Process Capability Studies

Comparison of Process Output to Product Requirements

Lynn Taylor OISM 470W Section 002

Process Capability Studies

3 Steps

Gauge Capability Process Characteristics

Stability Normality Control

Process Capability Analysis

Comparison of process output(s) to requirements.

Process Capability Studies

Definitions Process Work performed on a set of inputs to produce a result. Capability The predictable result(s) of a process allowed to operate without outside interference. Process Capability Study Comparison of process output(s) to product requirements.

Process Capability Studies

Uses In Our Plant Customer 1 < 407, Cpk > 1.25 Customer 1 > 407, Cpk > 1.50 Customer 2, Cpk > 1.33 With new clients, determine if tolerances are reasonable, if our processes are capable and robust, and if improvements are needed.

Process Capability Studies

Step 1 Gauge Capability

Six Measures Gauge Accuracy

Are the readings correct?

Gauge Linearity
Are the readings correct over the measurement range of the instrument?

Gauge Stability
Does the gauge return similar values over time?

Process Capability Studies

Step 1 Gauge Capability
Six Measures Gauge Repeatability
Does one operator return a similar result time after time (gauge variability)?

Gauge Reproducibility
Do different operators return similar results?

Gauge Repeatability and Reproducibility

Total variability of a test result (operator & gauge).

Process Capability Studies

Step 2 Process Characteristics

Analyze Process Data Normality Evidenced by the descriptive statistics skewness and kurtosis. Stability The absence of shifts or trends over time. Control Control chart analysis passing tests for special causes.

Process Capability Studies

Tests for Normality

Process Capability Studies

Tests for Stability and Control

Process Capability Studies

Comparing Distributions to Specifications

Process Capability Studies

Real World Example Part 504

Process Capability Studies

Part 504 Continued

Process Capability Studies

Part 504 Continued

Process Capability Studies

Part 613 - An Exercise
0.1083 0.10819 0.10827 0.10817 0.1084 0.10838 0.10836 0.10835 0.10794 0.10838 0.10797 0.1078 0.10816 0.10802 0.10797 0.10833 0.10816 0.1081 0.10817 0.10801 0.10822 0.10827 0.10833 0.10799 0.10803 0.10819 0.10814 0.10794 0.10826 0.10844 0.10813 0.10828 0.10778 0.10784 0.10789 0.10835 0.1082 0.10817 0.10833 0.10824 0.10819 0.10808 0.10793 0.10819 0.10814 0.10816 0.10817 0.1081 0.10836 0.10809 0.10841 0.10807 0.10822 0.10812 0.10811 0.10813 0.10822 0.10824 0.10807 0.10811 0.1081 0.10837 0.10815 0.10839 0.10802 0.10794 0.10802 0.10843 0.10785 0.10809 0.10811 0.10822 0.10826 0.10803 0.10817 0.10794 0.10813 0.1082 0.10802 0.10849 0.10837 0.10846 0.10811 0.10834 0.10811 0.10828 0.10796 0.10832 0.10815 0.10805 0.10815 0.10794 0.10798 0.10833 0.10799 0.10818 0.10809 0.10856 0.10846 0.10804

Process Capability Studies

Part 613 An Exercise
0.110 Diameter Part 613

35 30 25
Frequency

Descriptive Statistics Mean 0.1081636 Standard Error 1.64535E-05 Median 0.10816 Mode 0.10817 Standard Deviation 0.000164535 Sample Variance 2.70718E-08 Kurtosis 3.411886124 Skewness 0.017494357 Range 0.00078 Minimum 0.10778 Maximum 0.10856 Sum 10.81636 Count 100

20 15 10 5 0
77 78 79 8 81 82 83 84 85 86 0. 10 0. 10 0. 10 0. 10 0. 10 0. 10 0. 10 0. 10 0. 10 0. 10 M or e

Max Kurtosis Max Skewness

4.49 0.745

dia - in.

Process Capability Studies

Part 613 An Exercise
Xbar Chart .110 dia Part 613- n=4
0.1085 0.1084 0.1083 0.1082 0.1081 0.108 0.1079 0.1078 0.1077 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 UCLXbar Xbarbar Observation # Xbar LCLXbar

in.

R Chart .110 Dia Part 613 n=4 0.0008 0.0006

in.

0.0004 0.0002
UCLR Rbar R LCLR

11

13

15

17

19

21

23

Observation #

25

Process Capability Studies

Part 613 An Exercise
And the answer is:
Descriptive Statistics Mean Standard Error Median Mode Standard Deviation Sample Variance Kurtosis Skewness Range Minimum Maximum Sum Count 0.1081636 1.64535E-05 0.10816 0.10817 0.000164535 2.70718E-08 3.411886124 0.017494357 0.00078 0.10778 0.10856 10.81636 100 LSL = USL = Cp = CpL = CpU = Cpk = 0.105 0.115 10.1 6.4 13.8 6.4

Process Capability Studies

Summation Three Steps: Gauge Capability
Process Characteristics

Process Capability Analysis

Process Capability Studies

Bibliography
Introduction to Statistical Analysis sixth ed Dixon and Massey Introductory Statistics Weiss and Hassett, 1982 AT&T Statistical Quality Control Handbook 11th Printing 1985 Experimental Statistics Mary G. Natrella 1966 (NBS Handbook 91) General Motors Statistical Quality Control Handbook 1982 LTV Steel Integrated Process Control Handbook Norman Bresky and Joan Harley 1986 North American Refractories Co. SPC Handbook 1988 1994 Annual ASTM Book of Standards- ASTM E 691 - 92