SPC

TRAINING
TAPIO MÄKINEN
30/4-1/5/2019
Statistical process control
Statistical process control (SPC) is a method of QUALITY CONTROL which employs STATISTICAL
METHODS to monitor and control a process. This helps to ensure that the process operates efficiently,
producing more specification-conforming products with less waste (rework or scrap). SPC can be
applied to any process where the "conforming product" (product meeting specifications) output can be
measured. Key tools used in SPC include run charts, control charts, a focus on continuous
improvement, and the design of experiments. An example of a process where SPC is applied is
manufacturing lines.
SPC must be practiced in 2 phases: The first phase is the initial establishment of the process, and the
second phase is the regular production use of the process. In the second phase, a decision of the
period to be examined must be made, depending upon the change in 5M&E conditions (Man, Machine,
Material, Method, Movement, Environment) and wear rate of parts used in the manufacturing process
(machine parts, jigs, and fixtures).
An advantage of SPC over other methods of quality control, such as "inspection", is that it emphasizes
early detection and prevention of problems, rather than the correction of problems after they have
occurred.
In addition to reducing waste, SPC can lead to a reduction in the time required to produce the product.
SPC makes it less likely the finished product will need to be reworked or scrapped.
Uses of capability analysis
You can use a capability analysis to determine whether a process is capable of producing output that
meets customer requirements, when the process is in statistical control.
Usually, the capability of a process is determined by comparing the width of the process spread to the
width of the specification spread, which defines the maximum amount of variation allowed based on
customer requirements. When a process is capable, the process spread is smaller than the
specification spread.
Process capability

When your process is centered and well within the specification limits, it is more capable of consistently
producing product that meets customer expectations.
A capability analysis can also indicate whether your process is centered and on target. In addition, it
estimates the proportion of product that does not meet specifications.
In Minitab, a capability study may also include additional analyses for checking assumptions:
Probability plots and goodness-of-fit tests, to assess the distribution of the data.
Control charts, to assess whether the process is in control.
You can use a capability analysis to answer questions such as: Is the variability of a process low
enough to consistently provide parts that fall within the specification limits?
Is the proportion of defectives consistently less than 5% during a month?
Is a temperature curing process capable across multiple batches of the product?
Does a process need to be shifted to operate within the specification limits?
1. R Chart
Show the information for the columns
in the current worksheet
Assistant – Control charts
I-MR Charts, otherwise
known as Individual (I) and
Moving Range (MR) Charts,
are Control Charts that are
used to examine continuous
data. ... Individual
(I)Chart plots individual data
points over a specified period
and is very useful to detect
the various trends and shifts
that are evident in the
process.
A P-chart is an attributes
control chart used with data
collected in subgroups of
varying sizes. Because the
subgroup size can vary, it
shows a proportion on
nonconforming items rather
than the actual count. P-
charts show how the
process changes over time.
Xbar-R charts are often used Xbar-S chart The center line for
collectively to plot the process mean the X-bar chart represents the
(Xbar) and process range (R) over average of the plotted points (also
time for continuous data. ... The R called the process mean). The center
chart is used to review the process line on the S chart is the average of
variation which must be in control to all subgroup standard deviations.
correctly interpret the Xbar chart.
A U-chart is an attributes
control chart used with data
collected in subgroups of varying
sizes. U-charts show how the
process, measured by the number
of nonconformities per item or
group of items, changes over time.
Nonconformities are defects or
occurrences found in the sampled
subgroup.
Monitor the variation (Range) of your
process when you have continuous data
in subgroups. Works best with subgroup
sizes of 8 or less.
 R Chart of Readings UCL Upper Control Limit
LCL Lower Control Limit
5 UCL=4.960 R Range. The difference between the
maximum and minimum data points in a
4 sample.
Sample Range

_
R=2.346
2

0 LCL=0

1 2 3 4 5 6
Sample
 2. X bar
Stat – Control Charts – Variables Charts for Subgroups - Xbar
 Xbar Chart of Readings
41.0 UCL=40.974

40.5
Sample Mean

40.0
__
X=39.735

39.5

39.0

38.5 LCL=38.497

1 2 3 4 5 6
Sample
 3. Probability Plot
Graph – Probability Plot
4. P Chart

Show the information for the columns

in the current worksheet
Assistant – Control Charts
 P Chart of Defective Units
0.11
UCL=0.10753

0.10

0.09
Proportion

_
P=0.08341
0.08

0.07

0.06 LCL=0.05929

1-May 4-May 7-May 10-May 13-May 16-May 19-May 22-May 25-May 28-May
Date
Tests are performed with unequal sample sizes.
Paint all the sample size 5. Display Descriptive Statistics

Stat - Basic Statistics – Display Descriptive

Statistics
 P Chart of Defective Units
0.11
UCL=0.10719

0.10

0.09
Proportion

_
P=0.08341
0.08

0.07

0.06 LCL=0.05963

1-May 4-May 7-May 10-May 13-May 16-May 19-May 22-May 25-May 28-May
Date
6. Process Capability
Sixpack Report of
Concentricity
 7. Capability Analysis

Stat – Quality Tools – Capability Analysis - Normal

 Capability Analysis for Concentricit
Report Card
Check Status Description
Stability The process mean and variation are stable. No points are out of control.

Number of You only have 3 subgroups. For a capability analysis, it is generally recommended that you collect at least 25 subgroups over a long
Subgroups i enough period of time to capture the different sources of process variation.

Normality The transformed data passed the normality test. As long as you have enough data, the capability estimates should be reasonably accurate.

Amount The total number of observations is less than 100. You may not have enough data to obtain reasonably precise capability estimates. The
of Data ! precision of the estimates decreases as the number of observations becomes smaller.
 Capability Analysis for Concentricit
Diagnostic Report
Xbar-S Chart
Confirm that the process is stable.
24

16

Mean
8

15

10
StDev

1 2 3

Normality Plot (λ = 0.00)

The points should be close to the line.

Normality Test
(Anderson-Darling)
Original Transformed
Results Fail Pass
P-value < 0.005 0.178
8. Individual Distribution Identification
9.CAPABILITY REPAIR TIME ANALYSIS
Assistant – Control Charts
Stat – Quality Tools – Capacity Analysis - Normal
The left box
summarizes the
keys statistics of
the process The right hand box is
provided potential and
overall capability
statistics

The lower box is

provided observed in
expected parts of
million rights
Stat – Quality Tools – Pareto Chart
UNCLEAR
UNCLEAR
10.BTR STEERING PROCESS
 I-MR Chart of BTR Steering Process
1
1 1 1
1
1180 6
1
2 1
1
2
2 2 2 2 2 2 2 2 UCL=1175.8
5 5 5 5 5
2 2 2
6 2 2
Individual Value

6 6 2 6 2 2 2 2 2
2
2 2
1160 2
2 2
2 _
X=1150
1140

LCL=1124.2
1120
19/10 10:07 19/10 10:22 19/10 10:35 19/10 10:56 19/10 11:07 19/10 11:21 19/10 11:30 19/10 11:42 19/10 11:53 19/10 12:07
Date/Time

UCL=31.70
30
Moving Range

20

__
10 MR=9.70
2

0 2
2 LCL=0
19/10 10:07 19/10 10:22 19/10 10:35 19/10 10:56 19/10 11:07 19/10 11:21 19/10 11:30 19/10 11:42 19/10 11:53 19/10 12:07
Date/Time

At least one estimated historical parameter is used in the calculations.

Stat – Control Chart – Variable Charts for Individuals – I-MR

DELETE
 I-MR Chart of BTR Steering Process
UCL=1191.16
1188
Individual Value

1176 2

_
1164 X=1165.36

1152 6

1140 LCL=1139.56
19/10 10:07 19/10 10:22 19/10 10:35 19/10 10:56 19/10 11:07 19/10 11:21 19/10 11:30 19/10 11:42 19/10 11:53 19/10 12:07
Date/Time

UCL=31.70
30
Moving Range

20

__
10 MR=9.70
2

0 2
2 LCL=0
19/10 10:07 19/10 10:22 19/10 10:35 19/10 10:56 19/10 11:07 19/10 11:21 19/10 11:30 19/10 11:42 19/10 11:53 19/10 12:07
Date/Time

At least one estimated historical parameter is used in the calculations.

THANK YOU