Process Capability Studies

Comparison of Process Output to

Product Requirements

Lynn Taylor OISM 470W Section 002

Process Capability Studies

3 Steps
Gauge Capability
Process Characteristics
Stability
Normality
Control

Process Capability Analysis

Comparison of process output(s) to
requirements.

Process Capability Studies

Definitions
Process Work performed on a set of inputs
to produce a result.
Capability The predictable result(s) of a
process allowed to operate without outside
interference.
Process Capability Study Comparison of
process output(s) to product requirements.

Process Capability Studies

Uses In Our Plant

Customer 1 < 407, Cpk > 1.25

Customer 1 > 407, Cpk > 1.50
Customer 2, Cpk > 1.33
With new clients, determine if tolerances
are reasonable, if our processes are capable
and robust, and if improvements are needed.

Process Capability Studies

Step 1 Gauge Capability
Six Measures
Gauge Accuracy
Are the readings correct?

Gauge Linearity
Are the readings correct over the measurement
range of the instrument?

Gauge Stability
Does the gauge return similar values over time?

Process Capability Studies

Step 1 Gauge Capability
Six Measures
Gauge Repeatability
Does one operator return a similar result time after
time (gauge variability)?

Gauge Reproducibility
Do different operators return similar results?

Gauge Repeatability and Reproducibility

Total variability of a test result (operator &
gauge).

Process Capability Studies

Step 2 Process Characteristics
Analyze Process Data
Normality Evidenced by the descriptive
statistics skewness and kurtosis.
Stability The absence of shifts or trends
over time.
Control Control chart analysis passing
tests for special causes.

Process Capability Studies

Tests for Normality

Process Capability Studies

Tests for Stability and Control

Process Capability Studies

Comparing Distributions to Specifications

Process Capability Studies

Real World Example Part 504

Process Capability Studies

Part 504 Continued

Process Capability Studies

Part 504 Continued

Process Capability Studies

Part 613 - An Exercise
0.1083
0.10819
0.10827
0.10817

0.10816
0.1081
0.10817
0.10801

0.10778
0.10784
0.10789
0.10835

0.10836
0.10809
0.10841
0.10807

0.10802
0.10794
0.10802
0.10843

0.10837
0.10846
0.10811
0.10834

0.1084
0.10838
0.10836
0.10835

0.10822
0.10827
0.10833
0.10799

0.1082
0.10817
0.10833
0.10824

0.10822
0.10812
0.10811
0.10813

0.10785
0.10809
0.10811
0.10822

0.10811
0.10828
0.10796
0.10832

0.10794
0.10838
0.10797
0.1078

0.10803
0.10819
0.10814
0.10794

0.10819
0.10808
0.10793
0.10819

0.10822
0.10824
0.10807
0.10811

0.10826
0.10803
0.10817
0.10794

0.10815
0.10805
0.10815
0.10794

0.10816
0.10802
0.10797
0.10833

0.10826
0.10844
0.10813
0.10828

0.10814
0.10816
0.10817
0.1081

0.1081
0.10837
0.10815
0.10839

0.10813
0.1082
0.10802
0.10849

0.10798
0.10833
0.10799
0.10818

0.10809
0.10856
0.10846
0.10804

Process Capability Studies

Part 613 An Exercise
0.110 Diameter Part 613

Descriptive Statistics

35
30

Mean
0.1081636
Standard Error
1.64535E-05
Median
0.10816
Mode
0.10817
Standard Deviation 0.000164535
Sample Variance
2.70718E-08
Kurtosis
3.411886124
Skewness
0.017494357
Range
0.00078
Minimum
0.10778
Maximum
0.10856
Sum
10.81636
Count
100

Frequency

25
20
15
10
5
0

dia - in.

Max Kurtosis
Max Skewness

4.49
0.745

Process Capability Studies

Part 613 An Exercise

in.

Xbar Chart .110 dia Part 613- n=4

0.1085
0.1084
0.1083
0.1082
0.1081
0.108
0.1079
0.1078
0.1077
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
UCLXbar
Xbarbar
Observation #
Xbar
LCLXbar

R Chart .110 Dia Part 613

n=4
0.0008

0.0004
0.0002

R
LCLR

Observation #

25

23

21

19

17

15

13

11

0
3

UCLR
Rbar

in.

0.0006

Process Capability Studies

Part 613 An Exercise
And the answer is:
Descriptive Statistics
Mean
Standard Error
Median
Mode
Standard Deviation
Sample Variance
Kurtosis
Skewness
Range
Minimum
Maximum
Sum
Count

0.1081636
1.64535E-05
0.10816
0.10817
0.000164535
2.70718E-08
3.411886124
0.017494357
0.00078
0.10778
0.10856
10.81636
100

LSL =
USL =
Cp =
CpL =
CpU =
Cpk =

0.105
0.115
10.1
6.4
13.8
6.4

Process Capability Studies

Summation
Three Steps:
Gauge Capability
Process Characteristics
Process Capability Analysis

Process Capability Studies

Bibliography

Introduction to Statistical Analysis sixth ed Dixon and Massey

Introductory Statistics Weiss and Hassett, 1982
AT&T Statistical Quality Control Handbook 11th Printing 1985
Experimental Statistics Mary G. Natrella 1966 (NBS Handbook 91)
General Motors Statistical Quality Control Handbook 1982
LTV Steel Integrated Process Control Handbook Norman Bresky
and Joan Harley 1986
North American Refractories Co. SPC Handbook 1988
1994 Annual ASTM Book of Standards- ASTM E 691 - 92