Statistical Process

Control
(SPC)

K. N. RAI
Quality Growth Services Pvt. Ltd.
H-13, Kirti Nagar, New Delhi, India
E-mail: qgs@qgspl.com,
Website: www.qgspl.com
Phone: +9111-25431737 / 25918332

AGENDA – For This Course

 Voice of Customer
 Voice of Process & SPC
 Variation
 Control & Normal Distribution
 Control Charts Concept – Variables &
Attribute
 Control Charts-Variable
Additional interpretation
 Process Capability & Performance
 Control Charts – Attributes
 Process Capability Attribute
QGS/SPC Rev 01 2

1
ULTIMATE GOAL OF AN ORGANIZATION
Profits, Survival and Growth: How?
Products & Services must be preferable to
Customers over Competitors
Organization must continually meet Needs &
Expectations of Customers
i.e. Voice of Customers also called QUALITY

QGS/SPC Rev 01 3

Voice of Customer:
How to meet?
Must understand voice of customer
Must deploy it in
 Voice of Design (Design Width) and

 Voice of Process (Process Width)

“APQP” is a platform to satisfy the above needs
QGS/SPC Rev 01 4

2
 Process Control System
PRODUCT
THE
or
PROCESS
SERVICE

A PRODUCT OR SERVICE IS THE

RESULT OF A PROCESS

QGS/SPC Rev 01 5

Traditional Philosophy
– Goal Post Mentality

LSL USL

2 1 4
5

3
6

Is there a meaningful
difference between
kicks 2 and 6?

QGS/SPC Rev 01 6

3
 Traditional Philosophy

LSL USL

Anything outside
the specification limits
represents QUALITY LOSSES

Goalpost Mentality
QGS/SPC Rev 01 7

Is 100% Inspection 100% correct?

 Task: You have 60 seconds to document the number of times the
6th letter of the alphabet appears in the following text.

The Necessity of Training Farm Hands for First

Class Farms in the Fatherly Handling of Farm Live
Stock is Foremost in the Eyes of Farm Owners.
Since the Forefathers of the Farm Owners Trained
the Farm Hands for First Class Farms in the
Fatherly Handling of Farm Live Stock, the Farm
Owners Feel they should carry on with the Family
Tradition of Training Farm Hands of First Class
Farmers in the Fatherly Handling of Farm Live
Stock Because they Believe it is the Basis of Good
Fundamental Farm Management.
QGS/SPC Rev 01 8

4
PROCESS CONTROL: A BETTER APPROACH

M ethod
E nvironment PRODUCT
THE
P eople or
E quipment PROCESS
SERVICE
M aterial

•Listen Voice of Process

Collect

Act Record
Analyze

VOICE OF THEQGS/SPC
PROCESS Rev 01 9

VOICE OF THE CUSTOMER

Identifying Changing needs

& expectations

M ethod
E nvironment PRODUCT
THE
P eople or
E quipment PROCESS
SERVICE
M aterial
Data collection ,
Analysis &
Collect feedback to
Control Process
Act Record Inputs is a key
Analyze to Defect
Prevention.
VOICE OF THE PROCESS
QGS/SPC Rev 01 10

5
 LEARNING
VOICE OF
PROCESS
THROUGH SPC
QGS/SPC Rev 01 11

SPC HISTORY
Developed By
Dr. Walter A. Shewhart
During 1920’s in Bell Lab

Since then SPC has evolved to cover

different processes

QGS/SPC Rev 01 12

6
 SPC : Biggest Mis-concept:
SPC requires an in-depth and vast
STATISTICAL KNOWLEDGE

In fact, SPC can be said to involve:

15% Statistics
30% Common Sense
60% Effectively applied Job Knowledge

QGS/SPC Rev 01 13

KNOWLEDGE GENERATED BY SPC

WHAT A PROCESS CAN DO AND WHAT IT CANNOT DO

WHAT THE PROCESS IS SUPPOSED TO DO, AND WHAT IT

IS ACTUALLY DOING

WHEN A PROCESS SHOULD BE CORRECTED AND WHEN

IT SHOULD BE LEFT ALONE

HOW THE PROCESS IS DETORIATING

14

7
 GAINS OF SPC
1. REDUCES REJECTION
2. PARTS CAN BE EASILY ASSEMBLED
3. PARTS-CAN BE EASILY CHANGED IN THE FIELD
4. PERFORMANCE OF PRODUCTS IS IMPROVED
5. REDUCES COMPLAINTS OF CUSTOMERS
6. INCREASES PRODUCTION
7. REDUCES COST
8. REDUCES WASTAGES OF TIME
9. INCREASES CONFIDENCE OF CUSTOMERS.

15

BASIC CONCEPTS OF STATISTICS.

SIX PRINCIPLES:
1. VARIATION IS THE LAW OF NATURE. AS SUCH, NO TWO THINGS ARE
EXACTLY ALIKE.

2. VARIATION IN A PRODUCT OR PROCESS CAN BE MEASURED.

3. THINGS VARY ACCORDING TO A DEFINITE PATTERN.

4. WHENEVER MANY THINGS OF THE SAME KIND ARE MEASURED, A LARGE

GROUP OF THE MEASUREMENTS WILL TEND TO CLUSTER AROUND THE
MIDDLE.

5. IT IS POSSIBLE TO DETERMINE THE SHAPE OF THE DISTRIBUTION CURVE

FOR PARTS PRODUCED BY ANY PROCESS.

6. VARIATIONS DUE TO ASSIGNABLE CAUSES TEND TO DISTORT THE NORMAL

DISTRIBUTION CURVE.
16

8
 1.2 1.3 1.4 1.5 1.6 1.7 1.8

VARIATION:
The basic principle of SPC

QGS/SPC Rev 01 17

One Problem With Mother Nature

Everything is Different

VARIABILITY
• No two people are same…
• Temperature changes continuously…
• The products we produce change
continuously…

QGS/SPC Rev 01 18

9
 VARIABILITY
 All processes display variation e.g.
 Aeroplane never lands or takes off at Dot
scheduled time (Variations from schedule )
 Train Never comes / departs at scheduled
Dot time (Variation from schedule)
 We never reach office / factory at Dot
scheduled time (Variation from Specs)

 This means VARIATIONS from defined

schedules (Specifications)

QGS/SPC Rev 01 19

VARIABILITY
Output Y= f(Inputs “x”);
So, Data in general, fluctuates because of :
Changes in Process Inputs e.g.
• Material Differences
• Equipment Differences
• Human Performance Differences
• Power Fluctuation, etc.
• And Many other variable Inputs
QGS/SPC Rev 01 20

10
 Let us Watch Coin Game

Distance

QGS/SPC Rev 01 21

The variation in the

distance traveled,
if stable, can be described
as a DISTRIBUTION

Distance

QGS/SPC Rev 01 22

11
 Distance

QGS/SPC Rev 01 23

Common Causes
• Common to all individual readings in
time periods.

A process operating under common

causes is called under :
Statistical Control
QGS/SPC Rev 01 24

12
 Special Causes
• Sudden in nature
• Usually attract the attention of local
people associated with the process.

They are not common to all time periods,

but they can cause process fluctuations
which are large in magnitude. Also called
as “Assignable Causes”.
QGS/SPC Rev 01 25

If only common cause of variation are present. The voice of

the process is stable & predictable and is said to be under
statistical control

Prediction

Prediction???

If special cause of variation are

present. The voice of the process
is neither stable nor predictable
and is said to be out of control
QGS/SPC Rev 01 26

13
Distributions can differ in;

Location Spread

Shape

Or any combination
of these….
QGS/SPC Rev 01 27

Few Basic Concepts of Statistics

POPULATION:
Consists of all members of the Group about which
conclusion to be drawn

SAMPLE :
Portion of Population selected for Analysis

PARAMETER :
Numerical measure that describes a characteristics of
a population

STATISTICS :
Numerical measure that describes a characteristics of
a sample QGS/SPC Rev 01 28

14
“Population Parameters” vs. “Sample Statistics” of
Central Tendency
Population
Sample
µ = Population Mean

Population
 = Sample Standard
Standard Deviation
Deviation

Sample Estimates Population

Statistics Parameters
QGS/SPC Rev 01 29

MEAN
The Mean of ‘n’ numbers is the total of the
numbers divided by ’n’

In Standard Mathematical Notation it is

The symbol ” means ‘sum of’

QGS/SPC Rev 01 30

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 Measure of Spread or
Dispersion
Range : The difference between the Largest and the
Smallest of a set of numbers. It is designated
by a capital “R”

QGS/SPC Rev 01 31

Measure of Spread or Dispersion

Standard Deviation : The average distance between
the individual numbers and the mean. It is
designated by “”

 ( x1  x) 2  ( x2  x) 2 ....( xn  x) 2

n 1

QGS/SPC Rev 01 32

16
 HISTOGRAM
Histograms give a Graphical View of the
distribution of the values
It reveals the amount of variation that any
process has within it.
5

4
FREQUENCY 3

64 65 66 67 68 69 70 71 72
HEIGHT (mm)
QGS/SPC Rev 01 33

The Normal Distribution Curve

-3 -2 -1 + +2 +3

68.26%
95.46%
99.73%
99.99999975% of the data lies within ± 6  of the mean !!!
QGS/SPC Rev 01 34

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• Hence, “Prediction” can be made
about the “Process”

By collecting sample data from the

process and computing their :

• Mean;
• Standard Deviation; &
• Shape
QGS/SPC Rev 01 35

For routine process control, we need

• Simple computation
• Be used by operators for ongoing process control
• Help the process perform consistently , predictably for quality
and cost
• Achieve
• Less variation in output
• Lower unit cost
• Increase effective capacity
• Provide a common language for discussing process
performance
• Distinguish Special (Assignable) Causes from Common
causes of variation , as a guide for Local or Management
Actions. QGS/SPC Rev 01 36

18
 CONTROL CHARTS
• Transformation of a normal distribution curve in the form of 3
parallel lines, where
• The middle line indicates mean and called central line (C.L.)
• The upper line indicates Mean +3 Sigma and called upper control limit (UCL)
• The lower line indicates Mean -3 Sigma and called lower control limit (LCL)

U.C.L.
+3

Mean C.L.

-3
L.C.L.
QGS/SPC Rev 01 37

Types of Data
• Attribute • Variable
 Anything that can be  Anything that can be
classified measured
 Either/Or  Height
 Pass/ fail  Rupees
 Good/ Bad  Distance
 Go/No Go  Speed
 Discrete  Continues, infinite
 Detection Oriented  Stimulates Prevention

QGS/SPC Rev 01 38

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 Control Charts

Variable
 Average and Range ( X-R )
 Individual and Moving Range - IMR (X - MR)
 Median Range Charts

Attribute
 p / np Chart : Unit Nonconforming (Defectives)
 c / u Chart : Number of Nonconformities (Defects)

QGS/SPC Rev 01 39

Steps for Control Charts

1. Fulfill precondition
2. Complete preparatory steps
3. Data Collection
4. Making Trial Control Limits
5. Validation of Control limits
6. Process capability Study
7. On going control
8. Improvement
QGS/SPC Rev 01 40

20
 CONTROL CHARTS (Variable)
Average-Range ( X-R ) Chart
 Precondition:
Measurement must be variable
Situation must be practically feasible to have
at least 2 measurements in short span.
 Preparatory Steps
Create a suitable (conducive) environment
Understand the process (e.g CE Matrix)
Ensure Level 1 control i.e. Minimize un-
necessary variations .
QGS/SPC Rev 01 41

Average-Range ( X-R)Chart
 Preparatory steps
Select the Subgroup Size
 Rational Subgroup: Variability within subgroup should be small

QGS/SPC Rev 01 42

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 CONTROL CHARTS (Variable)
Average-Range ( X-R )Chart

 Preparatory steps
Select Subgroup Frequency
 Which can “Detect” change in the Process over span
of time.
 For initial study, may be consecutive or a very short
interval.

QGS/SPC Rev 01 43

CONTROL CHARTS (Variable)

Average-Range ( X-R )Chart
 Preparatory steps
Select No. of Subgroups
(for initial study: to define the control limits)
 To incorporate Major source of variation (Generally
25 subgroups or more containing about 100
individual measurements)
Decide Measurement system: Should qualify
MSA

QGS/SPC Rev 01 44

22
 Average-Range ( X-R)Chart
 Data Collection
 On a data collection sheet, called “Control Chart Sheet”

QGS/SPC Rev 01 45

AVERAGE RANGE CHART

46

23
AVERAGE-RANGE CONTROL CHARTS X-R

 Calculate Average of each Subgroup

X = ( X1 + X2 + … + Xn )/ n

 Calculate Range of each Subgroup

R= Xmax. - Xmin.
 Calculate Process average
=(X1 + X2 + … + Xk)/ k
X
 Calculate Average Range
R = (R1 + R2 + … + Rk )/ k
 X1, X2,…., Xn are individual values within the subgroup
 n is the Subgroup Sample Size
 k = No. of Subgroups

47

AVERAGE-RANGE CONTROL CHARTS

 Calculate Trial Control Limits for Range Chart

UCLR = D4 R
LCLR = D3 R.
 Calculate Trial Control Limits for Average Chart
UCLX = X + A2 R
LCLX = X - A2 R
 D4, D3 and A2 are constant varying as per sample size (n).

48

24
 AVERAGE RANGE CHART

49

AVERAGE-RANGE CONTROL CHARTS

 Calculate Trial Control Limits for Range Chart
UCLR = D4R
LCLR = D3 R.
 Calculate Trial Control Limits for Average Chart
UCLX = X + A2 R or Z σX-bar
LCLX = X - A2 R or Z σX-bar

 D4, D3 and A2 are constant varying as per sample size (n)

 Z is number of Standard Deviations within normal distribution (Usually
taken as 3 for 99.73% Confidence)

QGS/SPC Rev 01 50

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 TABLE OF CONSTANTS FOR
CONTROL CHARTS

QGS/SPC Rev 01 51

AVERAGE RANGE CHART

QGS/SPC Rev 01 52

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DRAW AVERAGE- RANGE CHART

QGS/SPC Rev 01 53

AVERAGE-RANGE CONTROL CHARTS

 Typical X bar – R Chart

QGS/SPC Rev 01 54

27
 QGS/SPC Rev 01 55

INTERPRETATION FOR CONTROL CHART

Identify any Out of Control or Special Cause situation
 Any point above UCL or below LCL:

QGS/SPC Rev 01 56

28
INTERPRETATION FOR CONTROL CHART

 Interpretation should be started with R-Chart first

 For each indication of Special Cause, analysis

should be done to identify the “Root Cause” and
action to be taken.

QGS/SPC Rev 01 57

INTERPRETATION FOR CONTROL CHART

 For initial control chart,
 Discard all the subgroup showing out of control situation (starting from R-
Chart)
 Re-Calculate Control Limits, plot and analyse for any out of control
situation.
 Re discard if any out of control situation again found.
 Continue the above cycle until all plot indicate a control situation.
 Repeat same exercise with Average chart.
 If more than 50% data are required to be discarded, reject all data and
re-collect.
 Once initial control chart indicates control situation,

 Calculate Initial Capability

 Extend control limits for ongoing control.
QGS/SPC Rev 01 58

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 Voice of the Process

-3  +3 

Process Width
Design Width

LSL T USL
Voice ofQGS/SPC
the Customer
Rev 01 59

PROCESS CAPABILITY

 Calculate Process Standard Deviation ( )

 = R/d2

d2 is a constant varying as per sample size (n)

 Calculate Process Capability (Cp)

Cp = (USL - LSL) / 6 USL = Upper Specification Limit
= Tolerance/ 6 LSL = Lower Specification Limit

 Calculate Process Capability (Cpk)

CpkU = (USL -X) / 3
or CpkL = (X - LSL) / 3
Whichever is “Minimum” will be Cpk
QGS/SPC Rev 01 60

30
PROCESS CAPABILITY
Standard Deviation () = R/d2 USL = 0.900
= 0.169/2.33 LSL = 0.500
= 0.0725
Process Capability
Cp = (USL - LSL) / 6 = (0.900 - 0.500) / 6 x 0.0725
= 0.920
CpkU = (USL - X) / 3 = (0.900 - 0.738) / 3 x 0.0725
= 0.743
CpkL = (X - LSL) / 3 = (0.738 - 0.500) / 3 x 0.0725
= 1.093
Cpk = 0.743
LSL USL

X

1.093 0.743
QGS/SPC Rev 01 61

Process Capability:
Cp Cpk Remarks

 Process Capable
 Continue Charting
 Bring Cpk closer to Cp

X
 Process has potential Capability
 Improve Cpk by Local action

X X
 Process lacks basic Capability
 Improve process by Management
action

QGS/SPC Rev 01 62

31
INTERPRETATION FOR CONTROL CHART
Identify any out of control or special cause situation
 Any point above UCL or below LCL:

QGS/SPC Rev 01 63

INTERPRETATION FOR CONTROL CHART

(During On-going Control)
 2/3 of the plotted points should be 1/3 region
between the Control Limits
 1/3 of the plotted point should be 2/3 region
between the Control Limits.

QGS/SPC Rev 01 64

32
INTERPRETATION FOR CONTROL CHART
 7 Points in a row on one side of the average (AIAG):
 7 Points in a row consistently increasing or decreasing

QGS/SPC Rev 01 65

Tests 1 & 2
Test 1. One Point Beyond Zone A
x
UCL
A
B
 Test 2
C  Caused by a process
C mean shift
B
A
LCL Test 2. Nine Points in a Row
x on One Side of the Center Line
UCL
 Test 1 – Basic Test. A
B
 Caused by a large C
change in the process C
B x
 Requires immediate A
LCL
action
QGS/SPC Rev 01 66

33
Tests 1 & 2 – Demonstration
X-bar

Rule
#2 Rule
#1
LCL UCL

     

QGS/SPC Rev 01 67

Tests 3 & 4
Test 3. Six Points in a Row Steadily
 Test 4 – Alternating
Increasing or Decreasing Patterns
UCL
A
 Over adjustment
B x  Shift-to-Shift variation
C
C
 Machine-to-machine
B variation
A x
LCL Test 4. Fourteen Points in a Row
Alternating Up and Down
 Test 3 – Trends up or UCL
A
down B
x
C
 Caused by C
 Mechanical wear B
 Chemical depletion A
LCL
 Increasing contamination
 Etc. QGS/SPC Rev 01 68

34
Test 3 – Demonstration
X-bar

Rule
#3

LCL UCL

     

QGS/SPC Rev 01 69

Test 4 – Demonstration
X-bar

Rule
#4

LCL UCL

     

QGS/SPC Rev 01 70

35
Tests 5 & 6
Test 5. Two Out of Three Points in a
Row in the same Zone A or Beyond
 Test 6
x x  Another test for shifts
UCL
A
 Test 1, 5, 6 are related
B
C and show conditions of
C high special cause
B
A
variability.
LCL
x
Test 6. Four Out of Five Points in a
row in the same Zone B and Beyond

 Test 5 UCL
A
x

 The second basic test B

C
 High variation w/o C
x
exceeding the 3 limit B
A
 Major special-cause LCL

variation QGS/SPC Rev 01 71

Test 5 & 6 – Demonstration

X-bar

Rule
Rule
#6
#5

LCL UCL

     
How do you calculate the probabilities?QGS/SPC
What are they?
Rev 01 72

36
Tests 7 & 8
Test 7. Fifteen Points in a Row in Zone C
(Above and Below Centerline)

UCL
A  Test 8 – Alternating Means
B x  Mixtures
C  Over control
C  Two different processes on the
B same chart
A Test 8. Eight Points in a Row on Both Sides
LCL
of Centerline with None in Zone C

UCL
 Test 7 – The Whitespace A
x
Test B
C
 Occurs when within subgroup
C
variation is large compared to B
between group variation or, A
 Old or incorrectly calculated LCL

limits
QGS/SPC Rev 01 73

Test 7 & 8 – Demonstration

X-bar
Rule
#7
Rule
#8
LCL UCL

     
How do you calculate the probabilities?QGS/SPC
What are they?
Rev 01 74

37
Interpretation Exercise
 Interpret these control
charts according to the
previous eight rules.

 Are there any out of

control conditions?
Which rule?

QGS/SPC Rev 01 75

INTERPRETATION FOR CONTROL CHART

X Bar Chart R CHART CONCLUSION

Under Control Under Control Enjoy

Under Control Out of Control Spread Changed

Out of Control Under Control Location Changed

Out of Control Out of Control Both Spread & Location

Changed

QGS/SPC Rev 01 76

38
INTERPRETATION FOR CONTROL CHART
OUT OF CONTROL / POSSIBLE CAUSES
SPECIAL CAUSE R-Chart X-Bar R Chart
SITUATIONS
Any Point Above UCL -Miscalculated/mis-plotted -Miscalculated / Mis-plotted
control limits / plot points Control Limits / Plot Points
-Measurement System Changed -Measurement System Changed
-Variability increased
Any Point Below LCL -do- -do-
7 Points in a Row above Avg. or -Spread Increased / Increasing -Process Average Changed or
Increasing -Measurement System Changed Changing
-Measurement System Changed
7 Points in a Row below Avg. or -Spread Decreased/ Decreasing -do-
Decreasing -Measurement System Changed
Substantially more than 2/3rd -Miscalculated/Mis-plotted Control Limits / Plot Points.
points in middle 1/3rd region -Process or Sampling method stratified
-Data is edited
Substantially fewer than 2/3rd -Miscalculated/Mis-plotted Control Limits / Plot Points.
points in middle 1/3rd region -Process or Sampling method stratified
QGS/SPC Rev 01 77

PROCESS CAPABILITY
• To measure the ability of the process to meet the specification
(Voice of Customer).

When Calculate Process Capability ?

 All the Assignable Causes are removed
and
 Process operates under Common
Causes

QGS/SPC Rev 01 78

39
PROCESS PERFORMANCE
Standard Deviation s =  (xi-X)2
i=1
for n=80

n-1 USL = 0.900

LSL = 0.500
Process Performance
Pp = (USL - LSL) / 6s = (0.900 - 0.500) / 6 x 0.0759
= 0.880
PpkU = (USL - X) / 3s = (0.900 - 0.738) / 3 x 0.0759
= 0.710
PpkL = (X - LSL) / 3s = (0.738 - 0.900) / 3 x 0.0759
= 1.045
Ppk = 0.710

QGS/SPC Rev 01 79

STOP LIGHT CONTROL CHARTS

 One chart to control location

and spread
 Three parts of control chart
 Target
 Warning (Low & High)
 Stop

QGS/SPC Rev 01 80

40
STOP LIGHT CONTROL CHARTS

 One chart to control location

and spread
 Three parts of control chart
 Target
 Warning (Low & High)
 Stop

QGS/SPC Rev 01 81

STOP LIGHT CONTROL CHARTS

+3
Mean

-3

QGS/SPC Rev 01 82

41
STOP LIGHT CONTROL CHARTS

• Follows double sampling plan

• Check 2 pieces.
• If in green, continue
• If any in red, stop -
• If one or both in yellow, go for re-sampling
• Check 3 pieces,
• If any in red, stop
• If 3 out of 5 in green, continue

QGS/SPC Rev 01 83

MOVING RANGE (IMR) CONTROL CHARTS

The Control Chart used for :

Slow production rate; or

Destructive testing; or

Homogenous process

QGS/SPC Rev 01 84

42
MOVING RANGE CONTROL CHARTS

QGS/SPC Rev 01 85

MOVING RANGE CONTROL CHARTS

QGS/SPC Rev 01 86

43
MOVING RANGE CONTROL CHARTS

 Upper Control Limits UCLX = X+E2R

 Lower Control Limits LCLX = X-E2R
 Upper Control Limits UCLR = D4R
 Lower Control Limits LCLR = D3R

Subgroup Size (n) d2 D3 D4 E2

2 1.128 - 3.267 2.660

QGS/SPC Rev 01 87

TABLE OF CONSTANTS –
CONTROL CHARTS

QGS/SPC Rev 01 88

44
SPC – Charts For All Occasions
%
Variable No Defective or Defects
Data? Defects?

Yes % Defective

No Constant Constant
Rational
I & MR chart Sample Sample
Subgroups?
Size? Size?

No No
Yes Yes Yes

p-chart u-chart
Yes Easy to
Subgroup
Compute
Size >9?
sigma?
np- or p-chart c- or u-chart
No Yes
No

X-bar & R chart X-bar & S chart

QGS/SPC Rev 01 89

CONTROL CHARTS (Attributes)

Why Attribute Control Charts
 For both technical as well as
administrative Process Control
 No additional data required
 Quick and inexpensive to obtain
 Prioritize Problem Areas

QGS/SPC Rev 01 90

45
CONTROL CHARTS (Attribute)
 Select Subgroup Size
For p-chart, sufficiently large so that np>5)

 Select Subgroup Frequency

Detect change in the Process over span of time

 Select No. of Subgroups

Major source of variation incorporate (25 or more)

QGS/SPC Rev 01 91

P Control Charts

QGS/SPC Rev 01 92

46
P Control Charts

QGS/SPC Rev 01 93

P Control Charts
 Calculate the Proportion Defectives
P= nP/n
n = no. of items inspected
nP = no. of Defectives
 Calculate Average Proportion Defectives

P = n1P1 + n2P2 + … + nkPk = P1 + P2 + … + Pk

n1 + n2 +… + nk k
k = No. of Subgroups
 Calculate Upper & Lower Control Limit

UCL = P +3 P(1- P) n

LCL = P -3 P(1- P) n

NOTE: If the Sample Size variation is 25% of the Average Sample Size take the value Average n for UCL & LCL
calculation QGS/SPC Rev 01 94

47
P Control Charts

QGS/SPC Rev 01 95

np Control Charts
Calculate the Average Number of Defectives
np = (n1p1 + n2p2 + … + nkpk) /k
np = No. of Defectives in Sample Size (n)
k = No. of Subgroups
n = Sample Size

Calculate Upper & Lower Control Limit

UCL = np +3np (1- np/n)

LCL = np -3np(1- np/n)

QGS/SPC Rev 01 96

48
Process Capability for Attribute

Capability (Attribute) = 1-P bar

Or with the help of Z-table

QGS/SPC Rev 01 97

C Control Charts

QGS/SPC Rev 01 98

49
C Control Charts

QGS/SPC Rev 01 99

C Control Charts

 Calculate Subgroup Proportion Non Conformity

C= Total no. of defects in a Sample Size (n)

 Calculate Process Average Proportion Non Conformity

C = (C1 + C2 + … + Ck)/ k
k = No. of Subgroups

 Upper Control Limit (UCL) = C +3C

 Lower Control Limit (LCL) = C -3C

QGS/SPC Rev 01 100

50
C Control Chart

QGS/SPC Rev 01 101

U Control Charts
 Calculate Subgroup Proportion Defects
U= C/n
n = Variable Sample Size

 Calculate Process Average Proportion Defects

U = C1 + C2 + … + Ck
n1+n2+n3 …. + nk

 Upper Control Limit (UCL) = U +3 U / n

 Lower Control Limit (LCL) = U -3 U / n

NOTE: If the Sample Size variation is 25% of the Average Sample Size take the value
Average n for UCL & LCL calculation

QGS/SPC Rev 01 102

51
 Other Charts – Good for Operators
Pre-Control
Same as Stoplight but meant for Non-conformance
control instead of Process Control
Based on Process Specifications & not on Process
Variations (i.e. Sigma)
First ensure that Process has Flat Loss Function &
Process Performance is less than or equal to
Tolerance which means :
 That all special sources of variations in the process are
being under Control
 99.73% of pieces are being produced within specification
without sorting

QGS/SPC Rev 01 103

Other Charts – Good for Operators

Pre-Control
 For Pre-control Sampling also uses a
sample of 2, but before sampling starts, at USL
least first 5 consecutive parts must be in Mean + 1/2 Tol
Green Area.
 Follow Rules: Mean + ¼ Tol
 Two Points in Green, Continue
 One Point in in Green and Other in Yellow, Mean
Continue
 2 Points in a row in Y.Zone (same Zone), Mean - ¼ Tol
adjust process
 2 Points in Y.Zone (Opp. Zone), stop &
Mean - 1/2 Tol
investigate
LSL
 One Point in Red Zone, Stop & Investigate
 Whenever Process is adjusted, before sampling
starts, it must produce Five consecutive parts in
Green Zone
 Not to be used when Cp, Cpk > 1
QGS/SPC Rev 01 104

52
 THANK
YOU

QGS/SPC Rev 01 105

53