Quality improvement 24Dec.

2011
(Statistic quality control)

Process Capability Study

The process capacity is one of the important indices to
evaluate the quality ability in the manufacturing process.
In the process capability study, it is important to confirm
the purpose enough to investigate the process capability and
to select the best method.
Learn practical investigation method to study the process
capability and the method of judging the process capability.
 TRAINING CONTENTS
1. What is the process capability and the machine capability
2. How to advance the process capability study
3. How to show the process capability and the machine capability.
4. How to judge the process capability and the machine capability
5. Method of calculating the process capability:
Calculation of Index Cp , Cpk and Cm
6. Use of the process capability study
7. Improvement of the process capability

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1.What is the Process Capability and the Machine Capability
1-1 What is the process capability?
If it says in short, the process capacity is an ability of the quality
of the process including all of 4M.
The process capability is shown with the index Cp or Cpk.
(4M=Machine, Method, Material and Man)

1-2 What is the machine capability?

The machine capacity is the ability of the quality that is separated
only the ability of the machine from the process capacity.
The machine capability is investigated with factors other than
machine made constant as much as possible.
The machine capability is shown with the index Cm.
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2. How to advance process capability study Study
procedure
Clarification of study Implementation of
objects standard work

Selection of Collection and

objective processes analysis of data

Selection of
When the process is When the process is
characteristic value
in the state of not in the state of
4M standardization control control

Examination of
measuring methods Grasp of process Investigation of
capability abnormal causes
Examination of
sampling
3
 Grasp of process capability Investigation of
abnormal causes
The process capability is The process capacity is
sufficient insufficient.

Continuous data: 　　　　 Cause study and grasp of Standardization for

･ Execution of process machine capability recurrence prevention
control (adjustment)
･ Process capability study Cause is unknown or the ･ Action
by appropriate interval action cannot be taken
technically and economically. ･ Standardization
Enumerated data:
･ Set the decrease target in ･ Process control (Process
consideration of the adjustment)
economy etc. ･ Restudy of tolerances
･ Advance the improvement ･ Selection by Inspection
activity. and repair of rejected
4
goods.
3. How to show the process capability and the machine capability
“Capability" of the process capability is width of the dispersion. Use the
symbol σ(sigma) to show this width of the dispersion.
1)The process capability is 2)The machine capability is shown
shown with 6σp(=6×σp). with 6σm(=6×σm)
Fig.1 Fig.2
6σp 6σm

σp σm

σp : Standard deviation by the σm : Standard deviation by the

dispersion due to the all of 4M dispersion due to only machine
Note: 4M is the initial of Machine, Method, Material, Men (worker)
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4. How to judge the process capability and the machine capability
4-1 The process capability index Cp or Cpk
1) For the specification with upper & lower limit
Tu Fig.4 TL Tolerance ( T ) Tu
Fig.3 TL Tolerance ( T )
6σp
6σp M
σp
σp

Center of tolerance X

X K (bias)

When the bias, the gap of X and the center

Process capability index of the tolerance (M), is considered,
T (1-K) | M-X |
Cp= Cpk= as K=
6σp T/ 6σp T/2 6
2) For the specification with only upper or lower limit

Upper limit only Lower limit only

Fig.5 Fig.6
Lower limit
Tu TL

σp σp

X X

Tu-X X-TL
Cp= Cp=
3σp 3σp
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4-2 The Machine capability index Cm

1) For the specification 2) Upper limit only 3) Lower limit only

with upper & lower limit
Fig.7 TL Fig.8 Fig.9 TL
T Tu Tu

σm σm σm

X X X

T Tu-X X-TL
Cp= Cp= Cp=
8σm 4σm 4σm
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4-3 Judgment criterion
1) Judgment of the process capability Cp and Cpk
Cp Judgment
1.33 ≦ Cp The process capability is enough.
1.0 ≦ Cp<1.33 The process capability cannot be said enough.
Cp<1.0 The process capability is insufficient.
Cpk Judgment The judgment by Cpk is applied for 1<Cp
1.0 ＜ The deviation of the mean value is acceptable
Cpk
Cpk ≦1.0 Action is necessary for the deviation of the mean value.
2) Judgment of the machine capability Cm
Cm Judgment
1.0 ≦ Cm The process capability is enough.
Cm<1.0 The process capacity is insufficient. 9
3)Relation between process capability index Cp and bias factor K
When bias K is large, even how the process capacity is good, the product becomes out of
standard. Therefore, when studying about the process capability, it is preferable to think
about bias. Use Fig. 10 when judging by using Cp and K.
Cp6.0 Fig.10
Cpk2.0 Cpk1.33

Cp5.0 Cpk1.0
(A) Maintain current
Cp4.0 conditions It is acceptable in
keeping current
Cp3.0 conditions if it
B continues for two
Cp2.0 months or more.

| M-X |
Cp1.0 K=
(C) Improvement is necessary 　　　 T / 2
M=center of
K 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 tolerance 10
Cp 1.33 ≦ Cp 1.00≦ Cp <1.33 Cp<1.00
Cm ― 1.00 ≦Cm Cm<1.00 1.00 ≦Cm Cm<1.00
1.Control the 1.Maintain the 1.Examine the 1.Examine 3M 1.Examine the
process with the process by machine and other than the machine and
control chart. using the improve it. machine and improve it.
control chart
improve it.
etc.
2.When Cp is 2.Examine 3M 2.Judge the 2.Judge the 2.Judge the
excessive, think other than the effect of the effect after effect of the
about the machine and improvement of improvement improvement of
simplification of improve it. Cm by using a by using a Cm by using
process control control chart. control chart. control chart.
and the cost
3.When Cm is 3.When Cm is 3..Examine 3M
decrease etc.
sufficient, shifts sufficient, other than the
4) The action after to the process shifts to the machine and
judgment of Cp or Cm control. process check the imp-
control. rovement of Cp
3.When Cp is
sufficient, shifts
to the process 11
5. Method of calculating the process capability index Cp and Cpk
5-1 How to correct data
1 Correct data as much Stratification of Machine, Jig, worker, working
as possible on the group and measurer etc.
same condition.
2 Number of data 100 pieces or more as much as possible are
referable.
Reliability decreases a little though even
Cp/Cpk can be calculated with 50-100 pieces.
3 Measuring tools As a rule, the reading scale of measuring
tools should be 1/10 of the product tolerance.
Example: product allowance ±0.1
→ Reading scale of the measuring tool 0.02
4 Method of recording Prepare the proper recording format.
data
Refer slide page No. 12
 5-2 Three methods of data analysis in process capability study
1 Use the histogram. ①When you want to know the data distribution as
the whole.
② The investigation period: 1-5 days.

2 Use the process ①When you want to understand the state of control
control chart. 　 in the process. This method is applied when
there
is room for the investigation period.
②The investigation period: 1-3 months.
　 The most dependable result is obtained.
3 Use the process ①This method is applied when the result of the
capability chart. survey is needed in the emergency or when it is
necessary to understand the tendency of the
change of data. 13
1) Calculation of Cp that uses histogram
Fig.11 Procedure 1: Mean
median Frequency value X=9.95
10 20 30
7.9 TL=8.0 1 Procedure 2: Standard
8.4 10 deviation σ=0.82
8.9 10 Procedure 3:
Process capacity 6×σ=
9.4 30 6×0.82 = 4.92
9.9 X=9.95 28 For standard value 10±2
10.4 Tu=10.0 17
Cp=T/6σp=4/4.92=0.81
10.9 18
Judgment:
11.4 5 Cp=0.81 ＜ 1.0
11.9 1 The process capability is
not sufficient.
120 14
 2) Calculation of Cp that uses the control chart Fig.12
1 2 3 4 R
X
1 38.3 38.9 39.4 38.3 38.92 1.1

2 39.1 39.8 38.5 39.0 39.10 1.3

3 38.6 38.0 39.2 39.9 38.92 1.9

4 40.6 38.6 39.0 39.0 39.30 2.0

5 39.0 38.5 39.3 39.4 39.05 0.9

n=2 d2=1.128
6 38.8 39.8 38.3 39.6 39.12 1.5
Formula σ ＝ R / d2 n=3
d2=1.693
n=4 d2=2.059
28 38.2 37.9 30.6 37.8 37.88 0.6 Procedure 1: from the control chart
R=1.57
29 38.0 38.2 37.9 38.8 38.22 0.9
Procedure2:σp=1.57/2.059=0.778
30 39.0 39.4 38.0 38.3 38.68 1.4
Mean 38.89 1.57 Procedure3: 6σp=6×0.778 ＝ 4.67
Procedure4: Cp=2.0/4.67=0.43
Tolerance39± １ Process capability is insufficient.15
3) Calculation of Cp or Cm that uses the process capability chart
This method is mainly used for the machine capability study.
(1) Application
①When it is necessary to examine the details after the process capability study
with the histogram or the control chart
②When you analyze process capability shortage
Fig.13
Process capability chart (X-Rs chart) -1
X

R
s

10 20 30 40 50 60 70 80 90 100
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(2) Method of calculation from the process capability chart
①Fill in data in order of the processing on the process capability chart.
②Fill in the presumed cause when abnormality or the tendency appear in
measured values.
③Fill in difference (Rs) with the previous data.
Example Rs=Difference with the previous value 　 (absolute value)
The order of processing ① ② ③ ④ ⑤ ⑥ ⑦
Measured data 3 3 1 3 2 3 3
Rs 0 2 2 1 1 0

④Calculation of machine capability (Calculated with the data from Fig.12)

Procedure 1: Calculate the total of Rs ΣRsi = 93.
Procedure 2: Calculate average of Rs Rs =ΣRsi/(N-1) = 93/(100-1) = 0.939

Procedure 3: Calculate σm. σm = Rs/d2 = 0.939/1.128 = 0.8324

Procedure 4: Calculate machine capability 6 σm = 6×0.8324 = 4.99
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4) Difference of application methods of the process capability study and the
machine capability study
(1)Difference of term and object
Process ①When the past data can be used for process capability study.
capability ②When you understand the state of standardization and
study process control, and when a lot of data can be collected.
③When a long term can be applied for the process capability
study.
Machine ①When neither standardization nor the state of control can not
capability be understood like in the installation of the machine.
study ②When it is necessary to understand distinguishing the ability
only of the machine.
③When it is necessary to understand the capability in a short
term.
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(2) Difference of data used for calculation of Cp, Cpk or Cm

Calculation ①Make the process capability chart by the data measured

of process at several intervals for several days.
capability
②Make the histogram by the data measured from the lot to
Cp, Cpk which grouping is correctly done.
③Use the control chart for process control purpose.
Calculation ①Make the process capability chart by the data continuously
of machine measured.
capability ②Make the histogram by the data that fixes conditions other
Cm than the machine.
③Make the control chart by the data continuously measured.

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6. Use of the process capability study
6-1 Use the results of process capability study effectively.
When information about the process quality is grasped by the
process capability study, company can use the information not
only for the process control but also various effective actions.
For example, ABC Ltd. delivers their products to the parent company.
ABC Ltd. investigated the process capability of their main processes.
And they compared it with the standards demanded by the parent
company. As the result, they understood that they can accept the severe
cost reduction request from the parent company, if the level of the quality
standards can be slightly loosened. ABC Ltd. proposed the standards
change to the parent company with the data of the process capacity.
The parent company re-examined the possibility of changes. As the
result of the re-examination, the proposals of ABC Ltd. were approved.
Therefore, not only ABC Ltd. but also parent company got advantages.
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 6-2 Comparison between the process capability and standards
1) In case of process capability shortage

Fig.14
The width of the standard is near ±2σ. 　　　　　　
Lower Upper The defects of several percents will be occurred.
limit limit
TL X Tu ①Improve the work methods and the process capability.
②Can not be extended the width of the standard?
③Review the work balance in consideration of the other
products or distribution of workers.
･ Replace to the machine which has more high capability.
･ Change to the worker who has more high skill.
④Change or improve the machine equipment.
⑤Screening inspection of all parts.
Cp=0.67
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Fig.15 X The width of the standard is the same as ±3σ.
TL Tu Defective goods will be occurred by a little change in
the process.
Take actions ①②③④⑤ shown in Fig.14, if necessary.
Cp=1.0

Fig.16 The case of lower limit only:

X
TL
TL is at about 1.5σ below from X. 10% or more
defective goods will be occurred In this process.
Take actions ①②③④⑤ shown in Fig.14.

Fig.17
X The case of lower limit only:
TL
TL is at about 3σ below from X.
If the X can be shifted to a slightly large direction, it is safe.

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Fig.18 X The case of upper limit only:
Tu
Tu is at about 1.5σ above from X. 10% or more
defective goods will be occurred In this process
Take actions ①②③④⑤ shown in Fig.14, if necessary.

Fig.19 X The dispersion is small. However, X is greatly shifted

TL Tu to the direction of TL. Therefore, defects are caused
at near the TL . In this case,
defective goods will be prevented by shifting X to the direction
of Tu.

Fig.20 X Fig. 19 has been improved.

TL Tu It is an ideal case. The width of the standard is the
4σp 4σp
best in case of 8σ.

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 The case of an excessive process capability ：
Fig.21
X is at the center of the standard, and the both of Tu
X and TL are at 7σ from X. In this case, defective goods
TL Tu are not occurred at all.
Following actions shall be considered when process
capability is too excessive compared with standard:
(1)When the dispersion may be enlarged a little
within the range of the standard.
　　 ①Increase the processing speed.
②Extend the inspection interval.
③Lower the quality of the raw material.
(2)In case of machining, process the part that is
required more high accuracy with the machine.
(3)Narrowing the width of tolerance, assure the
quality to the customer. As a result, improve the
company image and attempt an increase of orders.
　　
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7. Improvement of the process capability

7-1 Tools often used for the process capability improvement

①Graph
②Pareto Diagram
The use of QC
Seven Tools is 　　 ③Cause and Effect Diagram
very effective. (Fish-Bone Diagram)
④Check Sheet
⑤Histogram
⑥Stratification

Experimental design ⑦Control Chart

might be used if necessary. ⑧Scatter Diagram
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7-2 Procedure on the process capability improvement
Procedure 1 Select problems, characteristics, and set targets

Procedure 2 Set-up organization for process capability improvement

and clarify the section in charge and person in charge.
Procedure 3 Collect and analyze data

Procedure 4 Consider countermeasures.

Make or revise various standards.
Procedure 5 Apply countermeasures and check results
Compare before improvement and after improvement.

Note: Procedure 2 is very important. Otherwise, there is a possibility

of ending the process capability study halfway.
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