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Types of problems:
Types Examples of problems
Zero Problem As a floor manager in boiler area of a pesticide firm, you
have to solve the problem of recurring accidents
Increase Problem The production of sports goods in your firm has been
augmented by 55% in order to meet the demand created
by National Athletic Field
Decrease Problem You have to solve the problem of high inventory so that
you can minimize inventory costs incurred by your firm
Statistical Process Control (SPC) The use of statistical analysis to improve quality
by reducing unwanted variations in industrial and management processes and
process capabilities.
Types of variations:
Variations due to Random Cause e.g., someone bumps your elbow when
you are singing
Variations due to Assignable Cause e.g., all documents in your computer
are changed into bar codes due to a virus attack
A process is capable (or under statistical control) when Assignable Causes have been
identified and removed. SPC is used to:
Decide exactly how much variation is allowed in a process
Ensuring defect-free manufacturing / processing by reducing variations
Measure the consistency of processes
Keep processes under control
Out-of-Control Processes:
A continuous upward pattern indicates that the process is deteriorating with time. A
common reason may be wear and tear of machines.
A cyclic trend (peaks and valleys) indicate that the process faced variations due to
random causes such as worker fatigue, shift change, etc.
Peaks and valleys outside the control limits indicate the poorly trained workers,
defective materials and frequent readjustments of the machines
Another graph which is an outcome of wrong samples being picked up rather than
wrong processes followed. Apart from improper sampling, biased measurement may
also cause such a type of graph
Exercise 3.1: What can be concluded from appearance of the graph?
This shows that the operators of the unit are not trained properly
Zone Tests:
Zone tests are used to enhance the ability of the control charts to detect / study
small shifts in the process. The dividing line of each zone is exactly one third the
distance between center line and the UCL or LCL.
Nine points in Zone C or beyond: This pattern indicates that the process average has
changed. It is a useful test to alert the quality control engineer to potential shifts in
the process
Two out of three points in a row in Zone A or beyond: This pattern provides early
warning of a process shift
Four out of five points in a row in Zone B or beyond: This is also an early warning
indicator for a potential process shift
Eight points in a row in Zone A or B or beyond in either side of the centerline: This
test indicates that different samples are affected by different factors, resulting in
bimodal distribution of modes.
Variations are not only unproductive but also expensive. For an operation to be a
success it is very important to eliminate or at least minimize the variations
Chapter: 4 Total Productive Maintenance
Exercise 4.2: