SPC

&
PROCESS CAPABILITY

By C.S Sarangi
PROCESS
 MAN
 METHOD
 MACHINE
 MATERIAL
 EQUIPMENT
 ENVIRONMENT

4M & 2E - ALL WORK TOGETHER TO

PRODUCE OUTPUT.
TRADITIONAL APPROACH FOR
CONTROL
 PRODUCTION MANUFACTURES - Q.C
INSPECTS FINAL PRODUCT
 DETECTION STRATEGY
 WASTES MAN POWER USED TO
MANUFACTURE SUB STANDARD
PRODUCT
 WASTES MANPOWER TO INSPECT GOOD
LOT
 WASTES RESOURCES USED
STATISTICAL
PROCESS CONTROL
 TO MONITOR A PROCESS TO PREDICT &
PREVENT NON CONFORMANCE
 APPLIES TO PRESET & ONGOING
PROCESS
 ECONOMICALLY SOUND DECISSION -
AVOIDS OVER & UNDER CONTROL
 FEEDBACK SYSTEM - PREVENTION
STRATEGY- UNUSABLE PARTS NOT
PRODUCED
VARIATION
 NO TWO ITEMS IDENTICAL
 MUST BE WITHIN REQUIREMENT
 COMMON CAUSES (CHANCE
CAUSES) & SPECIAL CAUSES
(ASSIGNABLE CAUSES)
COMMON CAUSES
 MANY SMALL SOURCES
 STABLE
 OUTPUT PREDICTABLE
 PERMANENT UNLESS ACTION TAKEN
 PROCESS UNDER STATISTICAL
CONTROL
 MANAGERIAL ACTION NEEDED
 EXAMPLE-COMMON CAUSES

 POOR DESIGN OF PRODUCT

 SMALL INACCURACIES IN MEASUREMENT
 SMALL VARIATIONS IN INCOMING MATERIAL
 PROCEDURES NOT WELL SUITED TO THE REQUIREMENT
 SETTINGS OF MACHINE CHRONICALLY INACCURATE
 INADEQUATE ILLUMINATION
 VIBRATION, HUMIDITY
 OPERATOR FATIGUE
 NORMAL WEAR & TEAR OF TOOLS WITH PRESENT
CONDITION ETC.
SPECIAL CAUSES
 ONE OR FEW MAJOR SOURCES
 MAY BE IRREGULAR
 OUTPUT UNPREDICTABLE
 MAY REAPPEAR IF ACTION NOT
TAKEN
 MOST CORRECTED AT SHOP LEVEL.
 EXAMPLE -SPECIAL CAUSES

• FIXTURE NOT CLEANED PRIOR TO USE

• TOOL NOT SHARPENED WHEN DULL
• MACHINE NOT LUBRICATED AS PER SCHEDULE
• OPERATOR NOT FOLLOWING PROCEDURES
• PASSING KNOWN FAULTY PARTS
• OPERATOR TIRED FROM THE NIGHT BEFORE
• NOT SETTING MACHINE CORRECTLY
• BEING OVER CRITICAL IN REJECTING PARTS
• NOT READING MEASUREMENT TOOLS CORRECTLY
ETC.
CONTROL CHARTS

 SPC TOOL TO ANALYSE , MAINTAIN & IMPROVE

PROCESS
 CONTROLLED & UNCONTROLLED VARIATION - A.
SCHEWHART
 VARIABLES (X bar, R &  )
 ATTRIBUTES (P , NP , C)
 STANDARD ASSUMPTIONS
FOR VARIABLE CONTROL CHARTS

 DATA ARE NORMALLY DISTRIBUTED

 DATA ARE INDEPENDANT

 NORMAL DISTRIBUTION

68-95-99.7 Rule

68% of
the data
1σ

95% of the data

2σ

99.7% of the data

3σ

Normal Distribution Curve – Bell Shaped – Max data points at centre

 X bar-R CONTROL CHARTS

 R CHART FOR MEASUREMENT OF DISPERSION /

SPREAD
 X̅ CHART FOR CENTRAL TENDENCY
 BOTH CHARTS USED SIMULTANEOUSLY.

Why ?

# River Example
#Avg. of 4 & 6 is 5. Also Avg. of 2 & 8 is also 5
BENEFITS OF CONTROL CHARTS

 EASILY USED BY OPERATOR

 CONSISTENT PERFORMANCE
 PROVIDE COMMON LANGUAGE FOR
PERFORMANCE DISCUSSION
 DISTINGUISH COMMON & SPECIAL CAUSES
 HIGHER QUALITY, LOWER COST, SCOPE FOR
IMPROVEMENT
BEFORE USE OF Xbar-R CONTROL CHARTS

 PROCESS MUST BE UNDERSTOOD

 CHARACTERISTIC DETERMINED
 EXTERNAL CAUSE REDUCED
 CURRENT PROCESS SETTING NOTED
 EVENTS NOTED WHEN OCCUR
 RELIABLE MEASUREMENT SYSTEM.
STAGES - INITIAL SET UP
 DATA COLLECTION BY SETTING
FREQUENCY & SUBGROUP SIZE
 FINDING OUT UCL & LCL
 HOMOGENIZATION
 FIXING UCL & LCL (USING STANDARD
RANGE & MEAN) FOR FUTURE
CONTROL
STAGES - FUTURE USE
 CHART WITH FIXED UCL & LCL USED
FOR ON-GOING CONTROL
 UNDERSTANDING OF OCCURANCE
OF SPECIAL CAUSES
 REMOVE SPECIAL CAUSES
STAGES - IMPROVEMENT
 PROCESS STABLE FOR LONG
PERIOD
 COMMON CAUSES IDENTIFIED
 COMMON CAUSES MINIMISED
 CONTROL LIMITS REVISED
 MANAGERIAL ACTION NEEDED FOR
IMPROVEMENT
 INITIAL SET-UP &
HOMOGENIZATION OF R CHART

 RANGE CHART TO BE SET-UP FIRST

 MINIMUM 100 SAMPLES STUDIED
 R FOR EACH SUBGROUP CALCULATED
 (R̅ = XMAX - XMIN ).
 AVERAGE RANGE CALCULATED
 (R̅ = R / K , K IS NO. OF SUBGROUPS)
 UCLR= D4R̅ , LCLR = D3R̅ . D4 & D3 ARE
CONSTANTS FROM TABLE RELATED TO SUB
GROUP SIZE
HOMOGENIZATION OF RANGE CHART

 DRAW CHART WITH R̅ ,UCL & LCL

 COMPARE SUBGROUP RANGES
 OUT OF CONTROL POINTS-PRESENCE OF SPECIAL
CAUSE - ELIMINATED
 REST SUB GROUPS PLOTTED
 REPEATED TILL ALL POINTS WITHIN CONTROL
LIMITS
 RANGE FOR HOMOGENIZED SUBGROUPS CALLED
STANDARD RANGE
 POINTS AFFECTED BY SPECIAL CAUSE
ELIMINATED -ONLY COMMON CAUSES REMAIN
HOMOGENIZATION OF X-bar CHART

 HOMOGENISED SUB GROUPS FROM RANGE

CHART TO BE STUDIED
 SUBGROUP AVERAGES CALCULATED
(X̅=X1+X2+ --Xn / n )
 OVERALL AVERAGE X CALCULATED
(X̿ =  (X̅) / K , K - NO. OF SUBGROUPS)
 UCL = X̿ + A2 R̅ , LCL = X̿ - A2 R̅
HOMOGENIZATION OF X-bar CHART

 X̅ FOR ALL SUBGROUP PLOTTED

 OUT OF CONTROL POINTS ELIMINATED TILL ALL
POINTS REMAIN WITHIN CONTROL LIMITS
 NOT MORE THAN 25% IN X̅ & R CHART.
 MEAN VALUE CALLED STANDARD MEAN
 IF STANDARD MEAN IS FAR AWAY FROM SPEC.
MEAN , THEN SPEC. MEAN & STANDARD RANGE TO
BE USED FOR DRAWING CONTROL LIMITS -
PROCESS TO BE CENTRED - FOR ON GOING
PROCESS CONTROL.
 Control Chart Sheet
Sub group 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
Sam ple 1 0.555 0.555 0.565 0.555 0.555 0.555 0.57 0.565 0.57 0.555 0.58 0.575 0.56 0.57 0.57 0.575 0.555 0.555 0.555 0.56 0.565 0.565 0.565 0.56 0.565

Sam ple 2 0.55 0.56 0.55 0.555 0.565 0.56 0.56 0.56 0.575 0.56 0.575 0.565 0.565 0.575 0.57 0.57 0.55 0.57 0.565 0.565 0.57 0.56 0.57 0.57 0.57

Sam ple 3 0.56 0.55 0.555 0.555 0.565 0.565 0.55 0.57 0.575 0.575 0.56 0.57 0.575 0.575 0.565 0.57 0.56 0.55 0.555 0.575 0.595 0.56 0.56 0.575 0.565

Sam ple 4 0.55 0.56 0.555 0.56 0.575 0.565 0.565 0.57 0.56 0.565 0.56 0.57 0.565 0.56 0.56 0.565 0.56 0.57 0.56 0.57 0.56 0.565 0.56 0.575 0.56

Sam ple 5 0.55 0.56 0.57 0.57 0.56 0.56 0.57 0.57 0.56 0.565 0.555 0.565 0.565 0.575 0.56 0.565 0.56 0.565 0.555 0.555 0.59 0.565 0.565 0.555 0.555

X - BAR 0.553 0.557 0.559 0.559 0.564 0.561 0.563 0.567 0.568 0.564 0.566 0.569 0.566 0.571 0.565 0.569 0.557 0.562 0.558 0.565 0.576 0.563 0.564 0.567 0.563
RANGE 0.01 0.01 0.02 0.015 0.02 0.01 0.02 0.01 0.015 0.02 0.025 0.01 0.015 0.015 0.01 0.01 0.01 0.02 0.01 0.02 0.035 0.005 0.01 0.02 0.015
AV. X-BAR= 0.564 AV.RANGE= 0.015 UCL-R= 0.032 LCL-R= 0 UCL-X= 0.573 LCL-X= 0.555 SIGMA= 0.00653 Cp= 2.55

UCL-R LCL - R R R Bar

RANGE CHART

0.040
0.032
0.030
0.020 0.015
0.010
0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2 21 2 2 2 25

UCL-x bar LCL - x bar Av. X bar X BAR

X-BAR CHART
0.580
0.573
0.570
0.56
0.560
0.555

0.550
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
ON-GOING
PROCESS CONTROL
 UCL & LCL FOR HOMOGENIZED
SUBGROUPS TO BE SET AS LIMITS
FOR REGULAR PLOTTING
 SUBGROUP & FREQUENCY IN LINE
WITH INITIAL STUDY
 OUT OF CONTROL SITUATIONS
STUDIED & ACTIONS TAKEN
 CHART DIPLAYED IN SHOPFLOOR
OUT OF CONTROL
SITUATIONS
 OUT OF CONTROL LIMITS IN BOTH CHART
 RUN OF SEVEN POINTS ABOVE OR BELOW
CENTRAL LINE
 RUN OF SEVEN POINTS UP OR DOWN
 POINTS VERY NEAR TO CENTRAL LINE
 POINTS VERY NEAR TO CONTROL LIMITS
 POINT OUT OF
CONTROL LIMIT
AVERAGE CHART RANGE CHART
 LIMITS  LIMITS
MISCALCULATED MISCALCULATED
 PROCESS SHIFTED-  PIECE TO PIECE
EITHER AT THAT VARIABILITY
INCREASED
POINT OR PART OF A
 MEASUREMENT
TREND SYSTEM HAS
 MEASUREMENT CHANGED.
SYSTEM HAS
CHANGED.
 SEVEN POINTS ABOVE OR
BELOW CENTRAL LINE
AVERAGE CHART RANGE CHART
 PROCESS AVERAGE HAS ALL ABOVE CENTRAL LINE
CHANGED - SETTING NOT IN
 LOOSE FIXTURING - GREATER
THE CENTRE
SPREAD
 MEASUREMENT SYSTEM
 SHIFT IN PROCESS ELEMENT
HAS CHANGED.
 CHANGE IN MEASUREMENT
SYSTEM
ALL BELOW
 GOOD SIGN
 CHANGE IN MEASUREMENT
SYSTEM
 SEVEN POINTS IN A ROW
UP OR DOWN
AVERAGE CHART RANGE CHART
 DETORIARATION OF  IMPROVEMENT OR
M/C DETERIORATION OF
 TIRED OPERATOR OPERATOR SKILL
 TOOL WEAR  TIRED OPERATOR
 CHANGE IN
INCOMING MAT.
QUALITY.
 POINTS VERY NEAR TO
CENTRAL LINE

AVERAGE CHART RANGE CHART

 MISCALCULATION OF
CONTROL LIMITS  SAMPLING METHOD
 IMPROVEMENT DONE IN STRATIFIED
PROCESS SINCE LIMITS  IMPROVEMENT DONE
WERE CALCULATED
IN PROCESS SINCE
 INSPECTOR MAY NOT BE
MAKING CHECKS. LIMITS WERE
CALCULATED
 INSPECTOR MAY NOT
BE MAKING CHECKS.
POINTS VERY NEAR TO
CONTROL LIMITS
AVERAGE CHART RANGE CHART
 OVER CONTROL  MIXTURE OF MAT. OF
 LARGE DISTINCTLY
DIFFERENT QUALITY.
SYSTEMATIC
DIFFERENCES IN
MAT. QUALITY
 LARGE
SYSTEMATIC
DIFFERENCES IN
TEST METHOD AND
EQUIPMENT.
PROCESS CAPABILITY

 MEASURE OF INHERENT VARIATION

 VARIATION CORRESPONDING TO BEST
PERFORMANCE
 MINIMUM 25 SUBGROUPS
 SHORT TERM STUDY - MINIMUM
EXTERNAL INFLUENCE - M/C CAP.
 LONG TERM STUDY - ALL SOURCES OF
VARIATION EXPERIENCED.
ASSUMPTION
 PROCESS UNDER STATISTICAL
CONTROL
 INDIVIDUAL MEASUREMENTS
CONFORM NORMAL DISTRIBUTION
 SPECIFICATIONS DEFINED
 MEASUREMENT VARIATION
RELATIVELY SMALL
 CALCULATION OF P.C

 STANDARD DEVIATION ,  = R̅ / d2 , d2 RELATED TO

SUBGROUP SIZE
 P.C = 6 
 P.C INCEX Cp = USL - LSL /6 
 PERFORMANCE INDEX
Cpk =MIN. (USL - X̿ )/3 &(X̿ - LSL)/ 3
INTERPRETATION OF
Cp & Cpk
• Cp =Cpk =1 - PROCESS IS CENTRED &
0.27% DEFECTIVE PARTS PRODUCED
• Cp  Cpk - PROCESS NOT CENTRED -
SETTING TO BE ADJUSTED
• Cp , Cpk  1.33 - IDEAL CONDITION
• Cpk CAN NEVER BE MORE THAN Cp.
• Cpk MUST BE CALCULATED TO KNOW
ACTUAL PERFORMANCE.
 Formulae Recall

SPC Formulae
1. Upper Control limit -X̅ Chart , UCL x = X̿ + A2R̅
2. Lower Control limit -X̅ Chart , LCL x = X̿ - A2R̅
3. Upper Control limit-R Chart, UCL R = D4R̅
4. Lower Control Limit-R Chart, LCL R = D3R̅
5. Standard Deviation, σ = R̅ / d2
6. Process Capability = 6*σ
7. Cp = Tolerance / 6*σ
8. Cpk = Min. of ( USL-X̿)/3*σ , ( X̿ - LSL)/3*σ
 Statistical Table – Constants for Control Chart
No. of samples in
A2 D3 D4 d2
sub Group
2 1.88 0 3.268 1.128
3 1.023 0 2.574 1.693
4 0.729 0 2.282 2.059
5 0.577 0 2.114 2.326
6 0.483 0 2.004 2.534
7 0.419 0.076 1.924 2.707
8 0.373 0.136 1.864 2.847
9 0.337 0.184 1.816 2.970
10 0.308 0.223 1.777 3.078
11 0.285 0.256 1.744 3.173
12 0.266 0.284 1.717 3.258
13 0.249 0.308 1.692 3.336
14 0.235 0.329 1.671 3.407
15 0.223 0.348 1.652 3.472
 Process Capability : Practice Paper
Parameter - I.D Spec:450-550 mm M/C: CNC 2 OPT - XX

Sub group 1 2 3 4 5 6 7 8 9 10

1
500 490 515 500 515 505 525 500 520 505

2
500 515 510 520 510 525 525 515 500 525

3
515 510 510 535 520 510 510 510 515 525

4
490 515 525 515 505 525 525 515 515 510

5
515 510 515 515 495 480 525 500 475 525

X – BAR (X̅)

RANGE (R)
X̿ : R̅ : UCL X-Bar: LCL X-Bar: UCL R:
LCL R:
Range Chart

X̅ Chart

Standard Deviation(σ) : Process Capability : Cp : Cpk

 Process Capability : Practice Paper Answer
Parameter - I.D Spec:450-550 mm M/C: CNC 2 OPT - XX

Sub group 1 2 3 4 5 6 7 8 9 10

1
500 490 515 500 515 505 525 500 520 505

2
500 515 510 520 510 525 525 515 500 525

3
515 510 510 535 520 510 510 510 515 525

4
490 515 525 515 505 525 525 515 515 510

5
515 510 515 515 495 480 525 500 475 525

X - BAR 504 508 515 517 509 509 522 508 505 518

RANGE 25 25 15 35 25 45 15 15 45 20

X̿ :511.50 R̅: 26.50 UCL X-Bar: 526.87 LCL X-Bar: 496.13 UCL R: 56.05 LCL R: 0

UCL-R LCL - R R-BAR

60.000 RANGE CHART

40.000

20.000

0.000
1 2 3 4 5 6 7 8 9 10

UCL-x bar LCL - x bar Av. X bar X BAR

530.000 X-BAR CHART
520.000

510.000

500.000

490.000

480.000
1 2 3 4 5 6 7 8 9 10

Standard Deviation(σ) : 11.392 Process Capability : 68.352 Cp : 1.46 Cpk

 Cp, SIGMA LEVEL & PPM REJECTIONS

Cp Sigma PPM Rejn – Ideal PPM Rejn – Practical Yield

Level (Cp=Cpk) (1.5σ shift of centre)

0.33 1σ 317400 690000 31%

0.67 2σ 45600 308537 69%

1 3σ 2700 66807 93.3

1.33 4σ 64 6210 99.3

1.67 5σ 1 233 99.98

2 6σ 0.002 3.4 99.9997

 TO IMPROVE
PROCESS CAPABILITY
 TO IMPROVE PROCESS CAPABILITY (AND HENCE
PERFORMANCE OF PROCESS) , CONCENTRATE ON
REDUCING COMMON CAUSES

 SOME TIMES REQUIRES MANAGEMENT ACTION ON

THE SYSTEM