
) (
|
.
|

\
|

}
=
o

t o

Since it is difficult to evaluate this integral, easier approach to this problem is to find the positive
and negative values of Z and then find the percentage of conformity from the cumulative
standard normal distribution table or simply called Z-charts. The positive and negative values of
Z can be found from the following two formulas:
o

=
+ U
X
Z
o

=
L
X
Z


Where:
X
U
= Upper Specification Limit = USP
X
L
= Lower Specification Limit =LSP
= Process average, estimated from X
o = Standard Deviation, calculated from the process data

Using Microsoft Office Excel you can easily calculate these values:
USP LSP P-Val N-Val % Conf

64.8129 61.0511 0.9987 0.0013 99.730 3 o
64.1860 61.6780 0.9772 0.0228 95.449 2o





The P-value (Z
+
) is determined with the equation:
=NORMDIST(H24,I5,I17,TRUE)


This formula calculate the value using Z table. We just have to indicate the values of sigma(o ),
X
, USP
Similarly N-value (Z
-
) can be determined by:
=NORMDIST(I24,I5,I17,TRUE)
So, the % conforming is the difference between these two values multiplied by 100.
=SUM(J24-K24)*100


Discussion:
Repeat the procedure for the following sample data:

Reading Sample#1 Sample#2 Sample#3
1 8.3600 8.4600 8.4500
2 8.4400 8.4500 8.4700
3 8.4600 8.3900 8.4400
4 8.4300 8.4600 8.4300
5 8.3600 8.3500 8.4600
6 8.3700 8.4700 8.4200
7 8.4200 8.4000 8.4500
a) Find Mean, X , of each Sample
b) Find Range of each Sample
c) Find Mean of Samples, X .
d) Find average of Range, R, of Samples
e) Find the Control Limits UCL, LCL
f) Find Standard Deviation, o, of the Samples using the equation o = R /d
2

g) What percentage of PCB thickness will be within
USP LSP
8.35 8.47
8.39 8.45