SPC

ƒ SPC is a method to operate process efficiently using

statistical methods.
ƒ To identify sources of variation.
ƒ Applicable when mistake proofing cannot be done .
ƒ SPC uses control charts to monitor the process.
ƒ SPC is a monitoring Instrument.

1
 VARIATION

Random Non- Random

¾ Not a part of natural process.
¾ Natural for the process
¾ Unexpected , Sporadic variation
¾ Predictable
¾ result of some specific assignable
¾ Occurs randomly over time
cause
¾ Also called common cause variation
¾ Also called special called variation
¾ Generally process remains in control
¾ Process go out of control

Control charts display the total variation in the process so it can be

monitored and kept in control (within its operating capability)

2
 Population and Sample Statistics
Population Statistics Sample Statistics
Population mean (µ) Sample mean (X-bar)

µ= ∑ xi
X=
∑ Xi
N n
Population variance (σ2) Estimate for variance (s2)

σ 2
=
∑ (x − µ )
i
2
s2 =
∑ i
( x − x ) 2

N n −1
Population Std Deviation(σ) Estimate for Std Deviation(s)

σ = (σ 2 ) s = (s 2 )
3
Introduction to Control Charts
PFD

4
 TYPES OF CONTROL CHARTS
DATA TYPE

Quantitative Qualitative
Variable’s Attribute

Continuous Defect Defective

Subgroup size Subgroup size Subgroup size

Fixed NP Chart
N=1 IMR Chart Fixed C Chart

N=2~9 XR Chart
Variable U Chart Variable P Chart
N=>9 XS Chart
5
 CONTROL CHARTS

9 Control charts are designed to prevent defect occurrence in advance & control process
variation efficiently by detecting and addressing the occurrence of assignable cause in
the process

Control chart consists of

Center line CL= Sample mean (m)
Upper Control limit = m+3σ ( Control limits are at a distance of 3σ from mean)
Lower control limit = m-3σ

Control chart deals with analysis of process , process control & to

judge if the product under study is acceptable or not

6
DESIGNING CONTROL CHART

Suppose we have a process that we assume the

true process mean is µ = 74 and the process
standard deviation is σ = 0.01. Samples of size 5
are taken giving a standard deviation of the sample
average, is
σ 0.01
σx = = = 0.0045
n 5

7
 DESIGNING CONTROL CHART

• Control limits can be set at 3 standard

deviations from the mean in both directions.
• “3-Sigma Control Limits”
UCL = 74 + 3(0.0045) = 74.0135
CL= 74
LCL = 74 - 3(0.0045) = 73.9865

8
Introduction to Control Charts
Rational Subgroups

Constructing Rational Subgroups

• Select consecutive units of production.
– Provides a “snapshot” of the process.
– Good at detecting process shifts.
• Select a random sample over the entire sampling
interval.
– Good at detecting if a mean has shifted
– out-of-control and then back in-control.

9
 WHAT DO WE CHECK IN THE CHARTS

The Automotive Industry Action Group (AIAG) suggests using the following
guidelines to test for special causes:
■ Test 1: 1 point > 3 standard deviations from center line
■ Test 2: 9 points in a row on the same side of center line
■ Test 3: 6 points in a row, all increasing or all decreasing
Also additional to these tests we can also check

¾ Test 4: 14 points in a row ,alternating up & down

¾ Test 5: 2 out of 3 points > 2 standard deviation from center line (same side). Too much Variations
¾ Test 6: 4 out of 5 points > 1 standard deviation from center line (same side).Too much Variations
¾ Test 7 : 15 points in a row within 1 standard deviation of center line (either side).Measurement error
¾ Test 8 : 8 points in a row > 1 standard deviations from center line (either side). Mixture of data

10
 IMR CHART (SUB GROUP SIZE=1)

I-MR Chart

1) IMR charts is used when data is slow , that is time range & Collection is pretty large.
2) There is one value per subgroup.
3) There is one between variation and no within variation.
4) Range between adjacent data points (moving range) is used to control process standard
deviation.

EXAMPLE

¾ Torque is measured daily once , in first half hour and recorded .

Draw a suitable control chart to find if it is in control or not

11
 ANALYSIS OF IMR CHART

I-MR Chart of Torque

7.2
U C L=7.072
6.9
Individual V alue

6.6
_
X=6.431
6.3

6.0
LC L=5.790
07/03/2005 07/06/2005 07/09/2005 07/12/2005 07/15/2005 07/18/2005 07/21/2005 07/24/2005 07/27/2005 07/30/2005
Date

0.8 U C L=0.7875

0.6
M oving Range

0.4
__
M R=0.2410
0.2

0.0 LC L=0
07/03/2005 07/06/2005 07/09/2005 07/12/2005 07/15/2005 07/18/2005 07/21/2005 07/24/2005 07/27/2005 07/30/2005
Date

12
 X- R CONTROL CHART (1<Sub group Size<5)

¾X chart is used to control process mean

¾R chart uses the differences between the maximum & minimum of the observed
values in sample , to control process variation
¾ X-R chart is useful to control both mean and variation at the same time

Example

Data collected for 5 m/c for a part reading over 20 hrs

find the behavior of the process for the

13
 ANALYSIS OF X Bar R CHART

MC process variation
9.00
U C L=8.9644

8.85
Sample M ean

8.70 _
_
X=8.636
8.55

8.40
LC L=8.3076
2 4 6 8 10 12 14 16 18 20
Sample

1.2 U C L=1.204

0.9
Sample Range

_
0.6 R=0.569

0.3

0.0 LC L=0
2 4 6 8 10 12 14 16 18 20
Sample

14
 X- R CONTROL CHART CONSTANTS

SAMPLE SIZE A2 D3 D4 d2
UCL (R)= R D4

2
1.880 0 3.267 LCL (R)= R D3

3 1.023 0
2.574

4 0.729 0 2.282
UCL(X)= X A2 R
5 0.577 0
1.023
LCL(X)= X A2 R
6 0.483 0 2.004

7 0.149 0.076 1.924

8 0.373 0.136 1.864

9 0.337 0.184 1.816

10 0.308 0.223
1.777

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 RESULT X bar R

R Chart –
Asses the process variation is in control.
Consists of plotted points for subgroup ranges .
Four tests are conducted for special causes to detect points
beyond the control limits and specific patterns in data.
A failed point(marked in RED) indicates that there is non random
pattern (special cause variation).

In the given data:-

None of the subgroup ranges are outside the control limits
The points inside the limits display a random pattern.
There is no lack of control in variation .

16
 RESULT X bar R

X Chart
A failed point indicates that there is a Non-random pattern
due to special cause variation.
The R chart must be in control before X bar is interpreted.
Results are shown in the session window.
If the process is stable, how capable is it can be determined
by capability calculation.

17
 COMPARISON BETWEEN X bar R & X bar S

BOTH S CHARTS & R CHARTS

- Measure Subgroup variability.
-Give the estimate of the process standard deviation & Control limits.
S R

Represent Spread Using Standard Using

Deviation Range

Calculates Uses complete data Uses Max &

Min Values

Accuracy Better

Sensitivity to Variation Greater

For higher subgroup size( >5 ),high rate of production
Application ,data collection is quick & in expensive or when increased
sensitivity is desired.

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 CONTROL CHART FOR DEFECTIVES

P Chart’s

¾P Charts are used for defectives when SUB GROUP size is Variable.
Variable.
¾ Data follows binomial distribution. P(n, N) = pn.(1 - p)N-n.NCn
¾ Can be used for supplier lot quality on the basis of delivery.
¾ The P chart consists of the following:

¾Plotted points, which represent the proportion of defectives.

¾Center line (green), which is the average proportion defective

¾Control limits (red), which are located 3 s above and below the center line and provide a visual
means for when the process is out of control. The control limits are either fixed or varied,
depending on your data and choices:

¾When your sample sizes are the same or when you choose to use an average sample size, then
the control limits will be fixed. In this case, tests for special
special causes may be conducted.

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 P Chart of Number of Defectives
0.018

0.016 UCL=0.01627

0.014
Sample size is different
0.012
Proportion

_
0.010 P=0.00968

0.008

0.006

0.004
LCL=0.00310
0.002
1 2 3 4 5 6 7 8 9 10
Sample
Tests performed with unequal sample sizes
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 P Chart result analysis

¾When your sample sizes vary, then the control limits will vary.
In this case, tests for special causes cannot be conducted. You
should examine the P chart for points outside the control limits
and trends or other nonrandom patterns.
¾ Four tests are conducted for special causes by Minitab.
¾ Plotted points representing the PROPRTION OF DEFECTIVES.
¾ Center line (green) , which is the average proportion
defective.
¾ Control limit (red) either fixed or varied , depending on data.
¾ P Chart for the given data shows process in control.

21
NP CHART FOR DEFECTIVES (SUB GROUP SIZE SAME)

¾Use NP charts to examine the number of defectives in each sample and

determine whether or not the process is in control. The NP chart consists of
the following:

¾ Plotted points, which represent the number of defectives for each sample

¾ Center line (green), which is the average number of defectives

¾ Control limits (red), which are located 3 s above and below the center line
and provide a visual means for assessing when to take action on the
process.
Example:
For every lot of 100 Bush manufactured ,13 are randomly inspected
inspected & reported for defectives .Find the data is
in control.

22
 GRAPH

NP Chart for 13 randomly slected subgroup size

9
1
8
UCL=7.709
7

6
Sample Count

4
__
3 NP=3.1

0 LCL=0

3 6 9 12 15 18 21 24 27 30
Sample

23
 Test Results for NP Chart of No. of defectives

TEST 1. One point more than 3.00 standard

deviations from center line.
Test Failed at points: 23

NP chart should not be used for variable sample size because the
control limits & center line changes when sample size changes making
NP chart difficult to interpret.

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 CONTROL CHART FOR DEFECT ( C CHART)
SUB GROUP SIZE IS FIXED
¾Used to find defects as DPU (defects / unit) of the controlled
process.
¾ Inspection unit must be fixed.
¾Inspection units can more than one if the data is not
classified by the type of defect.

Example:

Following is the defect quantity per lot of bush manufactured ,

check the data is in control or not

25
 GRAPH

C Chart of No. of defects

9
1
8 1 point outside the control limit
7 UCL=7.204

6
Sample Count

3 _
C=2.48
2

0 LCL=0

5 10 15 20 25 30 35 40 45 50
Lot_no.

26
C Chart of No. of defects

Test Results for C Chart of No. of defects

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 13

* WARNING * If graph is updated with new data, the results above may no
longer be correct.

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 CONTROL CHART FOR DEFECT ( U CHART)
SUB GROUP SIZE IS VARIABLE

¾Used to asses the number of defects per unit of measurement to

determine if the process is in control.
¾ If the samples are of same size or when the average sample size is taken ,
Control limits will be FIXED.
¾ when the sample size vary , Control limits vary,Tests for special causes
cannot be conducted.

EXAMPLE

Find the given data is in control or not , sample size is not fixed.

28
 GRAPH

U Chart of No. of Defects

4
1

UCL=3.337
Sample Count Per Unit

2
_
U=1.5

0 LCL=0

2 4 6 8 10 12 14 16 18 20
Week_No.
Tests performed with unequal sample sizes

29
Results for: U_defects

TEST 1. One point more than 3.00 standard

deviations from center line.
Test Failed at points: 1

* WARNING * If graph is updated with new

data, the results above may no
* longer be correct.

30
 RUN CHART (Test for randomness of Data)

Run charts are plotted to find special patterns in data :

1) Mixtures
2) Clusters
3) Trends
4) Oscillations

Create a Run chart from the same data in which U charts are prepared

31
 GRAPH ANALYSIS

Run Chart of No. of Defects

14
12

10
No. of Defects

8
6
4
2
0
2 4 6 8 10 12 14 16 18
Sample
Number of runs about median: 9 Number of runs up or down: 12
Expected number of runs: 9.21053 Expected number of runs: 12.33333
Longest run about median: 5 Longest run up or down: 2
Approx P-Value for Clustering: 0.45379 Approx P-Value for Trends: 0.42438
Approx P-Value for Mixtures: 0.54621 Approx P-Value for Oscillation: 0.57562

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 A normal pattern for a process in control is one of randomness. If only
common causes of variation exist in your process, the data will exhibit
random behavior.
Run Chart provides two tests for randomness:

·Based on the number of runs about the median.

·Based on the number of runs up or down.

Test for Randomness Condition Indication

Number of runs about the More runs observed than Mixed data from two
median expected populations

Fewer runs observed than Clustering of data

expected
Number of runs up or down More runs observed than Oscillation - data
varies
Fewer runs observed than Trending of data
expected

Oscillation: It suggests that process is not in a controlled state(depends upon P value).

Trends: Trends may warn that a process is about to go out of control, and may
be due to such factors as worn tool, Change in operator etc. 33