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MECN3006A - Industrial Engineering Laboratory

Title: SPC Statistical Process Control

Name: Ayman Abdelhady
Student Number: 1716159
Group Number: Group 25
Date: 06/09/2019

A laboratory report submitted to the School of Mechanical, Industrial and Aeronautical

Engineering, Faculty of Engineering and the Built Environment, and contributing towards
the course MECN3003 - Aeronautical Engineering Laboratory I

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Declaration

UNIVERSITY OF THE WITWATERSRAND, JOHANNESBURG

SCHOOL OF MECHANICAL, INDUSTRIAL AND

AERONAUTICAL ENGINEERING

INDIVIDUAL DECLARATION WITH TASK SUBMITTED FOR ASSESSMENT

I, Ayman Abdelhady___________________________________________, (Student number: 1716159_______________)

am registered for Course No. ____________, MECN3006__________________________________

_____________________________________________________________ in the year 2019_________.

I herewith submit the following task, Ergonomic lab___________________________________________

_________________________________________________________________________________”
in partial fulfilment of the requirements of the above course.

I hereby declare the following:

o I am aware that plagiarism (the use of someone else’s work without their permission and / or without acknowledging
the original source) is wrong;

o I confirm that the work submitted herewith for assessment in the above course is my own unaided work except
where I have explicitly indicated otherwise;

o This task has not been submitted before, either individually or jointly, for any course requirement, examination or
degree at this or any other tertiary educational institution;

o I have followed the required conventions in referencing the thoughts and ideas of others;

o I understand that the University of the Witwatersrand may take disciplinary action against me if it can be shown that
this task is not my own unaided work or that I have failed to acknowledge the source of the ideas or words in my
writing in this task.

Signature: ____________________________ Date: _______07/09/2019__________________

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Abstract

The SPC (Statistical Process Control) is useful in identifying and eliminating the various
causes of variation in any production process or production line. In this report, the SPC was
used to identify the problems in a specific department of a production line by looking at the
different charts associated with this method. The control charts of the SPC has proven that
there was an error in the process after testing two different samples as will be discussed later
in this report. The experiment was conducted in the school of Industrial Engineering at the
university of the Witwatersrand.

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Contents

Declaration ii

Abstract ii

1 Introduction 1

1.1 Background………………………………………………………………………...6
1.2 Problem Statement …………………………………………………………………….6
1.3 Research Question……………………………………………………………………….6
1.4 Research Objectives……………… ……………………………………………………6

2 Literature Review………………………………………………………………………7
3 Research Method……………………………………………………………………….8
4 Data, Analysis and Results ………………………………………………………8,9,10
5 Discussion…………………………………………………………………………….11
6 Conclusions………………… ……………………………………………………….12

References 13

APPENDICES 14

A Appropriate Title 1 14

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 1 Introduction

1.1 Background
Statistical Process Control (SPC) is methodology for controlling and measuring the quality of
a process during the manufacturing process [1]. It also provides control charts to monitor the
process behavior in order to eliminate any sort of problems in the manufacturing process [1].
SPC can be used to verify if a process is under control or not based on the different charts that
it provides. Once data is collected from the process, it is evaluated by limits. These limits are
known to be control limits [1]. There are two tools that can be used to illustrate any process
graphically; the control charts and the capability studies [1].
To determine if a process is under control or not, one has to look at the data collected; if data
collected lies in the control limits that means that the process is operating perfectly and is
under control. If data collected lies outside the control limits, that indicated that process is
out of control [1].
1.2 Problem Statement
SPC is tool that can be used in the production process to ensure that products produced
conform to certain specifications. It also allows for problem areas in the production process
to quickly solve any issues within the products before many parts are produced. Six Sigma is
a slandered that has been used by many companies to ensure the quality of the process and
the accuracy of the products produced. In this paper, a company has found that costumers are
not happy with some of the products produced by them. The company is not sure in which
part of the process the problem is coming from, therefore SPC shall be implemented to check
where is the problem coming from and quickly react to the problem before the company
produces more of the same products with the same defects.

1.3 Research Question

A question to be asked would be, how different are the products that are coming out of our
department’s operation? How can we eliminate the variation of the products coming out of
this operation?

1.4 Research Objectives

a. To analyze the information collected with regards the goods produced in a specific
section of the production process line.

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 b. Determine whether the section process is capable or not.
c. Establish if the section process is in a statistical control.
d. Investigate whether the specific section fits with the Six Sigma standards in process
control.

2 Literature review

The term Statistical Process Control means to make use of some statistical tools in order to
ensure the quality of the process and to establish control of the process as well [2].

2.1 Advantages of SPC:

For each step in the process, SPC can help in maintain the standards of the process and
ensures that each step conforms to the specifications [2]. It can be used at any section of the
process. Since SPC does not require any direct inspection, it has an advantage over other
methods of control quality as it assures the process will not be affected due to any external
interruption [2].

2.2 Disadvantages of SPC:

SPC might lead to loss of production as it only covers the “Out of control processes” and the
“In control processes” does not always conclude a wanted result [2].

One of the main fundamental tools for the graphical representation of the SPC is the control
chart which can be to identify faulty process from the data collected [2]. In control charts the
“Central line” passes though the middle of the graph which will be shown later in control
charts figures. Control limits can be calculated using the statistical data collected from the
process. These control limits determine the behavior of the process whether it is “in control”
or “out of control” [2]. There are two existing types of control limits; the Upper control limit
and the Lower control limit which can be denoted by UCL and LCL respectively. The two
equations (1) and (2) can be used to find the values of the UCL and LCL [2]:
𝑈𝐶𝑙 = 𝑐𝑒𝑛𝑡𝑒𝑟𝑎𝑙 𝑙𝑖𝑛𝑒 + 3 ∗ 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 (1)
𝐿𝐶𝑙 = 𝑐𝑒𝑛𝑡𝑒𝑟𝑎𝑙 𝑙𝑖𝑛𝑒 − 3 ∗ 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 (2)
Standard deviation of the data points can be calculated from the data collected. To determine
of the process is in or out of control, one must look at the points and their locations relating
them to the UCL and LCL and if the points are lies under the LCL, then that process is
considered to be “Out of control” [2].

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3 Research Method

1. Based on the ability of a statistical data to be appropriate to be used, determine the

right sample size to be selected.
2. For a specific department of the process, use Excel sheet to gather all the which
would then help in formulating statistical charts.
3. Based on Six Sigma specifications, establish the Z-score required for this process.
4. Using the right equations, calculate the Upper and Lower Control Limits of the
process.
5. Establish the specifications of the design of the parts produced.
6. Identify the number of faulty parts in the sample.
7. Establish the X, R, and Z charts.
8. Plot the data collected on the graphs against the UCL and the LCL.

Procedure

The specific departments of the production process that is described in this report was
conducted by taking the measurements of two different
samples of bolts as shown in figure 1 below. The lab was
conducted in groups where the group used Vernier Calliper
to take the measurements. All the data was recorded
immediately to an Excel sheet as it was advised by the lab
coordinator. All measurements were sorted in the form
shown in table 1 and 2 below.

Figure 1 The bolts used to take measurements.

4 Data and Analysis

4.1Data

The data was collected via Excel sheet as it showed how important it is to use the Excel sheet.
The data in table 1 is the recorded data collected from the process of Sample A. The data
collected was saved as the total length of the screws and the head length of the screws. By
subtracting them, we got the Nominal length which will then be used to plot the R-chart and
the 𝑥̅ -chart. In this process, the sample used was 5 samples and a frequency of 10 as shown

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 in the table below. The data in table 2 represents the data collected from sample C.
Table 2 The collected data of sample A
Nominal length A
1 2 3 4 5
1 39.98 39.76 39.9 39.96 39.5
2 39.96 39.96 39.84 39.98 39.9
3 39.76 39.88 39.72 39.68 39.75
4 39.9 39.86 39.86 39.92 39.94
5 40.02 40 39.84 40.08 39.92
6 39.88 39.72 39.98 39.8 39.86
7 39.9 39.88 39.8 39.9 39.76
8 39.84 39.88 39.9 39.98 39.96
9 39.9 39.84 40.04 39.94 39.96
10 39.76 39.92 39.78 40 39.9

Table 1 The collected data of sample C

Nominal length C
1 2 3 4 5
1 35.62 35.52 35.7 35.48 35.68
2 35.54 35.71 35.7 35.54 35.75
3 35.8 35.6 35.4 35.5 35.8
4 35.6 35.58 35.38 35.7 35.35
5 35.68 35.88 35.6 35.68 36.05
6 36.05 38.23 35.31 35.3 35.8
7 35.84 34.15 35.3 35 35.5
8 35.67 34.9 34.85 35.8 35.3
9 35.9 35.95 35.45 35.2 35.7
10 34.91 35.5 35.5 35.78 35.8

4.2 Data Analysis

Data processing was done by using the process control with the different measurements
measured. By using the two tables in the above, one can make the decision whether to say if
process were in control or out of control. By using these data, the R-chart and X chart can be
conducted with the limits and make decisions if the values lie within the limits control. As
mentioned earlier, the frequency of the sample was 10. Since Six Sigma must be used for
control limits, that means that the variables must be set to 3 standard deviations and that will
be below and above the Mean of the sample. The control
limits can be calculated by conducting the 𝑋̅-chart and the R-chart.
R-chart calculations:
𝑈𝐶𝐿(𝑅) = 𝐷4 𝑅̅ [3]

𝐶𝐿(𝑅) = 𝑅̅ [3]

𝐿𝐶𝐿(𝑅) = 𝐷3 𝑅̅ [3]

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 ̅ chart calculations:
𝐗
𝑈𝐶𝐿(𝑋̅) = 𝑋̅ + 𝐴2 𝑅̅ [3]

𝐶𝐿(𝑋̅ ) = 𝑋̅ [3]

𝑈𝐶𝐿(𝑋̅) = 𝑋̅ + 𝐴2 𝑅̅ [3]

Where 𝐷4 , 𝐷3 and 𝐴2 are constants that can be looked up from Factors for calculating limits
for variable control charts. For all values and calculations obtained look at Appendix A.
4.3 Results

Graphs were conducted by using the values in table 1 and table 2 by using equations mentioned
̅ chart for sample A are shown in figures 1 and 2 respectively.
above. R-chart and 𝐗

R-Chart Sample A
0.6
0.5
0.4
0.3
0.2
0.1
0
1 2 3 4 5 6 7 8 9 10

R-Chart CL UCL LCL

Figure 2 R-Chart of sample A.

x̅-Chart Sample A
40
39.95
39.9
39.85
39.8
39.75
39.7
39.65
39.6
1 2 3 4 5 6 7 8 9 10

Mean CL UCL LCL

Figure 3 𝑋̅ chart for sample A.

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 ̅ chart for sample C are shown in figures 3 and 4 respectively.
R-chart and 𝐗

R-Chart Sample C
3.5

2.5

1.5

0.5

0
1 2 3 4 5 6 7 8 9 10

R-Chart CL UCL LCL

Figure 4 R-Chart of sample C.

x̅-Chart Sample C
36.4
36.2
36
35.8
35.6
35.4
35.2
35
34.8
34.6
1 2 3 4 5 6 7 8 9 10

Mean CL UCL LCL

̅ chart for sample C.

Figure 5 𝑋

5 Discussion
Main idea behind using the control charts was to check and monitor the production process
and ensures that products that do not fall under the six sigma specifications and the three
standard deviation must be removed from the process before lots of it is been produced. If
the values of the mean values of the data collected lies outside the interval of the control
limits, that means the process is out of control and corrections must be considered.

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 In figures 2 and 3 which represent the control charts for the sample A. One can see that there
are some points that lie outside the UCL and LCL in both the charts; and that suggests that
the process is operating out of control.
In figure 5, the x̅-Chart suggests that the process is operating in process, however the R-chart
says the opposite. The R-chart in figure 4 says the process is out of control where there are
points outside the limits control. Therefore, for both samples the process was out of control
which means that the process must be checked, and actions must be taken in order to correct
the process.

6 Conclusions

• The manufacturing process for samples A and C are not in control and do not adopt
to the Six-Sigma and does not operate with the three-standard deviation.
• Process for both samples A and C are not capable.
After the data is collected and all the observations one can conclude that by using the SPC,
one can monitor any production process and check if there is a fault in the system and also
take an action quickly to solve the problem before faultier product been produced.

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References

[1] V. D. M. Tatjana V. ŠIBALIJA, "SPC AND PROCESS CAPABILITY ANALYSIS–

CASE STUDY," Faculty of Mechanical Engineering, University of Belgrade , Serbia,
2009.

[2] W. E. Deming, "Elementary principles of the statistical control of quality," Tokyo,

Nippon Kagaku Gijutsu Remmei, Tokyo, 2004.

[3] M. Grunow, "Control Limits: X-bar & R-Charts," Taylor and Francis Group, Munich,
2012.

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6 APPENDICES

A Calculations done to
find the R-chart and the
X-chart

• R-Chart Sample A

UCL = D4 * R(Bar) D4 = 2.114 2.114 0.414344

LCL = D3 * R(Bar) D3 = 0 0 0

Mean Range
1 39.74 0.48
2 39.93 0.14
3 39.755 0.08
4 39.92 0.08
5 39.97 0.24
6 39.87 0.26
7 39.83 0.14
8 39.9 0.1
9 39.93 0.2
10 39.83 0.24

• x̅-Chart Sample A
UCL = X(Bar Bar) + A2 R(Bar) 39.98059
CL = X(Bar Bar) 39.8675
LCL = X(Bar Bar) - A2 R(Bar) 39.75441

Mean CL UCL LCL

39.74 39.8675 39.98059 39.75441
39.93 39.8675 39.98059 39.75441
39.755 39.8675 39.98059 39.75441
39.92 39.8675 39.98059 39.75441
39.97 39.8675 39.98059 39.75441
39.87 39.8675 39.98059 39.75441
39.83 39.8675 39.98059 39.75441
39.9 39.8675 39.98059 39.75441
39.93 39.8675 39.98059 39.75441
39.83 39.8675 39.98059 39.75441

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 • R-Chart Sample C
UCL = D4 * R(Bar) D4 = 2.114 2.114 1.86032
LCL = D3 * R(Bar) D3 = 0 0 0

Number Mean Range

1 35.6 0.22
2 35.648 0.17
3 35.62 0.4
4 35.522 0.35
5 35.778 0.45
6 36.138 2.93
7 35.158 1.69
8 35.304 0.95
9 35.64 0.75
10 35.498 0.89

• x̅-Chart Sample C

UCL = X(Bar Bar) + A2 R(Bar) 36.09836

CL = X(Bar Bar) 35.5906
LCL = X(Bar Bar) - A2 R(Bar) 35.08284

Mean CL UCL LCL

35.65 35.667 36.17476 35.15924
35.645 35.667 36.17476 35.15924
35.8 35.667 36.17476 35.15924
35.475 35.667 36.17476 35.15924
35.865 35.667 36.17476 35.15924
35.925 35.667 36.17476 35.15924
35.67 35.667 36.17476 35.15924
35.485 35.667 36.17476 35.15924
35.8 35.667 36.17476 35.15924
35.355 35.667 36.17476 35.15924

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