Teori QC

Chapter 10
Quality Control
Phases of Quality Assurance

Figure 10-1
Inspection
before/after
production
Acceptance
sampling
Corrective
action during
production
Process
control
Quality built
into the
process
Continuous
improvement
The least
progressive
Management
The most
progressive
Chapter 10 Quality Control
10-2
The Process (1 of 2)
Over time, the output of any process
shows a certain amount of natural or
inherent variability
This is also referred to as random
variability
It is due to countless minor factors and
is assumed to be out of managements
control in the short run, i.e., you have to
live with it
Management
10-3
The Process (2 of 2)
The distribution of a process output
has a mean, and a standard
deviation; it can have a wide variety
of shapes
Process
distribution
Mean
Management
10-4
Process Capability (1 of 3)
When selecting a process to
perform an operation, the inherent
variability of process output should
be compared to the range or
tolerances allowed by the
designers specifications
Management
10-5
Process Capability
(2 of 3)
process distribution
Lower
Specification
Upper
Specification
Much of the process output

fits within specification width
Almost all of the process output

fits within the specification width
In other words, is the

process capable of
producing the item
within
specifications?
A significant portion of the process output

falls outside of the specification width
Management
10-6
Process Capability (3 of 3)
The process capability index (cp)
compares the design specifications
with a measure of process
variability
specificat ion width
cp =
process variability width
upper specificat ion - lower specification
=
6
Management
10-7
Determine which of the following machines are

capable of holding the specification of 1.00 mm to
1.60 mm
Standard
Machine
Deviation
A
0.10
B
0.08
C
0.13
Management
10-8
Standard Machine
Machine
Deviation Capability
A
0.10
0.60
B
0.08
0.48
C
0.13
0.78
To Express the process capability of a machine or
process a ration of the specification width to the
process capability
specification width Upper Specification - lower specification
Cp
process width
6
Management
10-9
Machine
A
B
C
Standard Machine
Deviation Capability C(p)
0.10
0.08
0.13
0.60
0.48
0.78
0.60/0.60 =1.00
0.60/0.48 =1.25
0.60/0.78 =0.77
Machine A is a exact match - is this what we would like

to have? Why or Why Not?
Management
10-10
Three-Sigma Quality
Lower
design
specification
Upper
design
specification
1350 ppm
1350 ppm
-3 Sigma
Management
mean +3 Sigma
10-11
Three-Sigma Quality vs.

Six-Sigma Quality
Lower
design
specification
Upper
design
specification
1350 ppm
1.7 ppm
Management
1350 ppm
-3 Sigma
mean +3 Sigma
-6 Sigma
mean +6 Sigma
1.7 ppm
10-12
Process Control (1 of 6)
Once a process is in operation, a goal is to
maintain the status quo, i.e., keep the
process in control
What can make the process no longer be
in control, i.e., go out of control?
The presence of an assignable cause
The presence of an assignable cause may

cause the process distribution to
shift to the left or right, and/or
increase the variability (flatten out)
Management
10-14
If the process mean
shifts, more of output
falls outside the
specifications
Management
Time
lower design upper design

specification specification
10-15
If the process mean
shifts, more of output
falls outside the
specifications
If process variance
increases, more of the
output falls outside of
the specifications
Management
Time
lower design upper design

specification specification
10-16
In either case, the process is
considered to be out of control
It should be stopped, investigated
(the assignable cause found if
present) and corrected (the
process brought back to the
status quo)
Management
10-17
Examples of assignable causes
include
operator
raw material
equipment
environment
Management
10-18
How does management detect the
presence of an assignable cause?
Process output is monitored to
detect any changes by inspecting
the output of the process
Inspection means assessing some
characteristic of a unit of output
Management
10-19
Inspection Issues
Figure 10-2
How Much/How Often

Where/When
Centralized vs. On-site
Inputs
Acceptance
sampling
Management
Transformation
Process
control
Outputs
Acceptance
sampling
10-20
Where to Inspect in the

Operations System
Raw materials and purchased parts

Finished products
Before a costly operation
Before an irreversible process
Before a covering process
Management
10-21
Inspection Options
100% inspection of the process
output
can be costly and/or time consuming
inspection may alter or destroy unit
Sample from the process output

referred to as statistical process control
(SPC)
based on the Central Limit Theorem
error possible when deciding if the
process is in control
Management
10-22
Overview of the Statistical

Quality Control (QC) Process
Proce
ss
Outpu
t
Management
10-23

Proce
ss
Outpu
t
Management
Sample
of size n
10-24

Proce
ss
Outpu
t
Management
Sample
of size n
Inspect Each
Item in the
Sample
10-25

Proce
ss
Outpu
t
Sample
of size n
Inspect Each
Item in the
Sample
Sample
Information
Management
10-26

Proce
ss
Outpu
t
Sample
of size n
Compare
Inspect Each
Item in the
Sample
Sample
Information
Decision
Criteria
Management
10-27

Proce
ss
Outpu
t
Sample
of size n
Inspect Each
Item in the
Sample
IN CONTROL
Compare
Sample
Information
Decision
Criteria
Management
10-28

Proce
ss
Outpu
t
Sample
of size n
Inspect Each
Item in the
Sample
IN CONTROL
Compare
Sample
Information
OUT OF CONTROL
Decision
Criteria
Management
10-29
Central Limit Theorem

The distribution of sample means tend to be
normally distributed even though the process
distribution is not normal
The mean of the distribution sample means
(x) is equal to the mean of the process
distribution( )
The standard deviation of the distribution of
sample means ( x ) is equal to the standard
deviation of the process distribution(x )
divided by n
Management
10-30
Statistical Process Control

Primary purpose is to decide when
the process output may be affected
by an assignable cause
The decision is based on
an indicator of the status of the output
of a process (sample statistic)
the criteria placed on the distribution
of the sample statistic (control limits)
Management
10-31
Control Chart (1 of 5)
This information is typically
displayed as a control chart
upper
control limit
Sample
Statistic
central
line
Sampling
distribution
lower
control limit
Time
Management
10-32
After a sample is taken and
inspected, the resulting sample
statistic is computed and plotted
upper
control limit
Sample
Statistic
central
line
lower
control limit
Time
Management
10-33
If the sample statistic falls between
the control limits, the process is
considered to be in control
upper
control limit
Sample
Statistic
central
line
lower
control limit
Time
Management
10-34
If the sample statistic falls outside
the control limits, the process is
considered to be out of control
upper
control limit
Sample
Statistic
central
line
lower
control limit
Time
Management
10-35
Under this arrangement, there is
the possibility of making an error in
determining the processs status
upper
control limit
Sample
Statistic
central
line
lower
control limit
Sampling
distribution
Probability of deciding the
process is out of control
when it is still in control
Time
Management
10-36
Statistical Process Control

Control charts for the two inspection
methods will be examined
Two control charts for variables
inspection
sample means chart (x-bar chart)
sample range chart (R chart)
One control chart for attributes inspection

sample proportion defective chart (p chart)
Management
10-37
Control Charts for Variables

(1 of 3)
A sample of size n is taken from the

process output
Each unit in the sample is
inspected a variables basis
Measurement of the specified value is
taken on a continuous scale
Management
10-38
Variables (2 of 3)
These data are used to calculate
two sample statistics
sample mean, x (the sum of
measurement of each unit in the
sample divided by n)
sample range, R, (the highest
measurement in the sample minus
the lowest measurement in the
sample)
Management
10-39
Variables (3 of 3)
In this case two separate control
charts are used to monitor two
different aspects of the process
output
central tendency
variability
The central tendency of the output

is monitored using the x-chart
The variability of the output is
monitored using the R-chart
Management
10-40
R or range Charts (variable data)
UCL R D4 R
LCL R D 3 R
where : R average range of the sample
D 3 table value
D4 table value
Management
10-41
Calculating
Sample
1
23 45
1
12.1112.15
2
12.1012.12
Observation 312.11
12.08 12.1112.15
Mean 12.1012.12
R
.03
12.09
12.09
12.10
12.10
12.11
12.12
12.10
12.11
12.12
12.10
12.09
12.14
12.08 12.13
12.12
R = Largest Observation - Smallest Observation

Management
10-42
Calculating
Sample
1
23 45
1
12.1112.15
2
12.1012.12
Observation 312.11
12.08 12.1112.15
Mean 12.1012.12
R
.03.05
12.09
12.09
12.10
12.10
12.11
12.12
12.10
12.11
12.12
12.10
12.09
12.14
12.08 12.13
12.12

Management
10-43
Calculating
Sample
1
23 45
1
12.1112.15
2
12.1012.12
Observation 312.11
12.08 12.1112.15
Mean 12.1012.12
R
.03.05 .06
12.09
12.09
12.10
12.10
12.11
12.12
12.10
12.11
12.12
12.10
12.09
12.14
12.08 12.13
12.12

Management
10-44
Calculating
Sample
1
23 45
1
12.1112.15
2
12.1012.12
Observation 312.11
12.08 12.1112.15
Mean 12.1012.12
R
.03.05 .06
12.09
12.09
12.10
12.10
12.11
.04
12.12
12.10
12.11
12.12
12.10
12.09
12.14
12.08 12.13
12.12

Management
10-45
Calculating
Sample
1
23 45
1
12.1112.15
2
12.1012.12
Observation 312.11
12.08 12.1112.15
Mean 12.1012.12
R
.03.05 .06
12.09
12.09
12.10
12.10
12.11
.04
12.12
12.10
12.11
12.12
12.10
.05
12.09
12.14
12.08 12.13
12.12

Management
10-46
Calculating
1
2
Observation 3
4
Mean
R
R
1
12.11
12.10
12.11
12.08
12.10
.03
Sample
2
3
12.15 12.09
12.12 12.09
12.10 12.11
12.11 12.15
12.12 12.11
.05
.06
4
12.12
12.10
12.08
12.10
12.10
.04
5
12.09
12.14
12.13
12.12
12.12
.05
0.03 0.05 0.06 0.04 0.05

R
0.046
5
Management
10-47
Twenty - five samples of n = 10 observations

have been take from a milling process. The
average sample range was 0.01. Determine
the control limits.
R 0.01, n 10, From table 10 2 for n 10, D4 178
. and D3 0.22
UCLR 178
. 0.01 0.0178 0.018
LCLR 0.22 0.01 0.0022 0.002
Management
10-48
x-Chart
The central line is x, the sum of a
number of sample means collected
while the process was considered to
be in control divided by the number of
samples
Management
10-49
UCL x z x
LCL x z x
Mean or x-bar Charts

(variable data)
where : x mean of the sample means

z number of standard deviations
x sample standard deviation
or
UCL x x A 2 R
LCL x x A 2 R
where : x mean of the sample means
A 2 table value
Management
R average range of the samples

10-50
3, n 4, .02
1
2
Observation 3
4
Mean
1
12.11
12.10
12.11
12.08
12.10
Sample
2
3
12.15 12.09
12.12 12.09
12.10 12.11
12.11 12.15
12.12 12.11
4
12.12
12.10
12.08
12.10
12.10
5
12.09
12.14
12.13
12.12
12.12
12.10 12.12 12.11 12.10 12.12

x
12.11
5
.02
.02
12.08
UCL 12.11 3
12.14 LCL 12.11 3
4
4
Management
10-51
Given the following, Calculate the 3 sigma

control limits.
Twenty samples of n = 8 have been taken. The
average sample range for the 20 samples was
0.016 and the average mean was 3 minutes.
x 3, R 0.016, A2 0.37 for n 8 from table 10 2
UCL x A2 R 3 0.37 0.016 3.006

LCL x A2 R 3 0.37 0.016 2.994
Management
10-52
Mean and Range Charts
process mean is shifting upward
Figure 10-10A
Process
Distribution
UCL
Shift Detected
x-Chart
LCL
UCL
No shift detected
R-chart
LCL
Management
10-53
Mean and Range Charts
process variability is increasing
Figure 10-10B
Process
Distribution
UCL
x-Chart
No shift detected
LCL
UCL
Increase detected
R-chart
LCL
Management
10-54
Control Chart for Attributes

(1of 3)
A sample of size n is taken from the

process output
Each unit in the sample is inspected a
attributes basis
A unit is classified in one of two categories
good or bad
pass or fail
operates or doesnt operate
does or does not meet design specifications
Management
10-55
Attributes (2 of 3)
These data are used to calculate the
sample statistic
sample percentage defective, p (the
number of units found to be defective in
that sample divided by n)
Although the distribution of sample

statistic follows a binomial distribution,
that distribution can be approximated by
a normal distribution with a mean of p
and a standard deviation of p(1 p)/n
Management
10-56
p Chart (Attribute data)

UCL p p z p
LCL p p z p
where : p
z
mean fraction defective in the sample

number of standard deviations
p (1 p)
p
n
where : n size of each sample
Management
10-57
3.00 for 99.74 percent from Appendix Table A

Total number of defectives
220
p
011
.
Total number of observations 20 100
UCL p p z
LCL p p z
Management
p 1 p
p 1 p
n
0.11 3
0.11 3
0.11 1 0.11
100
0.11 1 0.11
100
0.20
0.02
10-58
Use of c-Charts
Use only when the number of
occurrences per unit of measure can
be counted; nonoccurrences cannot be
counted.
Scratches, chips, dents, or errors per
item
Cracks or faults per unit of distance
Breaks or Tears per unit of area
Bacteria or pollutants per unit of volume
Calls, complaints, failures per unit of time
Management
10-59
c Chart (Attribute data)

UCL c c z c
LCL c c z c
where : c average number of defects per unit
z number of standard deviations
Management
10-60
3.00
Total number of defectives 45
c
2.5
Total number of samples 18
UCLc c z c 2.5 3 2.5 7.24

LCLc c z c 2.5 3 2.5 2.24 0
Management
10-61

Teori QC

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Teori QC

Caricato da

Copyright:

Formati disponibili

Chapter 10

Phases of Quality Assurance

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Much of the process output

Almost all of the process output

In other words, is the

A significant portion of the process output

Chapter 10 Quality Control

Chapter 10 Quality Control

Determine which of the following machines are

Chapter 10 Quality Control

Chapter 10 Quality Control

Machine A is a exact match - is this what we would like

Chapter 10 Quality Control

Chapter 10 Quality Control

Three-Sigma Quality vs.

Chapter 10 Quality Control

The presence of an assignable cause may

Chapter 10 Quality Control

lower design upper design

Chapter 10 Quality Control

lower design upper design

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

How Much/How Often

Chapter 10 Quality Control

Where to Inspect in the

Raw materials and purchased parts

Chapter 10 Quality Control

Sample from the process output

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Overview of the Statistical

Chapter 10 Quality Control

Central Limit Theorem

Chapter 10 Quality Control

Statistical Process Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Chapter 10 Quality Control

Statistical Process Control

One control chart for attributes inspection

Chapter 10 Quality Control

Control Charts for Variables