Project Work on

PROCESS CAPABILITY ANALYSIS

& SIX SIGMA IN MANUFACTURING

SIX SIGMA

What is Six Sigma? Why Six Sigma

The New Definition of Quality

A BREAKTHROUGH STRATEGY OVERVIEW

Measure Analyze Improve Control

The Six Sigma Implementation Methodology

Identification Characterization Optimization Institutionalization

Recognize Define Measure Analyze Improve Control Standardize Integrate

Process Capability
and

Six Sigma

Control Charts

A statistical tool to study and control repetitive processes Graphical representation of collected information pertaining to a particular quality characteristics Specifies the state of statistical control and aims at attaining it

Types of Control Charts

Control charts for Variables X bar R chart X bar S chart X median R chart They control individual characteristics of a component
Control charts for attributes C chart U chart P chart nP chart Control of proportions of defectives or number of defectives

Components of a control chart

Upper control limit line Lower control limit line Center line Variability plot

Process Capability defined

Minimum spread of a specific measurement variation which will include 99.7% of the measurements from the given process

A highly capable process

6<(USL-LSL)

A barely capable process

6=(USL-LSL)

A not capable process

6>(USL-LSL)

Measure of performance of Process Capability

CP

CPK

Capability Index CP

Process Capability and Six Sigma

Process Capability Indices and Sigma Level

Process Capability Analysis is meaningful only where Process is under statistical control and errors in measurement (due to operator or instrument) are negligible

R & R Analysis
The Need

Variation in measurement due to : Parts Operator Part to Part Variation Reproducibility

Instrument error

Repeatability

R & R Analyses allow the engineer to evaluate the precision of gages and different operators (users) of those gages, relative to the variability of the items in the population.

We can compute the standard indices of repeatability, reproducibility, and part-to-part variation, based either on ranges or from the analysis of variance (ANOVA) table

R & R Analysis Results

Process Capability Analysis

At

Essae Digitronics Bommasandra Industrial Estate Bangalore

Machining Division

Manufacture of CNC Turned components Used in Engine and Brake assemblies

Customers include TVS motors and Honda Motorcycle and Scooters

Manufacture and Supply of Precision Turned and Assembled Components for Automotive Applications.

SIX SIGMA
Control Charts

No

In Control
Yes

Improve

Data Collection

Continual Process Improvement

No

Compute Cp Cpk

Improve

Capable ?
Yes

Next Process

Scope of Study
Component
Gear Primary Drive AX 100 Part No 3041013G

Parameter
Bore Diameter
Parallelity Bore Diameter

Specification
15.8 / 15.818
0.02 max 17.90H7 /17.918

Gear Primary Drive ST Part no 208039000

Parallelity 16 T Cam Chain Drive Bore Diameter Parallelity Gear Primary Driven Part No N3080119 Diameter

0.02 max 19.99 / 20.011 0.02 max 34.90 / 34.94

e.g. Gear Primary Drive AX 100

Bore Diameter"

X Bar 15.812 UCL 15.813 LCL 15.811

Steps Taken

Non controlled process Brainstorming session Participated in Quality Circle Identified possible causes Suggested recommendations to be implemented Following implementation performed another analysis Cycle Continued till Process is Capable

After improvement
X Bar
UCL LCL

15.810
15.812 15.807

Cp:

= 1.765

CpK (1) 1.642 CpK (2) 1.887 CpK = 1.642

Consolidated Results
Results of R&R Analysis
NO . Gauge No.

Type

R&R %

Comment s

ML AG 11

Pneumatic Gauge

27.55

Acceptable

ML ARG 06

Pneumatic Gauge

19.27

Acceptable

ML ARG 09

Pneumatic Gauge

8.27

Acceptable

ML CS 10

Dial Gauge

59.59

Not Acceptable

Results of Process Capability Analyses

No. Part
Gear Primary Driven

Parameter

Cp Cpk
Cp =5.73 Cpk=4.45 Cp =3.83 Cpk=2.71 Cp =2.32 Cpk=1.94 Cp =2.07 Cpk=1.33 Cp =3.46 Cpk=2.14 Out of control

Comments

Improved Cp, Cpk

N.A

Diameter

Capable

Gear Primary Drive ST Victor

Bore Dia

Capable

N.A

Parallelism

Capable

N.A

4 16T Cam Chain Drive 5

Bore Dia

Capable

N.A

Parallelism Gear Primary Drive Ax 100

Capable

N.A

Bore Dia

Improve Process

Cp =1.76 Cpk=1.64

Parallelism

Cp =1.27 Cpk=0.69

Not capable Improve

Cp =4.14 Cpk=1.71

Thank You