WELCOME

TRAINING PROGRAMME ON
STATISTICAL PROCESS
CONTROL
 STATISTICAL PROCESS
CONTROL

CONTENT
1.INTRODUCTION
2.PROCESS CONTROL
3.VARIATION
4.CAUSES
5.STATISITICAL CONTROL
 STATISTICAL PROCESS
CONTROL

CONTENT
6.TOOLS FOR STATISTICAL CONTROL
7.PROCESS CAPABILITY
8.PROCESS CAPABILITY INDICES
9.CONTROL CHART TYPES
10 CONTROL CHART MEHODOLOGY
EVALUATION
 INTRODUCTION

QUALITY OF CONFORMANCE

Vs

CONFORMANCE TO
SPECIFICATION
 PROCESS CONTROL

THREE TYPES OF PROCESS CONTROL

 PREVENTION OF DEFECTS
* MISTAKE PROOFING
 DETECTION OF CAUSES AND LEAD TO
CORRECTIVE ACTION
* VISUAL CONTROL, SPC
 DETECTION OF DEFECTS
* INSPECTION
 VARIATION

PRINCIPLES OF SPC
 
      VARIATION IS INEVITABLE
 
      VARIATION IS PREDICTABLE
 
      VARIATION IS MEASURABLE
 
 
 STATISTICAL PROCESS
CONTROL

  STATISTICAL PROCESS CONTROL

 
      10 % IS STATISTICS
 
      90 % IS PRODUCT & PROCESS
KNOWLEDGE
 
 STATISTICS

DETERMINE WHICH SAMPLE IS GOOD ?

SAMPLE –1
15,15,14,15,16,15,15
SAMPLE –2
14,15,20,15,16,10,15
SAMPLE - 3
19,20,15,14,11,10,16
 
 STATISTICS

  HENCE WE NEED TO CAPTURE

 AVERAGE
 RANGE
 STANDARD DEVIATION
TO EVALUATE SAMPLES
 VARIATION & CAUSES

TYPES OF VARIATION
 RANDOM VARIATION
 NON RANDOM VARIATION
 
CAUSES OF VARIATION
 COMMON OR CHANCE CAUSES
 SPECIAL OR ASSIGNABLE CAUSES

 
 CAUSES

COMMON CAUSES SPL./ASSIGNABLE

FEW IN NOS. PLENTY IN NOS.
VARIATION IS LOW VARIATION IS HIGH
PART OF THE VISITOR TO THE
PROCESS PROCESS
CONSTANT FLUCTUATING
VARIATION VARIATION
PREDICTABLE UNPREDICTABLE
 CAUSES

COMMON CAUSES SPL./ASSIGNABLE

STATISTICS STATISTICS CANNOT
APPLICABLE APPLY
MANAGEMENT OPERATOR
CONTROLLABLE CONTROLLABLE
e.g Pressure variation, e.g Wrong setting, wrong
Environment variation master
REDUCTION LEAD ELIMINATION LEAD
TO IMPROVEMENT TO MAINTENANCE
 TOOLS FOR CONTROL

HISTOGRAM ----------- BELL SHAPE

CONTROL CHART-- NO OUT OF CONTROL

NORMAL PLOT ----- STRAIGHT LINE

 
 NORMAL DISTRIBUTION

TAKE A SAMPLE OF 100

ASSUME MEAN = 50.00
S. D. = 1.5
 48.5 -------------51.5 (1sigma) 68.20%
  
47.0--------------53.0 (2Sigma) 95.4%
 
45.5--------------54.5 (3Sigma) 99.73%
 NORMAL DISTRIBUTION

 WHEN AVERAGE, MEDIAN & MODE

IS SAME
AVERAGE OF ALL VARIABLE DATA
FOLLOWS NORMAL DISTRIBUTION
ELONGATION,UTS,TWIST,OVALITY,
ETC., LIKE ONE SIDED DOES NOT
FOLLOWS NORMAL DISTRIBUTION
 STATISTICAL CONTROL &
PROCESS CAPABILITY

A PROCESS FREE FROM ASSIGNABLE

CAUSES (PREDICTABLE PROCESS)

PROCESS CAPABILITY
IS 
A MEASURE OF INHERENT
VARIATION 
(MANAGEMENT CONTROLLABLE)
 PROCESS CAPABILITY

Cp=Potential Process Capability Index

Cp = TOLERANCE
----------------------
TOTAL VARIATION
(6 SIGMA)
 PROCESS CAPABILITY
INDICES

TV Vs TOL PPM LEVELS

6 SIGMA > TOL Cp = 0.8

125 > 100 HIGHER REJECTION
6 SIGMA = TOL Cp = 1.0
100 = 100 2700 PPM
6 SIGMA < TOL Cp = 1.33
75 < 100 64 PPM
6 SIGMA < TOL Cp = 1.67
60 < 100 4 PPM
 PROCESS CAPABILITY INDICES

 Cp DOES NOT SPECIFY WHERE THE PROCESS

IS CENTERED.
 HENCE WE NEED TO HAVE ONE MORE INDEX
TO MEASURE ACTUAL PROCESS CAPABILITY
 Cpk = ACTUAL PROCESS CAPABILITY INDEX
 Cpk = Min ( USL – AVG / 3 SIGMA, AVG – LSL/ 3
SIGMA)
 USE Cp AND Cpk TOGETHER
 Cpk CANNOT EXCEED Cp
 ln METHOD, MIRROR IMAGE TECHNIQUE FOR
NON NORMAL DATA
 PROCESS CAPABILITY INDICES

Pp & Ppk Cp &Cpk

PROCESS PROCESS CAPABILITY
PERFORMANCE INDEX INDEX

USED DURING INITIAL ONGOING PROCESS

PROCESS STUDY CAPABILITY STUDY
DURING PPAP
CAN BE CAPTURED FOR USED ONLY FOR
STABLE AND STABLE PROCESSES
CHRONICALLY
UNSTABLE PROCESSES
 PROCESS CAPABILITY INDICES

Pp & Ppk Cp &Cpk

CAPTURES VARIATION CAPTURES VARIATION
DUE TO BOTH DUE TO COMMON
COMMON & SPECIAL CAUSES ONLY
CAUSES
SIGMA IS CALCULATED SIGMA IS CALCULATED
USING n-1 FORMULA USING R bar / d2
USING ALL INDIVIDUAL FORMULA
READINGS
Ppk > 1.67 Cpk > 1.33
 CONTROL CHARTS

OBJECTIVES OF CONTROL CHART

TO DETECT SPECIAL/ASSIGNABLE
CAUSES
TO MAINTAIN THE ACHIEVED
PROCESS CAPABILITY
TO IDENTIFY THE OPPORTUNITY
FOR IMPROVEMENT
CONTROL CHART STEPS

1.   GATHER DATA

2.   INITIAL STUDY
3.   CALCULATE CONTROL LIMITS
4.   INTERPRET FOR PROCESS CONTROL
5.   INTERPRET FOR PROCESS CAPABILITY
6.  ESTABLISH ONGOING CONTROL CHART
7.  MONITOR, REVIEW AND IMPROVE
PROCESS CAPABILITY
1.GATHER DATA

 ELIMINATE OBVIOUS DEFICIENCIES

 IDENDTIFY THE FACTORS AFFECTING
AVG. & RANGE
 UNDERSTAND PROCESS THROUGH
MASTER CAUSE & WHY WHY ANALYSIS
 PLAN SAMPLE SIZE, FREQ, CONTROL
CHART,NO. OF SUBGROUPS,ETC.,
SELECTION OF CHARTS

X BAR & R CHART

 MOST SENSITIVE CHART
MEDIAN & R CHART
 EASY SHOP ACCEPTANCE AS NO
CALCULATION OF AVERAGE
X BAR & S CHART
 SUBGROUP IS > 9,
 EFFECTIVE VARIABILITY INDICATOR
SELECTION OF CHARTS

X & MR CHART
 WHERE NOT SUITABLE FOR SUBGROUP
SAMPLING
 INSPECTION IS COSTLY/ DESTRUCTIVE
IN NATURE
 DIFFICULT TO INTERPRET
GATHER DATA

RECORD PROCESS EVENTS WHILE

COLLECTION OF DATA
RECORD AND PLOT READINGS
SIMULTANEOUSLY
INTERPRETATION FOR
CONTROL

FOCUS ON RANGE CHART

ALL 4 CONDITIONS ARE CHECKED
AND APPROPRIATE ANALYSIS
MADE AND CAUSES IDENTIFIED FOR
ALL 4 OUT OF CONTROL
CONDITIONS
INTERPRETATION FOR
CAPABILITY

 CALCULATE SIGMA, 6 SIGMA, Cp,Cpk

 IF Cpk < 1.33 INITIATE CA TO IMPROVE
THE VALUE
 INITIATE CA PLAN FOR PROCESSES NOT
UNDER STATISTICAL CONTROL
 IF Cpk >1.33 ESATBLISH ONGOING
CONTROL
ONGOING CONTROL

 FINALISE ONGOING AVGs FOR CONTROL

CHART
 ESTABLISH UCL & LCL
 ESTABLISH REACTION PLAN
 TRAIN THE OPERATOR
 ESTABLISH TO CONTROL TO MONITOR
ONLINE CHARTING
ONGOING CONTROL

 ONLINE MONORING TO ENSURE PROCESS

IS STOPPED IN THE EVENT OF OUT OF
CONTROL
 ANALYSED, ACTIONS ARE INITIATED AS
PER REACTION PLAN
 RECORDS OF THE SAME IS MAINTAINED
 PERIODIC REVIEW OF CFT IS ORGANISED
TO REVIEW THE EFFECTIVENESS OF SPC
EFFECTIVENESS OF SPC

MEASURED BY
 IMPROVED PROCESS KNOWLEDGE
 REVIEW AND REVISION OF UCL/LCL
 REDUCTION IN REJECTION ( ACTUAL Vs
ESTIMATED)
 IMPROVED PRODUCTIVITY
 LESS INSPECTION AND ADJUSTMENT
 CUSTOMER SATISFACTION DUE TO LESS
VARIATION
ATTRIBUTE CHART

P-CHART
- PROPORTION OF UNIT NONCONFORMING
- SAMPLE SIZE NEED NOT BE EQUAL

np-CHART
- NUMBER OF UNITS NONCONFORMING
- SAMPLE SIZE MUST BE EQUAL
ATTRIBUTE CHART

C – CHART
- NUMBER OF NONCONFORMITIES
- SAMPLE SIZE MUST BE EQUAL

U – CHART
- NUMBER OF NONCONFORMITIES PER UNIT
- SAMPLE SIZE NEED NOT BE EQUAL
 OPERATOR’s ROLE FOR ONE SUBGROUP
PLOTTING

1. CHECK AS PER CONTROL PLAN

2. CALCULATE AVG/RANGE/INDIVIDUALS
3. PLOT THE SAME IN CONTROL CHART
4. CHECK THE PLOTTED POINT IS IN CONTROL ( REFER
4 CONDITIONS IN CONTROL CHART)
5. IF IT IS IN CONTROL, CONTINUE THE PROCESS
6. ELSE, STOP THE PROCESS, TAKE CORRECTIVE
ACTION & DISPOSITION ACTION AS PER REACTION
PLAN
7. RECORD THE PROCESS EVENTS INCLUDING OUT OF
CONTROL CONDITIONS
EFFECT OF OVER
ADJUSTMENT

 THIS IS THE PRACTICE OF TREATING EACH

DEVIATION FROM TARGET IS DUE TO
SPECIAL CAUSES
 IF A STABLE PROCESS IS ADJUSTED ON THE
BASIS OF EACH MEASUREMENT MADE, THEN
THE ADJUSTMENT BECOMES AN ADDITIONAL
SOURCE OF VARIATION
 OVER ADJUSTMENT WILL INCREASE THE
VARIATION