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Chapter 6 P2

Statistical process control (SPC) uses statistical techniques to measure and control quality in a production process. The concepts of SPC were initially developed in the 1920s and were expanded upon after WWII. SPC involves collecting quality data from a process in real-time, using that data to monitor the process via control charts, and making adjustments to drive continuous improvement by keeping the process within established control limits. Control limits are determined based on the standard deviation of process measurements and indicate whether the process is in or out of statistical control.

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45 views19 pages

Chapter 6 P2

Statistical process control (SPC) uses statistical techniques to measure and control quality in a production process. The concepts of SPC were initially developed in the 1920s and were expanded upon after WWII. SPC involves collecting quality data from a process in real-time, using that data to monitor the process via control charts, and making adjustments to drive continuous improvement by keeping the process within established control limits. Control limits are determined based on the standard deviation of process measurements and indicate whether the process is in or out of statistical control.

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2021812718
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Statistical Process

Control
Introduction
• Statistical process control (SPC) is defined as the use of statistical
techniques to measure and controlling quality in a production process.

History :

• The concepts of Statistical Process Control (SPC) were initially developed


by Dr. Walter Shewhart of Bell Laboratories in the 1920's, and were
expanded upon by Dr. W. Edwards Deming, who introduced SPC to
Japanese industry after WWII.
SPC Method

 Quality data in the form of Product or Process measurements are obtained in


real-time during production process.

 The data is collected and used to evaluate, monitor and control a process. SPC is
an effective method to drive continuous improvement.

 this data is then plotted on a graph with pre-determined control limits.

 Control limits are determined by the capability of the process,


whereas specification limits are determined by the client's needs.
Data measurement  Standard deviation measures the dispersion of a dataset
relative to its mean.
Standard Deviation, σ
 A low standard deviation indicates that the values
tend to be close to the mean of the set,

 A high standard deviation indicates that the values


are spread out over a wider range.

Lowest Mean Highest  Histograms will approximate a Normal Distribution, with


frequency distributions in the Histogram
variations of measured raw data.

 In order to work with any distribution, it is important to


have a measure of the data dispersion or spread.

 This can be expressed by the range (highest less lowest),


but is better captured by the standard deviation (sigma).
Example :

LCL UCL

6.61 7.2 7.79


Control Limits
• Limits placed at three standard deviations
from the mean in either direction provide an 
economical tradeoff between the risk of
reacting to a false signal and the risk of not
reacting to a true signal.

• If the process has a normal


distribution, 99.7% of the population is
captured by the curve at three standard
deviations from the mean. (997/1000)

• Stated another way, there is only a 1−99.7%,


or 0.3% chance of finding a value 3σ
beyond 3 standard deviations.

• Therefore, a measurement value


beyond 3 standard deviations indicates that 27%
the process has become unstable (Out of
Controlled). 4.7%
Control Chart
 Consider that the distribution is turned sideways, and the lines denoting the mean
and ±3 standard deviations are extended.

 This construction forms the basis of the Control chart. Time series data plotted on this
chart can be compared to the lines, which now become control limits for the process.
Control Charts….X-Bar - R Charts
• Purpose: To examine the stability of processes and ready for improvement.

• To be used when the subgroups are eight (8) or less.


Control Charts

(Range, R = Max value – Min value)


Control Charts

Xbar = Average (Mean) value


Xdouble bar = Average of Xbar
Control Charts
Process Capability
 The ability of a process to meet specifications (customer expectations) is defined as
Process Capability.

 which is measured by indexes that compare the spread (variability) and centering of the
process to the upper and lower specifications.

 The difference between the upper and lower specification is know as the tolerance.
Control Charts
Control Charts
Process Capability

Capable

Not-Capable

Well Capable
Example

i.
ii.

Day 1
Day 2
Day 3
Day 4
Day 5
Calculating Range, R (For every Sub-group)
1. Calculate Means of samples R(1) = Max value- Min Value
= 2.4 – 2.2
= 0.2
Weight (Kg) *Repeat for R(2), R(3), R(4) & R(5)
Day M1 M2 M3 M4 means R
1 2.3 2.2 2.4 2.3 2.30 0.2 UCLR = D4*Rbar = 2.282*0.26 = 0.593
2 2.2 2.1 2.3 2.4 2.25 0.3 LCLR = D3*Rbar = 0* 0.26 = 0
Sub-Groups 3 2 2.2 2.2 2.1 2.13 0.2
4 2 2.1 2.1 2.3 2.13 0.3 Plot R-Bar Chart
5 2.5 2.2 2.4 2.3 2.35 0.3 0.593
2.23 0.26 v
0.26 Rbar

1 2 3 4 5
Xbar Chart
UCLX = Xbar + A2*Rbar = 2.23+(0.729*0.26) = 2.42
LCLR = = Xbar - A2*Rbar = 2.23-(0.729*0.26) = 2.04
Plot X-Bar Chart
2.42
2.23 Xbar

0
1 2 3 4 5

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