10/19/2016

Process Capability & Tolerance

The process spread will be referred to as the
process capability and is equal to 6
The difference between specifications is called
the tolerance

Process Capability Analysis

When the tolerance is established by the design

engineer without regard to the spread of the
process, undesirable situations can result

Process Capability & Tolerance

Process Capability & Tolerance

Three situations are possible:

Case I: When the process capability is less
than the tolerance 6<USL-LSL
Case II: When the process capability is equal
to the tolerance 6=USL-LSL
Case III: When the process capability is
greater than the tolerance 6 >USL-LSL

Case I: When the process capability is less than

the tolerance 6<USL-LSL

Case I 6<USL-LSL
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11

Process Capability & Tolerance

Process Capability & Tolerance

Case II: When the process capability is equal to

the tolerance 6=USL-LSL

Case III: When the process capability is greater

than the tolerance 6>USL-LSL

Case I 6=USL-LSL

Case I 6>USL-LSL
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Process Capability

Process Capability

The range over which the natural variation of

a process occurs as determined by the system
of common or random causes

This following method of calculating the process

capability assumes that the process is stable or in
statistical control:
Take 25 (g) subgroups of size 4 for a total
of 100 measurements
Calculate the range, R, for each subgroup
Calculate the average range, RBar= R/g
Calculate the estimate of the population
R

d
standard deviation
Process capability will equal 60

Measured by the proportion of output that

can be produced within design specifications

14

15

Capability Index

Process Capability

Process capability and tolerance are combined

to form the capability index.

The process capability can also be obtained by using the

standard deviation:
Take 25 (g) subgroups of size 4 for a total of
100
measurements
Calculate the sample standard deviation, s, for each
subgroup
Calculate the average sample standard deviation,
sbar = s/g
Calculate the estimate of the population
s
0
standard deviation
c4
Process capability will equal 6o
16

Capability Index

17

Capability Index

The capability index does not measure process

performance in terms of the nominal or target
value. This measure is accomplished by Cpk.

Cp = USL - LSL
6 o
The Capability Index does not measure
process performance in terms of the
nominal or target

Cpk = min{ (USL- X), (X-LSL)}

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Capability Index

Capability Index

1. The Cp value does not change as the process

center changes
2. Cp=Cpk when the process is centered
3. Cpk is always equal to or less than Cp
4. A Cpk = 1 indicates that the process is producing
product that conforms to specifications
5. A Cpk < 1 indicates that the process is producing
product that does not conform to specifications

6. A Cp < 1 indicates that the process is not

capable
7. A Cpk=0 indicates the average is equal to one
of the specification limits
8. A negative Cpk value indicates that the
average is outside the specifications

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21

Cpk Measures

Exercise 4
A new process is started , and the sum
of the sample standard deviation for
25 subgroups of size 4 is 750. If the
specifications are 700 +/ - 80, What is
the process capability index? What
action would you recommend?

Cpk = negative number

Cpk = zero
Cpk = between 0 and 1
Cpk = 1
Cpk > 1
22

Different Control Charts

Charts for Better Operator Understanding:
1. Placing individual values on the chart: This
technique plots both the individual values and
the subgroup average. Not recommended since
it does not provide much information.
2. Chart for subgroup sums: This technique plots
the subgroup sum, X, rather than the group
average, Xbar.

Chart for
Individual Values & Subgroup
Averages

UCL X n(UCLX )
UCL X n( LCLX )

24

Subgroup Sum Chart

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Different Control Charts

Charts for Variable Subgroup Size:
Used when the sample size is not the same
Different control limits for each subgroup
As n increases, limits become narrower
As n decreases, limits become wider apart
Difficult to interpret and explain
To be avoided

Chart for Variable Subgroup Size

27

Different Control Charts

28

Chart for Trends

Use Least Square Calculations

Chart for Trends:

Used when the plotted points have an upward
or downward trend that can be attributed to an
unnatural pattern of variation or a natural
pattern such as tool wear.
The central line is on a slope, therefore its
equation must be determined.

30

Chart for Trends

31

Trend Charts( Tool wear)

Steps In Creating Trend Chart
1. Create table showing values of X, X2, Y and XY and
sums of the variables
2. Create Range Chart
3. Calculate the slope and intercept
4. Use the slope and intercept to find the center line
5. Find Control limits use same formula for regular
Xbar chart.
6. Set the charts scale
7. Plot the data points and control limit points and
connect them

Chart for Trend

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10/19/2016

Moving-Average and Moving-Range

Charts

Moving-Average and Moving-Range

Charts

X bar and R charts track performance of processes that

have long production runs or repeated services
Sometimes, there may be insufficient number of sample
measurements to create the traditional Xbar and R chart.
Only one sample may be taken from the process
Rather than plotting each individual reading , use moving
average and moving range charts to combine n number
of individual values to create an average.

Chart for Moving Average and

Moving Range
Value

Used when we cannot have

multiple observations per
time period

NOTE: n (Range) here is equal to 12, NOT 14

Xbar

Use for continuous processes chemical industry:

Smoothing effect on the moving averageoften has an effect on
the figures similar to the blending and mixing that takes place in
the remainder of the production process.

Use for seasonal products:

Combining values produced over time, moving averages smooth
out short term variations, and provide the trends in the data.

Chart for Moving Average and Moving

Range
R

Extreme readings have a greater effect than in

conventional charts. An extreme value is used
several times in the calculations, the number
of times depends on the averaging period.

44

46
54

48.00

10

38

46.00

16

49

47.00

16

46

44.33

11

45

46.67

31

40.67

15

55

43.67

24

37

41.00

24

42

44.67

18

43

40.67

47

44.00

51

47.00

An example
37

Exercise: Moving Average and Moving Range

38

Chart for Median and Range

This is a simplified variable control chart.

Determine the trial central line and control limits for a

moving average and moving-range chart using a time
period of 3. Data in liters are as follows : 4.56, 4.65, 4.66,
4.34, 4.65, 4.40, 4.50, 4.55, 4.69, 4.29, 4.58, 4.71, 4.61,
4.66, 4.46, 4.70, 4.65, 4.61, 4.54, 4.55, 4.54, 4.54, 4.47,
4.64, 4.72, 4.47, 4.66, 4.51, 4.43, and 4.34. Are there any
out-of control points?

Minimizes calculations
Easier to understand
Can be easily maintained by operators
Recommended to use a subgroup of 3,
then all data is used.

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Chart for Median and Range

Exercise Median and Range

The Get Well Hospital has completed a quality improvement project on the
time to admit a patient using Xbar and R charts. The hospital now wishes to
monitor the activity using median and range charts. Determine the central
line and control limits with the latest data in minutes as given below
Subgroup
X1
No

For Table for A5, D5 and D6

Where : Md md = grand median (median of the

medians)
A5 factor for determining 3 control limits
Rmd = median of the subgroup ranges

= Rmd/D3 estimate of the

population standard deviation

1
2
3
4
5
6
7
8
9
10
11
12

6.0
5.2
5.5
5.0
6.7
5.8
5.6
6.0
5.5
4.3
6.2
6.7

X2
5.8
6.4
5.8
5.7
6.5
5.2
5.1
5.8
4.9
6.4
6.9
7.1

X3
6.1
6.9
5.2
6.5
5.5
5.0
5.2
6.0
5.7
6.3
5.0
6.2

Subgroup
X1
No
13
14
15
16
17
18
19
20
21
22
23
24

6.1
6.2
4.9
7.0
5.4
6.6
4.7
6.7
6.8
5.9
6.7
7.4

X2
6.9
5.2
6.6
6.4
6.5
7.0
6.2
5.4
6.5
6.4
6.3
6.8

X3
7.4
6.8
6.6
6.1
6.7
6.8
7.1
6.7
5.2
6.0
4.6
6.3

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Chart for Individual values

Individual and Moving-Range i-chart

Used when only one measurement is taken

on quality characteristic

The chart is useful when number of products produced is too small to form
traditional Xbar and R chart charts and data collection occurs either once a day, or
a week-to-week or month-to-month basis.

Too expensive

The individual Xi measurements are taken and plotted on the individual chart

Time consuming

Two consecutive individual data-point values are compared and the absolute
value of their difference is recorded on the moving-range chart. The movingrange is usually placed on the R chart between the space designated for a value
and its preceding value.

Destructive
Very few items

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Chart for Individual Values

Chart for Individual Values

Revised Limits:

To use those equations, you have to use a moving range with n=2

Where = 0.8865 R

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10/19/2016

Chart for Individual Values

Individual and Moving-Range i-chart

Interpretation of individual and moving-range charts is similar to that of
the Xbar and R charts
Once the process is considered control, the process capability is
determined
i-charts are more reliable when the number of samples exceeds 80.

Control Charts for Individual Values and Moving Range

48

Charts with Non-Acceptance Limits

Exercise Individual Values

Create a chart for individuals with a moving range for the
measurements given below. (Values are coded 21 for .0021 mm). After
determining the limits, plotting the values, and interpreting the chart,
Calculate using Rbar/d2. Is the process capable of meeting the
specifications of 0.0025 +/- 0.0005 mm?

Sample
1
2
3
4
5
6
7
8
9
10
11
12
13

X
21
22
22
23
23
24
25
24
26
26
27
27
25

Sample
14
15
16
17
18
19
20
21
22
23
24
25

Non-Acceptance limits have the same

Relationship to averages as specifications
have to individual values. Control Limits tell what the
process is capable of doing, and reject limits tell
when the product is conforming to specifications.

X
26
23
23
25
25
26
23
24
24
22
23
25

V = 3 - 3 /n -

prescribed distance from the specification and varies

with subgroup size

51

Exponential Weighted Average

(geometric moving average)

Charts with Non-Acceptance Limits

Gives greatest weight to most recent values.

Ability to detect small shifts in the process
average.
The EWMA is defined by the equation
Vt = Xbart + (1 ) Vt-1
where Vt = most recent plotted point

Vt1 = previous plotted point

= weight given to subgroup average

or individual value

Xbar = the subgroup average or individual

value

Relationship of non-acceptance limits, control limits

and specifications.
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Exponential Weighted Average

Exponential Weighted Average

UCL = Xdbar + A2Rbar(((SqRt(/(2 )))
LCL = Xdbar - A2Rbar(((SqRt(/(2 )))
should be between 0.05 and 0.25, - lower values give better
ability to detect smaller shifts.

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55

Exercise EWMA
Determine an EWMA for = 0.05, and 0.25

Subgroup
No.

Subgroup
No.

476

32

14

482

22

466

24

15

506

23

484

32

16

496

23

466

26

17

478

25

470

24

18

484

24

494

24

19

506

23

486

28

20

476

25

496

23

21

485

29

488

24

22

490

25

10

482

26

23

463

22

11

498

25

24

469

27

12

464

24

25

474

22

13

484

24