Statistical Process Control For All.: N. Miyamoto 4/june/2021

Statistical Process Control for all.
N. Miyamoto
4/June/2021
FMT Confidential
© 2013 Renesas Semiconductor KL Sdn Bhd.
©2021 Confidential & all rights reserved
FUJIMI-MICRO TECHNOLOGY SDN.BHD., All rights reserved.
Statistical Process Control Flow
Machine operating at normal condition
PC data collection & enter / link in SPC tool
OK Alarm NO
System Any data out of
PC re-sampling to confirm
judgment? spec limit?
Warning
YES System
Flow lot & provide info to engineer
judgment?
(email triggered by system)
Engineer judge & take action if Stop machine, Any data out of
required suspend lot & issue spec and / or
REPORT control limit?
Lot flow & stop machine
Machine repaired & confirmed by

technician
PC Data collection
Warning System Alarm

judgment?
OK
Proceed production
2 FMT Confidential
Statistical Process Control Rules
USL : Upper Spec Limit
- Warning (Engineer to judge / investigate)

LSL : Lower Spec Limit
UCL : Upper Control Limit
LCL : Lower Control Limit
i. 7 points in a row up/down (based upon points plotted on chart)
ii. 7 points in a row all on either side (based upon points plotted on chart)
iii. 2 out of 3 points in upper/lower Zone A and beyond (based upon points plotted on chart)
iv. 4 out of 5 points in upper/lower Zone B and beyond (based upon points plotted on chart)
v. 6 points in a row not changing (based upon points plotted on chart)
USL USL
UCL UCL
Zone A
Zone B
CL CL Zone C
Zone B
Zone A
LCL LCL
LSL LSL
3 FMT
©
©2013 Confidential
2013Renesas
RenesasSemiconductor KL Sdn
©2021
Semiconductor KL Bhd. Confidential
FUJIMI-MICRO
Sdn Bhd. & all rights
Confidential reserved
TECHNOLOGY
& all rights reserved SDN.BHD., All rights reserved.
Statistical Process Control Rules
USL : Upper Spec Limit
Alarm (Machine compulsory breakdown) LSL : Lower Spec Limit

UCL : Upper Control Limit
LCL : Lower Control Limit
i. 1 point out of specification (based upon each individual data)
ii. 1 point out of control limit (based upon point plotted on chart)
iii. 7 points in a row up/down all on one side (based upon points plotted on chart)
USL USL
USL
UCL UCL
UCL
CL CL
CL
LCL LCL LCL

LSL
LSL LSL
(i) (ii) (iii)
4 FMT
©
©2013 Confidential
2013Renesas
©2021
FUJIMI-MICRO
TECHNOLOGY
Limits setting
1) Control Limit for Average & Range

UCL = XDBar + (3 * StdDev(XBar_Data))
LCL = XDBar - (3 * StdDev(XBar_Data))
URL = RBar + (3 * StdDev(R_Data))
LRL = RBar – (3 * StdDev(R_Data))
Auto calculation formula will compute / re-compute control limit after sub-grouping.
2) Spec Limit shall be determined by Customer and Government

requirement.
5 FMT
©
©2013 Confidential
2013Renesas
©2021
FUJIMI-MICRO
TECHNOLOGY
Just image by Miyamoto : Electronic SPC & SBL for “Change Control ”
Machine/
Auto data capturing, alarming , e-mailing material
2 Process
1 Product SPC Chart
1) Product and Waste good

Characteristics
Inspection
e.g PH, Composition…
2) Process Characteristics
Customer e.g Volume, Weight,
Temp, Humidity, DI
water resistibility…
SPC : Statistical Process Control; SBL : Statistical Bin Limit

FMT Confidential
Acceptance Criteria for X & R Chart
USL Line & Control Zone of a Control Chart ISO/ IATF16949 That is for Automotive
UCL
8.1.2 Knowledge of basic statistical
Zone A
Upper concepts
Zone B
Zone C Zone Basic statistical concepts, such as
CL
Zone C variation, control (stability), process
Zone B Lower capability and over-adjustment shall be
Zone A Zone
LCL understood and utilized throughout the
organization
LSL
Trend of Chart Criteria Action Required

* Based upon points plotted on chart Machine Product
1 1 point out of specification (based upon each individual Alarm Repair / Adjustment Reject
data) (Reporting)
2) 1 point out of control limit* Repair / Adjustment Reject
(Reporting)
3) 7 points in a row up / down all on the same side* Repair / Adjustment Accept
4 7 points in a row up / down across 2 sides* Warning Monitor & Follow Up Accept
By Engineer.
5 7 points in a row all on either side*
If warning alarm is
6 2 out of 3 points in upper / lower Zone A & beyond* continual, review of
process limit is
7 4 out of 5 points in upper / lower Zone B & beyond*
required
8 6 points in a row not changing*
Note : – for alarm 2) and 3),

upon alarm triggered, Process Control PIC is given 2nd sampling chance for the measurement.
FMT Confidential
SPC trend / Run rules
Trend of Chart Criteria Action Required
* Based upon points plotted on chart Product Machine
1 1 point out of specification Alarm Reject Machine Repair /
(based upon each individual data) (Reporting) Adjustment
2) 1 point out of control limit*
3) 7 points in a row up / down all on the same side* Alarm
4 7 points in a row up / down across 2 sides* Warning Accept Monitor by Prod

and Engineer
5 7 points in a row all on either side* Warning Accept Action judged by

Engineer
(avoid over-
6 2 out of 3 points in upper / lower Zone A & beyond* Warning Accept adjustment)
-Review CL on
next revision (item
7 4 out of 5 points in upper / lower Zone B & beyond* 4,5)
8 6 points in a row not changing* - Machine

adjustment (item
6,7)
FMT Confidential
Example of Alarm Trend and Warning Trend
USL
UCL
Alarm / Warning
Zone A
CL
Zone B
Zone C
Upper Zone
Alarm
Zone C (7 point in a row up for the
Zone B Lower Zone same side)
Zone A
LCL
LSL
USL
UCL
Zone A
Warning
Zone B Upper Zone
Zone C (4 out of 5 point is
CL
Zone C beyond zone B)
Zone B Lower Zone
Zone A
LCL
LSL
USL
UCL
Zone A
Warning
Zone B Upper Zone
Zone C (2 out of 3 point is
CL
Zone C beyond zone A)
Zone B Lower Zone
Zone A
LCL
LSL
FMT Confidential
Cpk Expectation of Product Parameter
Cpk
scale
1 2 3 4 5
1.33 1.67 Judgement for full

confidence
Cpk expectation for 3.13
Cpk expectation for
Severe customer product”
“standard product”
SPC control SPC control

(3 sigma (3 sigma
control limit) control limit)
With trend / run With “alarm”
rule of warning rule only
+ alarm
FMT Confidential
SPC control is to detect special cause and improve common cause
Severe customer (e.g. Automotive) requirement :

Continue to improve product capability using statistical process control
Continue to
reduce
Variation by
USL eliminating
special
UCL( + 3 sigma) Improve UCL( + 3 sigma) cause
CL
LSL ( - 3 sgma) Improve LCL( - 3 sigma)

Cpk > 1.67 (based on sub-
Z = 5, groupimg)
Cpk =1.67 LSL
Initial Cpk data obtained Control limit review after

during qualification sub-group data from
mass production lots
FMT Confidential
What is the more High Capability Process?
• When a stable process has been showing high capability, SPC control can be stopped.
Judgement for stopping SPC control is Cpk > 3.13.
• Stopping SPC control refers only to the removal of trend/run rules.
• Sampling shall still proceed as normal and prompts for out of specification limit and control
limit still applies. Please refer the following flow.
Normal SPC
control
Cpk > NO
3.13
Why Cpk > 3.13? Criteria of
YES
Area from -Z to +Z
judging
Data NO Cpk > 3.13
Accurate?
as safety
YES margin for
Stop SPC control
(maintain sampling)
-Z
1.5sigma
+Z Confidence
Every 6 mths
- Assuming a shift of 1.5 sigma (closer to real life
application and non-symmetric distribution), as Z
process control
approaches 9.4, area reaches 100% (20 decimal
accuracy).
YES Cpk still >
- When Z = 9.4 , Cpk = 9.4 / 3 = 3.13
3.13?
FMT Confidential
Quality First mind-set enhancement
could aim to
Cost Competitiveness
On Time Delivery
then,
Customer satisfaction
Finally,
FMT should be more Profitable Company
and Employee Satisfaction Company.
*Quality means is not only for Product but also for all of FMT job.
Renesas Semiconductor KL Sdn. Bhd.

FMT Confidential

Statistical Process Control For All.: N. Miyamoto 4/june/2021

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Statistical Process Control for all.

PC data collection & enter / link in SPC tool

Lot flow & stop machine

Machine repaired & confirmed by

Warning System Alarm

- Warning (Engineer to judge / investigate)

Alarm (Machine compulsory breakdown) LSL : Lower Spec Limit

LCL LCL LCL

(i) (ii) (iii)

1) Control Limit for Average & Range

2) Spec Limit shall be determined by Customer and Government

1 Product SPC Chart

1) Product and Waste good

SPC : Statistical Process Control; SBL : Statistical Bin Limit

Trend of Chart Criteria Action Required

Note : – for alarm 2) and 3),

3) 7 points in a row up / down all on the same side* Alarm

4 7 points in a row up / down across 2 sides* Warning Accept Monitor by Prod

5 7 points in a row all on either side* Warning Accept Action judged by

8 6 points in a row not changing* - Machine

1.33 1.67 Judgement for full

SPC control SPC control

Severe customer (e.g. Automotive) requirement :

LSL ( - 3 sgma) Improve LCL( - 3 sigma)

Initial Cpk data obtained Control limit review after

Renesas Semiconductor KL Sdn. Bhd.

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