Professional Documents
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SPC (Small)
SPC (Small)
SPC (Small)
CUSTOMER & COMPETITIVE INTELLIGENCE FOR PRODUCT, PROCESS, SYSTEMS & ENTERPRISE EXCELLENCE
SPC Techniques
,raphs and charts ha(e to be chosen for their simplicity, usefulness and (isibility
Pareto Diagram Process -lo# Diagram Cause-and-.ffect Diagram Chec$ Sheets /istogram Scatter Diagram Control Charts
Scatter Diagrams
x x x x x x x x
Pareto Analysis
Pareto Diagram
,raph that ran$s data classifications in descending order from left to right
0 Problems, causes, complaints, field failures, )C etc
23ital -e#4 are placed on the left and 21seful 5any4 on the right
0 Some of 21seful 5any4 are grouped together and placed on the far right side of graph
Pareto Analysis
(um$er of %efects Off Smeare% )issing *oose Other centre print la$el
!"# !"#of of the the pro$lems pro$lems may may $e $e attri$ute% attri$ute% to to &"# &"#of of the the causes' causes'
Pareto Diagram
Pareto diagram is constructed in fi(e steps
0 Determine the method of classifying the data: by problem, cause, )C etc 0 Decide of dollars 7best8, fre+uency, or both are to be used to ran$ the characteristics 0 Collect data for an appropriate time inter(al or use historical data 0 Summari9e the data : ran$ order categories from largest to smallest 0 Construct the diagram and find the 23ital -e#4
%t subse+uently leads to impro(ements by reducing, combining, or eliminating steps The symbols are also used to pro(ide additional information about processes : decision ma$ing
1sed to in(estigate a 2*ad>,ood .ffect4 and to ta$e action to correct>learn the causes Causes are bro$en do#n into ma6or : then into numerous minor causes 5ost li$ely causes are then selected by the team Solutions for these causes are proposed and e(aluated before implementation
Cause-and-Effect Diagram
)etho%s
Cause Cause Cause Cause Cause Cause Cause
)aterials
Cause Cause Cause
En,ironment
Cause Cause
Effect
People
E+uipment
*enefits
0 Analy9e actual conditions for +uality impro(ements, efficient use of resources : reduced costs 0 .liminate conditions causing )Cs : complaints 0 Standardi9e eAisting : proposed operations 0 .ducate : train personnel in decision-ma$ing and correcti(e-action acti(ities
Chec# Sheets
5eant to ensure that data are collected carefully : accurately by operating personnel
0 So that they are analy9ed +uic$ly : carefully
.ach chec$ sheet is indi(iduali9ed for each situation : designed by the pro6ect team Chec$ sheets may also be designed to sho# location %t should be user friendly and may also include information on time and location, #hene(er possible
Chec# Sheet
$illing Errors
%rong Account %rong Amount
(onday
A&' Errors
%rong Account %rong Amount
)istogram
*asic statistical method that describes (ariation in the process 7li$e a snapshot of a process8 %t gi(es sufficient info about a +uality problem to pro(ide a basis for +uic$ decision ma$ing %t can determine the process capability, compare #ith the specs, suggest the shape of population : indicate discrepancies in the data, such as gaps
0 ,raphically estimates the process capability : relationship to the specifications : target
)istogram
Some means are thus essential to summari9e the data to sho#&
0 ;hat (alue the data tend to cluster about 0 /o# the data are dispersed or spread out
T#o techni+ues are needed to accomplish this summari9ation of data- graphical : analytical
,raphical techni+ue is a picture of fre+uency distribution
0 Summari9ation of ho# the data points occur #ithin each subdi(ision of obser(ed (alues or groups of obser(ed (alues
Analytical techni+ues summari9e data by computing a measure of the central tendency 7a(g, median : mode8
Data %nterpretation
Consider these B! measurements
$ore Diameter *+.*, -.../mm *+.,0 - *+.*0mm" CD.CD CD.CG CD.CG CD.CC CD.CB CD.CC CD.CC CD.CG CD.CB CD.CB CD.CE CD.CB CD.CF CD.CB CD.CG CD.CG CD.CB CD.CC CD.CF CD.CB F FF FC FG FB FD FE FH FI C! CD.CG CD.CE CD.CG CD.CB CD.CG CD.CB CD.CD CD.CC CD.CD CD.CH C CF CC CG CB CD CE CH CI G! CD.CB CD.CB CD.CD CD.CE CD.CG CD.CD CD.CH CD.CG CD.CB CD.CB G GF GC GG GB GD GE GH GI B! CD.CD CD.CE CD.CE CD.CB CD.CE CD.CD CD.CB CD.CG CD.CB CD.CG
F C G B D E H I !
F C G B D E H I F!
Data 1nter2retation
As a set of numbers it is difficult to see any pattern ;ithin the table, numbers C! and CE #ere outside the tolerance 0 but were they easy to spot? A #ay of obtaining a pattern is to group the measurements according to si9e
The tally chart groups the measurements together by si9e as sho#n The t#o parts that #ere out of tolerance are no# easier to detect 7CD.CHmm8
The tally chart sho#s patterns and #e can obtain the 'A),. CD.CFmm to CD.CHmm The most -'.?1.)T@J <CC1''%), si9e is CD.CBmm
)istogram
;e can redra# the fre+uency chart as a bar chart $no#n as a histogram:
7+ 76 7, 7. 5 + 6 , . *+.*7 *+.*, *+.** *+.*6 *+.*/ *+.*+ *+.*0 *+.*5 *+.*4
Smoothed Frequency
%f #e dra# a smooth cur(e through the top of each boA #e get a bell-shaped pattern:
7+ 76 7, 7. 5 + 6 , . *+.*7 *+.*, *+.** *+.*6 *+.*/ *+.*+ *+.*0 *+.*5 *+.*4
Distri<ution
The bell-shaped pattern is fairly typical of most industrial processes There is a central (alue at the highest point of the cur(e and the pattern of results spread out e+ually on both sides of the central (alue The further #e mo(e from the central (alue, the fe#er (alues #e #ill find This bell-shaped pattern is $no#n as the 289'(A: D1ST'1$;T1984 0 .Apected #here the process is running in a stable condition
Scatter Diagram
The simplest #ay to determine if the cause-andeffect relationship eAist b># t#o (ariables -e# steps to construct a scatter diagram are&
0 Data are collected as ordered pairs 7A,y8 0 The sample numbers are plotted and scatter diagram is complete 0 After constructing the scatter diagram, correlation b># the t#o (ariables can be e(aluated
%f 2J4 increases #ith 2=4, it has a positi(e correlation %f 2J4 decreases #ith 2=4, it has a negati(e correlation %f 2J4 does not change #ith 2=4, it has no correlation Cur(ilinear correlation may eAist
Process =ariation
Process Variability
1ariations %ue to2
(atural Causes2
' (nvironment variation ' )aterial variation ' (!ui"ment variation ' *"erator "er#ormance
Assigna$le Causes2
' )achine is breaking ' +ntrained o"erative ' )achine movement ' Process has changed
)ust $e monitore%
' ,hat 0oes a Control Chart 0o. 1ocuses attention on detecting 2 monitoring "rocess variation over time3 . 0istinguishes special #rom common causes o# variation/ as a guide to local or management action3 . Serves as a tool #or ongoing control o# a "rocess3 . 4el"s im"rove a "rocess to "er#orm consistentl and "redictabl #or higher !ualit / lower cost/ and higher e##ective ca"acit 3 . Provides a common language #or discussing "rocess "er#ormance
'un Chart
5 .9 8 5 .9 7 5 .9 6 5 .9 : 5 .9 5 .6 8 5 .6 7 5 .6 6 ; : < 6 9 7 = 8 > ;5 ;; ;: 3 im e 4 5 o u rs 6
Diameter
3ime 45ours6
Control Chart
7.,. 7.7. 7... 44. 45. 40. . 7 , * 6 / + 0 5 4 7. 77 7, 7* 76 7/
UCL
LCL
Trac$ing %mpro(ements
;C: ;C: ;C:
:C: Process centered Process not centered and sta<le and not sta<le :C:
M M M M M
M M M M M MM
$ C
M C
$ A
M M
DB or DBange ChartA
@lso used to monitor "rocess dis"ersion when onl one observation is "ossible at a time and data are normal (!uations are based u"on moving range o# two
Championship
n a e 5 e l p B! m a S
S a m ple)um be r
e g C! n a ' e l p F! m a S
!
S a m ple)um be r
' Is the "rocess #re!uentl adLusted' 0id the sam"les come #rom di##erent "arts o# the "rocessShi#ts- Individuals' 4as there been a change in "olicies or "rocedures such as maintenance "rocedures' @re em"lo ees a#raid to re"ort bad news
P-Chart
%t is used to report the performance of group or +uality of produced item %t is used to control&
0 <ne +uality Characteristic or& 0 ,roup of ?uality Characteristic of the same type or same part or& 0 To control the entire product
A hierarchy of utili9ation eAists so that data collected for one chart can also be used on a more all-inclusi(e chart
P Chart Control Lines & Limits 3he coor%inates for the se,en lines on the P
chart are positione% at2 C* < =/S* < =&SW* < =C* < p p > Sp p > &Sp p > 9Sp */S* < p - Sp *&SW* < p - &Sp *C* < p - 9Sp
Process Capa$ility2
1. Construct t ! contro" c #rt #n$ r!%o&! #"" s'!c(#" c#us!s. NOTE) s'!c(#" c#us!s #r! *s'!c(#"+ on", (n t #t t !, co%! #n$ -o, not .!c#us! t !(r (%'#ct (s !(t !r *-oo$+ or *.#$+
/. Est(%#t! t ! st#n$#r$ $!&(#t(on. T ! #''ro#c us!$ $!'!n$s on 0 !t !r # R or P c #rt (s us!$ to %on(tor 'roc!ss &#r(#.("(t,.
1 2 R 3 $/ 2 H.H//HG3/.A/7 2 H.HHIKJ C' 2 51.H/HH 8 H.IJHH6 3 75.HHIKJ6 2 H.LHA BL 2 5.IIJA/ E .IJHHH635.HHIKJ6 2 1.I BU 2 51.H/HHH 8 .IIJA/635.HHIKJ6 2 /.A so t #t B%(n 2 1.I C'C 2 B%(n 3 A 2 1.I 3 A 2 H.7A