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Collection,
Tabulation,
Analysis,
Interpretation,
Presentation of
quantitative data.
SPC is one of the best technical tool for improving product and
service quality.
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It is an effective method
Helps in preventing defects
Helps continuous quality improvement.
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Statistical:
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PROCESS
People
Equipment
Method
Environment
Materials
Procedures
machines,
materials,
methods,
management
and environment
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The Process
People
Machines
Material
Output
Management
Methods
Environment
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guiding it
the predictability
and capacity of a process
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Detection Drawbacks:
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Customer dissatisfaction.
Repetitive problems.
Neglected improvements.
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Prevention Benefits:
Improved design and process capability.
Improved manufacturing quality.
Improved organisation.
Continuous Improvement.
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preventing defects.
With stable processes, the cost of inspection and defects are
significantly reduced.
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Process Variations
Process Element
Variable Examples
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Process Variations
No industrial process or machine is able to produce consecutive
The differences may be large or very small, but they are always
there.
The differences are known as variation.
This is the reason why tolerances are used.
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Designed Size
10
17
11
12
13
14
15 16
17 18 19
20
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Natural Variation
15.3
15.4 15.5
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Process Variability
Variations due to:
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Natural Causes:
Special Causes:
Temperature variation
Material variation
Customer differences
Operator performance
Machine is breaking
Untrained operative
Machine movement
Process has changed
Must be monitored
Stability
Common causes are the many sources of variation that are
always present.
A process operates within normal variation when each element
is said to be stable.
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Process Control
predictable results.
Its variability is stable over a long period of time.
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Start
Produce Good
Provide Service
Take Sample
No
Assign.
Causes?
Yes
6-22
Inspect Sample
Stop Process
Create
Control Chart
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X bar , R
X bar, S
Start
IX, Moving
Range
p (fraction defective)
or
n p (number def. Per
sample
c (defects per
sample or
u defects per unit
u
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Individual X charts
How is it done?
The data must have a normal distribution (bell curve).
Have 20 or more data points. Fifteen is the absolute minimum.
List the data points in time order. Determine the range between
each of the consecutive data points.
Find the mean or average of the data point values.
Calculate the control limits (three standard deviations)
Set up the scales for your control chart.
Draw a solid line representing the data mean.
Draw the upper and lower control limits.
Plot the data points in time sequence.
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Control Charts
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are in zone C
Four out of five consecutive points
is in zone A
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Basic
Control
Charts
interpretation rules:
Specials are any points above
the UCL or below the LCL
A Run violation is seven or
more consecutive points above
or below the center (20-25 plot
points)
A trend violation is any upward
or downward
movement of
five or more consecutive points
or drifts of seven or more
points (10-20 plot points)
A 1-in-20 violation is more
than one point in twenty
consecutive points close to the
center line
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X-bar chart
R-chart
Control charts
Control charts for Attributes
P-chart
C-Chart
np-Chart
U-Chart
Sources Of Variation
Types Of Variation
Types Of Variable Control Charts
Control Chart Patterns
Control Chart And Warning Control Limit
Basic Equations And Example
Consequences Of Misinterpreting Control Charts
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Control chart is a graph that displays data taken over time and
behavior charts
When variations are very small, it may appear that items are
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SOURCES OF VARIATION
Mainly there are four sources of variations. They are,
Processes
Materials
Operators
Miscellaneous factors
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TYPES OF VARIATIONS
There are two kinds of variations. They are,
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These are difficult to trace and control even under best conditions of
production.
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R or Range chart
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Trend pattern in X bar chart may occur because of tool wear, die wear etc
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5. Cyclic Patterns
Cyclic patterns are characterized by a repetitive periodic behavior in the system.
Cyclic patterns in X bar chart may occur because of rotation of operators, periodic
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Formula
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look like washers. They fit around shaft such as drive shafts in
machinery or motors. In the production process for a
particular slip ring bearing the employees have taken 10
samples (during a 10 day period) of 5 slip ring bearings. The
individual observations are shown below. Prepare the R chart
and X bar chart.
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Sample
No
52
5.02
5.01
4.94
4.99
4.96
5.01
5.03
5.07
4.95
4.96
4.99
4.93
4.92
4.99
5.03
4.91
5.01
4.98
4.89
4.95
4.92
5.03
5.05
5.01
4.97
5.06
5.06
4.96
5.03
5.05
5.01
5.1
4.96
4.99
5.09
5.1
4.99
5.08
5.14
5.1
4.99
5.08
5.09
10
5.01
4.98
5.08
5.07
4.99
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Spending time and money looking for problems that do not exist.
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Our goal
Quality improves!!
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Process Capability
is the ability of a process to make a feature within its tolerance.
Process Capability
Nominal
value
Process distribution
Lower
specification
20
Upper
specification
25
Process is capable
30
Nominal
value
Process distribution
Lower
specification
20
Upper
specification
25
Process is not capable
30
( Cp ) .
which is computed as the ratio of the specification width to
R
Process width = 6X
d2
Cpk = Minimum of
=x Lower specification
3
Upper specification x=
3
We take the minimum of the two ratios because it gives the worstcase situation.
Cp = 1
Cp <= 1
Cp >= 1
Yes:
No:
too wide
Yes:
No:
potentially capable
if re-centered
Yes:
No:
potentially capable
if re-centered
Problem
In a capabilty study of a lathe used in turning a shaft to a
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R
Pr ocesswidth = 6 X
d2
d2 = 2.534
A2=0.48
D3=0
D4=2
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ucl = 23.802
Lcl= 23.7322
Cp=1.254
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Problem
The length of time customers of Statistical Software, Inc.
waited from the time their call was answered until a technical
representative answered their question or solved their
problem is recorded in Table 20-1.
Develop a control chart.
Does it appear that there is any time when there is too much
variation in the operation?
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Attribute charts
nonconforming.
np charts
This chart shows the number of nonconforming.
Almost the same as the p chart.
c charts
This shows the number of defects or nonconformities
u charts
This chart shows the nonconformities per unit produced by
a manufacturing process.
p charts
In this chart, we plot the percent of defectives (per
batch, per day, per machine, etc.).
Formula
Fraction nonconforming:
p = No of defects/n
sample or subgroup,
n = number in the sample or subgroup,
P chart
No of defectives
p=
total no inspected
p (1 p )
UCL = p + 3
n
p (1 p )
LCL = p 3
n
Sample
1
2
3
4
5
6
7
8
9
10
88
Nof pieces
inspected
300
300
300
300
300
300
300
300
300
300
No of defects
identified
25
30
35
40
45
35
40
30
20
50
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89
Sample no
1
2
3
4
5
6
7
8
9
Sample size
90
65
85
70
80
80
70
95
90
No of defective
pieces
9
7
3
2
9
5
3
9
6
10
75
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Example
P chart
np Chart
When the subgroup size is constant, the chart constructed
for the actual no. of defectives rather than the fraction
defectives is called np-chart.
Advantages
calculations.
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c Chart
The procedures for c chart are the same as those for the p
chart.
If count of nonconformities, co, is unknown, it must be found by
collecting data, calculating UCL & LCL.
LCL = c 3 c
UCL = c + 3 c
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u Chart
c
u=
n
u
UCL = u + 3
n
u=
n
u
LCL = u 3
n
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No of Defects
Castings
1
2
3
4
5
6
7
8
9
10
114
2
4
1
5
5
6
3
4
0
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Nonconformity Classification
Critical nonconformities
Indicate hazardous or unsafe conditions.
Major nonconformities
Failure
Minor nonconformities
control procedures.