Statistical Process Control

This is a control system which uses statistical

techniques for knowing, all the time, changes in the
process.

It is an effective method in preventing defects and

helps continuous quality improvement.
Statistical Process Control
Statistics are tools used to make predictions on
performance.
There are a number of simple methods for analysing
data and, if applied correctly, can lead to predictions
with a high degree of accuracy.
Statistical Process Control
The process involves people, machines, materials,
methods, management and environment working
together to produce an output, such as an end product.
Statistical Process Control
Controlling a process is guiding it and comparing
actual performance against a target.
Then identifying when and what corrective action is
necessary to achieve the target.
Statistics aid in making decisions about a process
based on sample data and the results predict the
process as a whole.
Definition
S.P.C. is statistical analysis of the predictability and
capacity of a process to give a uniform product
The Aim of S.P.C
Detection:
This focuses on identification of problems after
production, by 100% inspection or by customer
complaints.

It is a history-based strategy.

The Aim of S.P.C.

Detection Drawbacks:
 Production is already made.
 Customer dissatisfaction.
 Inflated costs - rework; inspection.
 Repetitive problems.
 Neglected improvements
Prevention:
This focuses on in-process production and
identification of problems through analysis of process
capability.

It is a future-orientated strategy.

Prevention Benefits:
 Improved design and process capability.
 Improved manufacturing quality.
 Improved organisation.
 Continuous Improvement.
The S.P.C. has to be looked at as a stage towards
completely preventing defects.
With stable processes, the cost of inspection and
defects are significantly reduced.
The Benefits of S.P.C.
Assesses the design intent.
Achieves a lower cost by providing an early warning
system.
Monitors performance, preventing defects.
Provides a common language for discussing process
performance
Process Variations
Process Element Variable Examples
Machine………………………….Speed, operating
temperature, feed rate
Tools………………………………..Shape, wear rate
Fixtures…………………………..Dimensional accuracy
Materials…………………………Composition,
dimensions
Operator…………………………Choice of set-up,
fatigue
Maintenance…………………Lubrication, calibration
Environment…………………Humidity, temperature
No industrial process or machine is able to produce
consecutive items which are identical in appearance,
length, weight, thickness etc.
The differences may be large or very small, but they
are always there.
The differences are known as ‘variation’. This is the
reason why ‘tolerances’ are used.
Stability
Common causes are the many sources of variation that
are always present.
A process operates within ‘normal variation’ when
each element varies in a random manner, within
expected limits, such that the variation cannot be
blamed on one element.
When a process is operating with common causes of
variation it is said to be stable.
Process Control
The process can only be termed ‘under control’ if it
gives predictable results.

Its variability is stable over a long period of time.

Process Control Charts
Graphs and charts have to be chosen for their
simplicity, usefulness and visibility.
They are simple and effective tools based on process
stability monitoring.
They give evidence of whether a process is operating
in a state of control and signal the presence of any
variation.
7 tools of Quality
Cause and Effect Diagram
Check Sheet
Control Chart
Flow Chart
Histogram
Pareto Chart
Scatter Diagram
Cause and Effect Diagram
Also known as Ishikawa diagram.
Ishikawa proposed this concept.
Looks like skeleton of a fish.
Idea is to identify and state the problem.
Then to find out all possible causes of that problem.
To draw this cause and effect diagram one has to think
logically and carefully.
Cause and effect diagram
Also called fishbone diagrams (because of their
shape).
Helps in identifying root causes of the quality failure.
Cause and Effect Diagram
Check Sheet

A form used to collect data in such a way that

it makes collection of data very easy
Analysis of data from that format is also very easy.
Check Sheet
Control Chart
Simple graph or chart
Time is depicted on X axis
The quality characteristic measured is depicted on Y
axis.
A control chart is a continuous graphic indication of
the state of the process with respect to a quality
characteristic being measured.
Control charts
 Control chart: Add Upper Control Limit and Lower Control
Limit to the run chart.
Procedure to Establish the Control
Charts
1. For each sample, an average is calculated
n
 Xij
j=1
X = n where X is the j-th measurement in the i-th sample.
i ij

2. Calculate the range within the sample:

R =X -X
i largest smallest

3. Calculate the GRAND AVERAGE:

N
 X
i
i=1
X = , where N is the number of subgroups.
N
4. Calculate the average of the sample RANGES:
N

R i

R i 1
N
5. Control limits for R-chart

LCL  D3 R , UCL  D4 R

6. Control limits for X-bar chart

UCL  X  A2 R
LCL  X  A2 R
where A2 D3 , and D4 are functions of sample size.
Flow Chart
A schematic diagram of a process including all the
steps or operations in the sequence they occur.
This will help in better understanding of the entire
process.
Flow chart
Process map identifies the sequence of activities or the
flow in a process.
Objectively provides a picture of the steps needed to
accomplish a task.
Helps all employees understand how they fit into the
process and who are their suppliers and customers.
Can also pinpoint places where quality-related
measurements should be taken.
Also called process mapping and analysis.
Histogram
Is a bar chart or bar graph
It is a graphical depiction of a number of occurrences
of an event.
Pareto Chart
A Pareto chart is nothing but a histogram
Where no. of occurrences of an event are arranged in
descending order.
Named after Vilfredo Pareto (1848-1923).
Used when one needs to separate important from
trivial
Scatter Diagram
Simplest and most useful.
A scatter diagram is a plot of one variable vs. another
variable.
Useful in finding relation between two factors.
Example : Yarn strength may depend upon Twist per
inch.
If slope is going up then +ve correlation.
If slope going down then –ve correlation.
If there is no pattern then there is no correlation.
Thank you!!