PROCESS CAPABILITY

BPT2423 – STATISTICAL PROCESS CONTROL

CHAPTER OUTLINE
 Estimation of Population σ from Sample Data
 Control Limits versus Specification Limits
 The 6σ Spread versus Specification Limits
 Calculating Process Capability Indices
LESSON OUTCOMES
 Understand the difference between
specification limits and control limits
 Learn to calculate and interpret the process
capability indices: Cp, Cr and Cpk
INTRODUCTION
 Process capability refers to the ability of a process to
produce products or provide services capable of meeting
the specifications set by the customer or designer
 Knowing the process capability gives insight into
whether or not the process will be able to meet future
demands place on it
 Determining the process capability aids industry in
meeting their customer demands – a customer may ask
for part tolerances so fine that the machines are not
capable of producing to that level of exactness
 An undersized part A may not mate correctly with an
oversized part B
ESTIMATION OF POPULATION σ
 Sample values and their averages provide insight into the
behavior of an entire population
 ẋ becomes a more reliable estimate of µ as the sample size
is increased
 If the process can be assumed to be normal, the
population standard deviation can be estimated from
either the standard deviation associated with the sample
standard deviation (s) or the range (R) :
CONTROL LIMIT vs SPEC. LIMIT
 It is important to note that a process in statistical control will
not necessarily meet specifications as established by the
customer
 There is a difference between a process conforming to
specifications and a process performing within statistical
control
 Specifications communicate what the customers expect,
want or need from the process – considered the voice of the
customer
 Control limits are the voice of the process – a prediction of
the variation that the process will exhibit in the near future
 Difference : specifications relay wishes and control limits tell
of reality
CONTROL LIMIT vs SPEC. LIMIT
THE 6σ SPREAD vs SPEC. LIMITS
The spread of the individuals in a process, 6σ, is the
measure used to compare the realities of production with
the desires of the customers
Case I : 6σ < USL - LSL

This allows for more room for

process shifts while staying
within the specifications.

Notice that even if the process

drifts out of control, the
change must be dramatic
before the parts are
considered out of
specification.
THE 6σ SPREAD vs SPEC. LIMITS
Case II : 6σ = USL - LSL

A shift in the process

mean or an increase in
the variation present in
the process will creates
an out of specification
situation

Case III : 6σ > USL - LSL

Process is incapable of
meeting the specification set
by the customer. To correct
this problem, management
intervention will be necessary.
The capability of the process
cannot be improved without
changing the existing process
CAPABILITY INDICES
Capability Index, Cp
Cp > 1.00 : Case I situation exists. The greater this value, the better
Cp = 1.00 : Case II situation exists. This is not optimal, but it is feasible
Cp < 1.00 : Case III situation exists. Value of less than 1 are undesirable
and reflect the process’s inability to meet the specification
CAPABILITY INDEX & 3 CASES
CAPABILITY INDICES
Capability Ratio, Cr
Cr < 1.00 : Case I
Cr = 1.00 : Case II
Cr > 1.00 : Case III

Centering of the Process, Cpk

Where Z (min) is the smaller of :

MEANINGS OF Cpk MEASURES

Cpk = negative number

Cpk = zero

Cpk = between 0 and 1

Cpk = 1

Cpk > 1

Note : Cpk is the ratio that reflects how the process is performing in relation to a nominal, center or
target value.
 RELATIONSHIP BETWEEN
Cp AND Cpk
1. When Cp has a value of 1.0 or greater, the process is producing product
capable of meeting specifications
2. The Cp value does not reflect process centering
3. When the process is centered Cp = Cpk
4. Cpk is always less than or equal to Cp
5. When Cp is greater than or equal to 1.0 and Cpk has a value of 1.00 or more, it
indicates the process is producing product that conforms to specifications
6. When Cpk has a value less than 1.00, it indicates the process is producing
product that does not conform to specifications
7. A Cp value of less than 1.00 indicates that the process is not capable
8. A Cpk value of zero indicates the process average is equal to one of the
specification limits
9. A negative Cpk value indicates that the average is outside the specification
limits
Cp AND Cpk FOR THE 3 CASES
EXERCISE
Hotels use statistical information and control charts to
track their performance on a variety of indicators.
Recently a hotel manager has been asked whether or not
his team is capable of maintaining scores between 8 and
10 (on a scale of 1 to 10) for “overall cleanliness of room”.
The most recent data has a mean of 8.624, a standard
deviation of 1.446 and n = 10. calculate and interpret Cp
and Cpk
REVISE THE CHARTS
State of Process Control
 A process is considered to be in a state of control or
under control when the performance of the process
falls within the statistically calculated control limits
and exhibits only chance / common causes
 When a process is under control, it is considered stable
and the amount of future variation is predictable
 Several benefits to a stable process:
 There is a rational basis for planning
 Quality levels are predictable
 When improvements are made, the effects of the changes
can be determined quickly and reliably
REVISE THE CHARTS
Control Chart Interpretation
 Correct interpretation of control charts is essential to
managing a process
 Understanding the sources and potential causes of
variation is critical to good management decisions
 Misinterpretation can lead to a variety of losses,
including:
 Blaming people for problems that they cannot control
 Spending time and money looking for problems that do
not exist
 Spending time and money on process adjustments or new
equipment that are not necessary
 Taking action where no action is warranted
REVISE THE CHARTS
 There are two circumstances under which the control chart is
revised and new limits calculated
 If a charts exhibits good control and any changes made to
improve the process are permanent
 When the new operating conditions become routine and no
out-of-control signals have been seen
 The revisions provide a better estimate of the population
standard deviation – a better understanding of the entire
process can be gained
 Control limits are also revised if pattern exist – provided that
the patterns have been identified and eliminated
 The new limits will reflect the changes and improvements made
to the process – used to judge the process behavior in the
future
REVISE THE CHARTS
Steps taken to revise the charts:
1. Interpret the original chart
2. Isolate the cause
3. Take corrective action
4. Revise the chart

 It is necessary to remove any undesirable points or

groups of points, the causes of which have been
determined and corrected
 If no cause can be found and corrected, then the points
cannot be removed from the chart
 The points removed will equal zero and the calculations
will continue from there