QUALITY PROJECT

IMPLEMENTATION

OF
SPC-Statistical
process control.
SPC

STATISTICAL PROCESS
CONTROL

Application of statistical to monitor and control

methods a process in producing
a confirming product.
IMPLEMENTATION OF SPC
 Understanding the process;
The process is typically mapped out and the process is
monitored using control charts. (define)

 Understanding the causes of variation;

Gauge RnR performed (measure and analyse)

 Elimination of the sources of special cause variation. (implement

and control)
 UNDERSTANDING THE PROCESS
The inner dia of coupling
hole (ɸ86mm H7) of
bujagali generator lower
shaft are observed to have
variation / deviation from
the required dimension on
application of the boring
operation by NEW
INNOCENTI horizontal
boring machine.

.
Contd…..

 It was not feasible to go for quality check on every product individually

so we decided to apply SPC to the machines carrying out certain
operations. (Boring , Drilling & Turning)

 We collected data(excel sheets) of the operation done by various

machines (skoda boring m/c, innocenti new and old, kolb,…) on different
products (DE &NDE shafts of different projects (bujagali , subansiri , etc
).

 And then plotted the data into x-bar charts under the specified limits to
identify any deviations.
 BORE Φ 86 Avg Reading 1 -
MACHINE COMPONENT PROJECT *16 nosH7 READING 1 READING 2 Reading 2 SPEC

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 1 86.01 86.02 86.015 86 86.035

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 2 86.02 86.03 86.025 86 86.035

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 3 86.01 86.02 86.015 86 86.035

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 4 86.02 86.03 86.025 86 86.035

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 5 86.01 86.02 86.015 86 86.035

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 6 86.03 86.04 86.035 86 86.035

New Gen. Lower

Innocenti Shaft Unit 3 Bujagali Bore no. 7 86.02 86.03 86.025 86 86.035
X-BAR CHART x-bar
86.07

86.06

86.05

usl
86.04

86.03

86.02
lsl
86.01

86

85.99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

x-bar
 Define
Step A

IDENTIFYING PROJECT CTQS

Customer Sample Comments Key Output Characteristics
Important to Customer (CTQs) Key Questions

What customer groups are the

Variation in the Bore Diameter primary focus for this project?
dimensions of the 16
Coupling COUPLING HOLE ASSEMBLY
coupling holes of
assembly PROCESS
inner dia 86 mm of
Process
bujagali generator What methods were used to
lower shaft. understand customer
requirements?
<> <>
VOC-Voice of customer

Which CTQ(s) will be the primary

focus for this project?

<> <> <> Bore Diameter

 Define
Step A
CTQ DRILLDOWN TREE

Shaft

Casting Machining

Drilling Turning Boring

Sizing Straightness Concentricity

 Define
Step B

Business Case: Project Scope

The inner dia of coupling hole are
observed to have variation /
deviation from the required
dimension on application of the
boring operation by NEW
INNOCENTI horizontal boring
machine.
Process Starts With: Fit up, alignment and levelling.
Process Ends With: Boring and checking co-centricity with plug gauge.
Inscope : alignment,dialing,pre-boring,insertion check by plug gauge,final
boring.
Outscope : all other processes
Constraints (Conflicting CTQ):
Process Impacted:
Business Y Impacted:

Problem Statement:
The dimensions of inner diameter Team Roles
of the coupled bore deviates from Champion:
the specification limits. Black Belt:
Master Black Belt / Coach:Mr.Vimal Vyas
Quality Leader: Mr.Rajni Panchal
Goal Statement & Estimated Process Owner:
Benefit: Team Members: Harmanpreet Singh Maan
The dimension of inner dia of
coupled bore must lie within the
specified limit. Project Timeline
This will save time (quickly Customer Want Date:
moving onto assembly STEP (**) Estmtd Date Actual Signoff Date
process),labour and cost.
Define
Measure
Analyze
Improve
Control
 Define
Step C

HIGH LEVEL PROCESS MAP

S I P O C Key Questions
Supplier Input Process Output Customer
(Use nouns) (Use verbs) (Use nouns) What are the process boundaries?
Start:
1.Fit up(clamping Fit-up
and Stop:
NEW Machined
FINAL INNOCENTI Alignment / Coupling Co-centricity check by
MACHINING shaft plug gauge
(horizontal levelling) assembly
PROCESS Boring
(ON HTL SKODA) machine) What is included/excluded in
the scope of this project?
2.Dialing of Includes:
template bore
DE SHAFT Stainless
Final steel Excludes:
machined
3.Pre-boring Scrap.
What is the Unit, Opportunity, Defect?

Plug gauge
4.Checking and
insertion by
plug gauge Has this process map been validated
by key people?

5.Boring

Manpower
(Operator) 6.Checking
co-centricity <Takeaway Box>
by plug gauge
GAUGE RNR
Gauge RnR measures the amount of There are two important aspects of
variability induced in the a Gauge R&R:
measurements by the measurement •Repeatability: The variation in
system itself. measurements taken by a same
operator on the same item and by the
There are several factors affecting a same instrument.
measurement system, including: •Reproducibility: The variability
(sources of measurement induced by the operators. It is the
variation) variation induced when different
•Measuring instruments. operators (or different laboratories)
•Operators. measure the same part.
•Test methods (how the devices are
set up)
REPEATIBILITY REPRODUCIBILITY
Same operator Different operator
Same Gauge Same Gauge
Same Object Same Object
 HOW TO PERFORM GAUGE R&R?
 The Gauge R&R (GRR) is performed by measuring parts using the established
measurement system. The goal is to capture as many sources of
measurement variation as possible, so they can be assessed and
understood.
 To capture repeatability errors, the same part is usually measured several times by
each operator.
 To capture reproducibility errors, multiple operators are needed to measure the same
parts.

GAUGE Rn R – was carried on Φ74mm(H7) BORE by a bore gauge of 10µ and then
for better precision was carried out using a 1µ bore gauge.
There are a no. of methods to analyze GAUGE R n R:
1.Done in the minitab software
2.Gauge Rn R EXCEL SPREAD SHEET.
3. Mathematical method.
STEP –1
Defining the size of gauge Rn R Study
1.No.of operators(2-3)=2
2.No.of trials(2-3)=2
3.No.of parts(2-10)=10 (out of the 16 holes we choose 10 at random)

STEP -2
Selection of bore and measuring instrument:
Bore-74 mm H7 bore
Measuring instrument- 1µ or 10µ bore gauge.

STEP -3
Calibration and taking readings
(filling of excel spread sheet)

STEP-4
ANALYSES done on minitab software
CONCLUSIONS
•Implementation of SPC (statistical process
control)
•Gauge RnR came out satisfactory using a 1µ dial gauge.
Implementation of spc is underway and it will serve well in improving
product quality for future projects that will help in improving customer
satisfaction and thus be of great value for the company.
Spc on the machining operations like drilling, boring and turning on
different machines ,will soon begin on the same lines as the one
implemented by me.

•Assembly of Kaplan runner (bujagali project,Uganda)

unit-5 has been sent to dispatch and its on site work assembly is underway
at this very moment.
THANK YOU