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chapter 14

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9 views38 pages

chap+14+-+statistical+process+control

chapter 14

Uploaded by

Christian Jay Rivera Iligan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Chapter 14

Statistical
Process
Control

1
Statistical Process Control
(SPC)

 A methodology for monitoring a


process to identify special causes
of variation and signal the need
to take corrective action when
appropriate
 SPC relies on control charts

2
Histograms vs. Control
Charts
 Histograms do not take into account
changes over time.
 Control charts can tell us when a
process changes
Control Chart
Applications

 Establish state of statistical


control
 Monitor a process and signal

when it goes out of control


 Determine process capability

4
Key Idea

Process capability calculations make


little sense if the process is not in
statistical control because the data
are confounded by special causes
that do not represent the inherent
capability of the process.
Capability Versus Control

Control
Capability In Control Out of Control

Capable IDEAL

Not Capable

6
Commonly Used Control
Charts

 Variables data
– x-bar and R-charts
– x-bar and s-charts
– Charts for individuals (x-charts)
 Attribute data
– For “defectives” (p-chart, np-chart)
– For “defects” (c-chart, u-chart)

7
Developing Control
Charts

1. Prepare
– Choose measurement
– Determine how to collect data, sample
size, and frequency of sampling
– Set up an initial control chart
2. Collect Data
– Record data
– Calculate appropriate statistics
– Plot statistics on chart
Next Steps

3. Determine trial control limits


– Center line (process average)
– Compute UCL, LCL
4. Analyze and interpret results
– Determine if in control
– Eliminate out-of-control points
– Recompute control limits as
necessary
Key Idea

When a process is in statistical


control, the points on a control chart
fluctuate randomly between the
control limits with no recognizable
pattern.
Typical Out-of-Control
Patterns
 Point outside control limits
 Sudden shift in process average
 Cycles
 Trends
 Hugging the center line
 Hugging the control limits
 Instability
16
Shift in Process Average
Identifying Potential
Shifts
Cycles
Trend
Final Steps

5. Use as a problem-solving
tool
– Continue to collect and plot
data
– Take corrective action when
necessary
6. Compute process capability
Key Idea

Control charts indicate when to take


action, and more importantly, when
to leave a process alone.
Process Capability
Calculations
Spreadsheet Template
Special Variables Control
Charts

 x-bar and s charts


 x-chart for individuals
Key Idea

Control charts for individuals offer


the advantage of being able to draw
specifications on the chart for direct
comparison with the control limits.
Charts for Attributes

 Fraction nonconforming (p-chart)


– Fixed sample size
– Variable sample size

 np-chart for number nonconforming

 Charts for defects


– c-chart
– u-chart
Key Idea

Confusion often exists over which


chart is appropriate for a specific
application, because the c- and u-
charts apply to situations in which
the quality characteristics
inspected do not necessarily come
from discrete units.
Control Chart Formulas
Control Chart Selection

Quality Characteristic
variable attribute
defective defect
no
n>1? x and MR
yes constant
yes constant
p or sampling
sample
np unit?
n>=10 or no size?
x and R
computer? yes no
no
yes
p-chart with c u
x and s variable sample
size 31
Control Chart Design
Issues
 Basis for sampling
 Sample size
 Frequency of sampling
 Location of control limits

32
Key Idea

In determining the method of


sampling, samples should be chosen
to be as homogeneous as possible
so that each sample reflects the
system of common causes or
assignable causes that may be
present at that point in time.
Key Idea

In practice, samples of about five


have been found to work well in
detecting process shifts of two
standard deviations or larger. To
detect smaller shifts in the process
mean, larger sample sizes of 15 to
25 must be used.
Economic Tradeoffs
Pre-Control

LTL UTL

Red Red
Zone Green Zone Zone

nominal
value

Yellow Zones 37
Key Idea

Pre-control is not an adequate


substitute for control charts and
should only be used when process
capability is no greater than 88
percent of the tolerance, or
equivalently, when Cp is at least
1.14. If the process mean tends to
drift, then Cp should be higher.

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