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SPC
SPC
Statistical Process Control (SPC) can be thought of as the application of statistical methods for the purposes of quality control and improvement. Quality Improvement is perhaps foremost among all areas in business for application of statistical methods.
Use of Statistics
Use of Statistics
Use of Statistics
College of Science
Department of Statistics
n=1
2<n<9 median
n is small 3<n<5
n is large n > 10
X & Rm
X&R
X&R
X&S
Use of Statistics
College of Science
Department of Statistics
Defective Data
Constant n > 50
Variable n > 50
c chart
u chart
p or np chart
p chart
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College of Science
Department of Statistics
4. 5.
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College of Science
Department of Statistics
Initiate data collection: Run the process untouched, and gather sampled data. Record data on an appropriate Control Chart sheet or other graph paper. Include any unusual events that occur. Calculate the appropriate statistics and control limits: Use the appropriate formulas. Construct the control chart(s) and plot the data.
Use of Statistics
College of Science
Department of Statistics
Time, Production & Spatial Analysis An event taken in isolation or a group of items each selected from a process during the same (brief) time span can generally provide information about process performance ONLY during that brief span.
Unless process performance is static through time this will be true. Dynamic processes vary through time.
Use of Statistics
College of Science
Department of Statistics
Time, Production & Spatial Analysis If a process varies through time, it is often useful to know how the process varies so that it can be controlled or guided in its behavior. videotaping the process - in some sense, the process has a life of its own and we want to nurture that life.
Use of Statistics
College of Science
Department of Statistics
Stable process: one which performs with a high degree of consistency at an essentially constant level for an extended period of time
In-control
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College of Science
QU ST HO O S E N R
L a in ed g
A
Department of Statistics
PR G A O R M
* * * * *
US L 2 W US 1 L C L LS 1 L LS L 2 W L L C
* * * * * * *
B C
* C
B C
* *
Use of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Yi =
^i = Yi / ni p
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Sp = p (1-p)/ ni
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Wallpaper Ltd
WL is a custom wallpapers and borders manufacturer. While their products vary in visual design, the manufacturing process for each of the products is similar. Each day a sample of 100 rolls of wallpaper border is sampled and the number of defective rolls in the sample is noted. The number of defective rolls in samples from 25 consecutive production days follows. Determine all coordinates; construct & interpret the p chart. PATs 1, 2, 3 and 4 apply to p charts.
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College of Science
Day Defective Rolls Day
Department of Statistics
Defective Rolls
1 2 3 4 5 6 7 8 9 10 11 12 13
13 4 7 11 8 10 2 9 12 6 4 7 9
14 15 16 17 18 19 20 21 22 23 24 25
8 9 3 5 14 10 11 6 6 9 3 10
WL
Use of Statistics
College of Science
WL
Department of Statistics
Total # of items sampled = 2500 Total # of defective items = 196 p = 196/2500 = .0784 Sp = .0784(.9216)/100 = .02688 Use of Statistics
College of Science
WL
CL = U1SL = L1SL = U2SWL = L2SWL = UCL = LCL = .0784
Department of Statistics
.0784 + 2(.0269) = .1322 .0784 + 3(.0269) = .1590 .0784 - .0806 = -.0022 (na)
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College of Science
0.15
Department of Statistics
3.0SL=0.1590 2.0SL=0.1322
Proportion
0.10
1.0SL=0.1053 P=0.07840
0.05
-1.0SL=0.05152 -2.0SL=0.02464
-3.0SL=0.000
Use of Statistics
College of Science
WL
Department of Statistics
P Chart Interpretation
No violations of PATs one through four are apparent. This implies that the process is in a state of statistical control. It does not indicate that we are satisfied with the performance of the process. It does, however, indicate that the process is stable enough in its performance that we may seriously engage in PDCA for the purpose of long-term process improvement.
Use of Statistics
College of Science
Department of Statistics
When data originates from a Poisson process, it is customary to monitor output from the process with a defects or C chart Recall the Poisson Distribution with mean = c and standard deviation = c P(y) = cye-c/y!
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College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
STML produces material for use as gaskets in scientific, medical, and engineering equipment. Scarred material can adversely affect the ability of the material to fulfill its intended use. A sample of 40 pieces of material, taken at a rate of 1 per each 25 pieces of material produced gave the results on the following slide. Use this information to construct and interpret a C chart.
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College of Science
STML
Piece Scars Piece Scars Piece Scars Piece Scars 1 4 2 4 3 2 4 3 5 1
Department of Statistics
6 2
7 0
8 2
9 3
10 1
11 12 13 14 15 16 17 18 19 20 1 1 2 3 0 4 3 2 2 1 21 22 23 24 25 26 27 28 29 30 2 1 0 3 5 4 2 1 4 2 31 32 33 34 35 36 37 38 39 40 2 1 1 3 2 0 1 5 9 1
Use of Statistics
College of Science
STML
Department of Statistics
C= 90/40= 2.25= CL, Sc= 2.25 = 1.5 UCL= 2.25+ 3(1.5) = 6.75 LCL= 2.25- 4.5 = -2.25 (NA) U2SWL= 2.25+ 2(1.5)= 5.25 L2SWL= 2.25- 3 = -0.75 (NA) U1SL= 2.25+ 1.5 = 3.75 L1SL= 2.25- 1.5 = Statistics Use of 0.75
College of Science
10 9 8 7 6 5 4 3 2 1 0
25 10
Department of Statistics
UCL
U2SWL
U1SL CL
L1SL
40 22 7 28 13 31 4 34 37 16 19
Use of Statistics
College of Science
Department of Statistics
STML
C Chart Interpretation Application of PATs one through four indicates a violation of PAT 1 at sample number 39 where 9 scars appear on the surface of the sampled material. Corrective measures would be identified and implemented. After process stability was (re) assured, we would move into PDCA mode.
Use of Statistics
College of Science
U = (u1+u2+...+um) / (n1+n2+...+nm)
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Process Capability:
The Control Chart Method for Attributes Data
1. Construct the control chart and remove all special causes. NOTE: special causes are special only in that they come and go, not because their impact is either good or bad. 2. Process capability is estimated using the CENTERLINE value. In the case of binomial data, this is generally the proportion defective. In the case of Poisson data, this is that average number of defects per unit.
Use of Statistics
College of Science
Department of Statistics
R or Range Chart:
Also used to monitor process dispersion Use of Statistics
College of Science
each.
Department of Statistics
m = 20 to 40 initial samples of n observations Xi = mean of ith sample Si = standard deviation of ith sample Ri = range of ith sample
X = (X1 + X2 +... + Xm) / m S = (S1 + S2 + ... +Sm)/m R = (R1 + R2 + ... + Rm)/m
College of Science
Department of Statistics
UCL= X- A2R U2SWL= X+ 2A2R/3 L2SWL= X- 2A2R/3 U1SL= X+ A2R/3 L1SL= X- A2R/3
A2 is a constant that depends only on n.
Use of Statistics
College of Science
CL= R UCL= D4R LCL= D3R U2SWL= R+ 2(D4-1)R/3 L2SWL= R- 2(D4-1)R/3 U1SL= R+ (D4-1)R/3 L1SL= R- (D4-1)R/3
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
n=5 X = 49.63 S = 7.42 R = 18.63 d2 = 2.326 A2 = 0.577
Department of Statistics
A3 = 1.427 B3 = NA B4 = 2.089 D3 = NA D4 = 2.115 = R/d2 = 8.01
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Sample Mean
Sample Number
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College of Science
Department of Statistics
S m Rn a ple a ge
Use of Statistics
College of Science
Department of Statistics
Application of PATs one through four to the R chart indicated a violation of PAT
We are close to being able to apply PDCA to the process for the purpose of
Use of Statistics
College of Science
CL= X UCL= X= A3S LCL= X- A3S U2SWL= X+ 2A3S/3 L2SWL= X- 2A3S/3 U1SL= X+ A3S/3 L1SL= X- A3S/3 where A3 depends only on n
Department of Statistics
Coordinates for the X Control Chart: S
Use of Statistics
College of Science
CL= S UCL= B4S LCL= B3S
Department of Statistics
Coordinates on an S Control Chart
U2SWL= S+ 2(B4-1)S/3 L2SWL= S- 2(B4-1)S/3 U1SL= S+ (B4-1)S/3 L1SL= S- (B4-1)S/3 where B3 and B4 depend only on n
Use of Statistics
College of Science
Department of Statistics
49.8 8.76 46.8 6.72 44.2 8.53 50.8 11.95 48.4 6.19
46.8 6.50 49.2 3.19 45.6 7.96 57.6 14.38 51.4 6.80
Use of Statistics
College of Science
UCL U2SWL U1SL CL L1SL L2SWL LCL 60.22 56.69 53.16 49.63 46.11 42.58 39.05
Department of Statistics
S
15.49 12.80 10.11 7.42 4.72 2.03 ------
X based on S
College of Science
Department of Statistics
Limits Based on S
3.0SL=60.22 2.0SL=56.69
Sample Mean
Sample Number
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College of Science
Department of Statistics
Sample Stdev
10
1.0SL=10.11 S=7.416
- 1.0SL=4.724 - 2.0SL=2.032
0 0 10 20 30
- 3.0SL=0.000
Sample Number
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
Process Capability:
The Control Chart Method for Variables Data
1. 2. Construct the control chart and remove all special causes. NOTE: special causes are special only in that they come and go, not because their impact is either good or bad. Estimate the standard deviation. The approach used depends on whether a R or S chart is used to monitor process variability.
^ _
= S / c4
= R / d2
Use of Statistics
College of Science
^
Department of Statistics
^
This index is generally used to evaluate machine capability. tolerance to the engineering requirements. Assuming that the process is (approximately) normally distributed and that the process average is centered between the specifications, an index value of 1 is considered to represent a minimally capable process. HOWEVER allowing for a drift, a minimum value of 1.33 is ordinarily sought bigger is better. A true Six Sigma process that allows for a 1.5 shift will have Cp = 2.
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
College of Science
Department of Statistics
This index is generally used to evaluate machine capability. Note this is only MACHINE capability and NOT the capability of the full process. Given that there will be additional sources of variation (tooling, fixtures, materials, etc.) CM uses an 8 spread,
rather than 6. For a machine to be used on a Six Sigma process, a 10 spread would be used.
Use of Statistics
College of Science
= ^ =
Department of Statistics
^
Zmin = Minimum (ZL , ZU) Cpk = Zmin / 3 This index DOES take into account how well or how poorly centered a process is. A value of at least +1 is required with a value of at least +1.33 being preferred. Cp and Cpk are closely related. In some sense Cpk represents the current capability of the process whereas Cp represents the potential gain to be had from perfectly centering the process between specifications.
Use of Statistics
College of Science
Department of Statistics
Assume that we have conducted a capability analysis using X-bar and R charts with subgroups of size n = 5. Also assume the process is in statistical control with an average of 0.99832 and an average range of 0.02205. A table of d2 values gives d2 = 2.326 (for n = 5). Suppose LSL = 0.9800 and USL = 1.0200
Process Capability:
Example
CR = 100*(6*0.00948) / (1.0200 0.9800) = 142.2% CM = (1.0200 0.9800) / (8*(0.00948)) = 0.527 ZL = (.99832 - .98000)/(.00948) = 1.9 ZU = (1.02000 .99832)/(.00948) = 2.3 so that Zmin = 1.9 Cpk = Zmin / 3 = 1.9 / 3 = 0.63
Use of Statistics
College of Science
Department of Statistics
Use of Statistics
Cthere differences in the measurement accuracy of instrumentstatistics ollege of Science Department of S / Are
methods used? Are there differences in the methods used by different personnel? Is the process affected by the environment, e.g. temperature/humidity? Has there been a significant change in the environment? Is the process affected by predictable conditions such as tool wear? Were any untrained personnel involved in the process at the time? Has there been a change in the source for input to the process such as a new supplier or information? Is the process affected by employee fatigue? Has there been a change in policies or procedures such as maintenance procedures? Is the process frequently adjusted? Did the samples come from different parts of the process? Shifts? Individuals? Are employees afraid to report bad news?
Use of Statistics