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SPRING 2019
PROFESSOR VAN SCOTER
LECTURE 8
1
TOPICS TO REVIEW TO PREPARE FOR MIDTERM
• DOCUMENT HOW YOU INVESTIGATED, WHAT YOU LEARNED, THE CAUSE AND
HOW IT WAS COLLECTED
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11
• I-CHART IS USED TO DETECT TRENDS AND SHIFTS IN THE DATA, AND THUS
IN THE PROCESS (DATA MUST BE ENTERED IN SEQUENCE)
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• THE CHART’S X-AXES ARE TIME BASED, SO THE CHART SHOWS THE
HISTORY OF THE PROCESS, SO IT IS IMPORTANT THAT THE DATA IS IN TIME-
ORDER 16
Xbar chart
Xbar-R chart
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• APPROXIMATELY 68% OF THE DATA IS WITHIN ONE STANDARD DEVIATION OF THE MEAN,
95% WITHIN TWO, AND 99% WITHIN THREE STANDARD DEVIATIONS OF THE MEAN
• THE CENTRAL LIMIT THEOREM IMPLIES THAT THE SUM OF Ƞ INDEPENDENTLY DISTRIBUTED
RANDOM VARIABLES IS APPROXIMATELY NORMAL, REGARDLESS OF THE DISTRIBUTION OF
THE INDEPENDENT VARIABLES. THE APPROXIMATION IMPROVES AS Ƞ INCREASES
• IN GENERAL, IF XI ARE IDENTICALLY DISTRIBUTED, AND THE DISTRIBUTION DOES NOT DEPART
RADICALLY FROM THE NORMAL, THEN THE CENTRAL LIMIT THEOREM WORKS QUITE WELL,
AND THESE CONDITIONS ARE FREQUENTLY MET FOR QUALITY ENGINEERING PROBLEMS
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2. THIS WILL RESULT IN TIGHTER CONTROL LIMITS BECAUSE THE AVERAGING EFFECT IN
EACH GROUP SMOOTHS OUT INDIVIDUAL HIGH AND LOW MEASUREMENTS, RESULTING
IN A CONTROL CHART THAT CAN DETECT SMALLER CHANGES IN THE PROCESS THAN
ONE WHICH PLOTS ONE POINT FOR EACH MEASUREMENT
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• THE CONTROL LIMITS FOR THE RANGE CHART ARE NOT SYMMETRICAL
ABOUT THE CENTER AVERAGE LINE
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24
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IN PRACTICE, WE USUALLY DON’T KNOW AND
• XBAR = 𝚺𝒎𝒙𝒊 /𝒎
• R = XMAX – XMIN
• RBAR = 𝚺𝒎𝑹𝒊 /𝒎
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CONTROL LIMITS FOR X CHART
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ESTIMATORS FOR SIGMA AND MU
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CONTROL LIMITS FOR THE X CHART – PROCESS
MEAN CHART
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CONTROL LIMITS FOR R CHART
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ESTIMATORS FOR SIGMA AND MU
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THE R CHART – PROCESS VARIABILITY CHART
• WE NEED AN ESTIMATE OF R
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IN PRACTICE, WE USUALLY DON’T KNOW AND
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ESTIMATING PROCESS CAPABILITY (CP)
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EXAMPLE 6.1 FROM TEXT – USED FOR HOMEWORK
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ESTIMATING PROCESS CAPABILITY (CP)
Xbar+/-variability
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WHEN TO USE XBAR R VERSUS XBAR S CHARTS
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2. SELECT THE PROCESS OPERATING CONDITIONS. CAREFULLY DEFINE CONDITIONS – THESE MAY
BE SOURCES OF VARIATION IN CAPABILITY TO UNDERGO FURTHER STUDIES.
4. CAREFULLY MONITOR DATA-COLLECTION PROCESS AND RECORD TIME ORDER WITH DATA.
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PROCESS CAPABILITY RATIOS
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PERCENTAGE OF THE SPECIFICATION BAND USED
UP BY THE PROCESS
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DOES A PROCESS CAPABILITY RATIO ALWAYS
NEED TO BE TWO-SIDED?
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CONFIDENCE INTERVALS AND PROCESS CAPABILITY
RATIOS
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CONFIDENCE INTERVALS ON PROCESS CAPABILITY
RATIOS
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Process
Capability
Analysis
using
Control
Charts
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Since LSL = 200
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PROCESS CAPABILITY ANALYSIS USING DESIGNED
EXPERIMENTS
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WHAT IS EXPERIMENTAL DESIGN?
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OBJECTIVES OF THE DESIGNED EXPERIMENT
1. DETERMINING WHICH VARIABLES ARE MOST
INFLUENTIAL ON THE RESPONSE, Y
2. DETERMINING WHERE TO SET THE INFLUENTIAL
X’S SO THAT Y IS NEAR THE NOMINAL
REQUIREMENT
3. DETERMINING WHERE TO SET THE INFLUENTIAL
X’S SO THAT VARIABILITY IN Y IS SMALL
4. DETERMINING WHERE TO SET THE INFLUENTIAL
X’S SO THAT THE EFFECTS OF THE
UNCONTROLLABLE VARIABLES Z ARE
MINIMIZED
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WHEN TO USE DESIGNED EXPERIMENTS
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FACTORIAL DESIGNED EXPERIMENTS
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HOMEWORK #1
• SOLUTION:
WE ARE GIVEN K = 24 SUBSETS FOR THIS SITUATION AS THERE ARE IN TOTAL OF
24 DATA SETS. SINCE, THERE ARE TOTAL OF FOUR PH MEASUREMENTS BEEN
TAKEN EVERY HOUR, SO FOR EACH SUBSET N = 4.
• WE NOW KNOW THAT THE VALUE OF XGA = 6.997. WITH THIS WE CAN
CALCULATE THE UPPER CONTROL LIMIT THAT IS UCL AND LOWER CONTROL
LCL FOR THE XBAR CONTROL TYPE CHART.
LIMIT THAT IS
UCL = XGA + A2 RA UCL=6.99+0.729*0.1217 = 6.99+.0887 = 7.0787
LCL = XGA – A2 RA LCL = 6.99-0.729*0.1217 = 6.99-.0887 = 6.9013
• WE NOW KNOW THAT THE VALUE OF RA = 0.1217. WITH THIS WE CAN ALSO
CALCULATE THE UPPER CONTROL LIMIT THAT IS UCL AND LOWER CONTROL
LIMIT THAT IS LCL FOR THE RANGE CONTROL TYPE CHART.
UCL = D4 RA AND LCL = D3 RA
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HOMEWORK #1- SECOND PART- USED HISTORICAL
DATA TO CREATE CHART PARAMETERS
• SOLUTION:
WE ARE GIVEN K = 24 SUBSETS FOR THIS SITUATION AS THERE ARE IN TOTAL OF
24 DATA SETS. SINCE, THERE ARE TOTAL OF FOUR PH MEASUREMENTS BEEN
TAKEN EVERY HOUR, SO FOR EACH SUBSET N = 4.
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HOMEWORK #1 HISTORICAL DATA ONLY
• WE NOW KNOW THAT THE VALUE OF SBAR = .06. WITH THIS WE CAN
CALCULATE THE UPPER CONTROL LIMIT THAT IS UCL AND LOWER CONTROL
LCL FOR THE SBAR CONTROL TYPE CHART.
LIMIT THAT IS
UCL = B4 *SBAR=UCL=2.266*0.06 = 0.1359
LCL = B3 * SBAR =UCL=0*0.06 = 0
CENTER LINE = SBAR = .06
SO, FROM THE FORMULA AND VALUES ABOVE WE GET: UCL = 0.1359 AND
LCL = 0. CENTERLINE = 0.06
• EXPERIMENTAL DATA: GREATEST SBAR IS 0.15 SMALLEST IS 0 => WITHIN
CONTROL
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HOMEWORK PROBLEMS FOR 2/17
CHAPTER 6
• 6.6
• 6.8
• 6.10
• 6.18
• 6.42
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• 6.6. THE NET WEIGHT (IN OZ) OF A DRY BLEACH PRODUCT IS TO
• BE MONITORED BY X AND R CONTROL CHARTS USING A SAMPLE SIZE OF N = 5. DATA FOR 20
PRELIMINARY SAMPLES ARE SHOWN IN TABLE 6E.6.
• (E) WHAT FRACTION OF CONTAINERS PRODUCED BY THIS PROCESS IS LIKELY TO BE BELOW THE
LOWER SPECIFICATION LIMIT OF 15.7 OZ?
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• 6.8 REWORK EXERCISE 6.3 USING THE S CHART.
• THE DATA SHOWN IN TABLE 6E.3 ARE THE DEVIATIONS FROM NOMINAL DIAMETER FOR
HOLES DRILLED IN A CARBON-FIBER COMPOSITE MATERIAL USED IN AEROSPACE
MANUFACTURING.
• THE VALUES REPORTED ARE DEVIATIONS FROM NOMINAL IN TEN-THOUSANDTHS OF AN
INCH.
• (A) SET UP X AND R CHARTS ON THE PROCESS. IS THE PROCESS IN STATISTICAL
CONTROL?
• (B) ESTIMATE THE PROCESS STANDARD DEVIATION USING THE RANGE METHOD. SIGMA
=RBAR/D2 D2=4.918
• (C) IF SPECIFICATIONS ARE AT NOMINAL ±100, WHAT CAN YOU SAY ABOUT THE
CAPABILITY OF THIS PROCESS? CALCULATE THE PCR CP. (USL-LSL)/6SIGMA >1
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• 6.10 TABLE 6E.7 SHOWS 15 ADDITIONAL SAMPLES FOR THE PIS-TON RING PROCESS (TABLE
6.3), TAKEN AFTER THE INITIAL CONTROL CHARTS WERE ESTABLISHED. PLOT THESE DATA ON THE
X AND R CHART DEVELOPED IN EXERCISE 6.9. IS THE PROCESS IN CONTROL?
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• 6.18 CONSIDER THE X AND R CHART THAT YOU ESTABLISHED IN EXERCISE 6.9 FOR THE PISTON
RING PROCESS. SUPPOSE THAT YOU WANT TO CONTINUE CONTROL CHARTING PISTON RING
DIAMETER USING N = 3. WHAT LIMITS WOULD BE USED ON THE X AND R CHART?
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• 6.42 CONTROL CHARTS FOR X AND S WITH N = 4 ARE MAINTAINED ON A QUALITY
CHARACTERISTIC. THE PARAMETERS OF THESE CHARTS ARE AS FOLLOWS:
x Chart s Chart
UCL = 201.88 UCL = 2.266
Center line = 200.00 Center line = 1.000
LCL=198.12 LCL = 0
• Both charts exhibit control. Specifications on the quality characteristic are 197.50 and
202.50. What can be said about the ability of the process to produce product that conforms
to specifications?
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HOMEWORK PROBLEMS FOR 2/21
CHAPTER 6
• 6.4
• 6.15
• 6.16
• 6.33
• 6.55
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• PROBLEM 6.4
• THE THICKNESS OF A PRINTED CIRCUIT BOARD IS AN IMPORTANT QUALITY
PARAMETER. DATA ON BOARD THICKNESS (IN INCHES) ARE GIVEN IN TABLE
6E.4 FOR 25 SAMPLES OF THREE BOARDS EACH.
• (A) SET UP X AND R CONTROL CHARTS. IS THE PROCESS IN STATISTICAL
CONTROL?
• (D) IF THE SPECIFICATIONS ARE AT 0.0630 IN. ± 0.0015 IN., WHAT IS THE
VALUE OF THE PCR CP?
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• PROBLEM 6.15
• PARTS MANUFACTURED BY AN INJECTION MOLDING PROCESS ARE SUBJECTED TO A
COMPRESSIVE STRENGTH TEST. TWENTY SAMPLES OF FIVE PARTS EACH ARE COLLECTED, AND
THE COMPRESSIVE STRENGTHS (IN PSI) ARE SHOWN IN TABLE 6E.11.
• (A) ESTABLISH X AND R CONTROL CHARTS FOR COMPRESSIVE STRENGTH USING THESE DATA. IS THE
PROCESS IN STATISTICAL CONTROL?
• (B) AFTER ESTABLISHING THE CONTROL CHARTS IN PART (A), 15 NEW SUBGROUPS WERE COLLECTED
AND THE COMPRESSIVE STRENGTHS ARE SHOWN IN TABLE 6E.12. PLOT THE X AND R VALUES
AGAINST THE CONTROL UNITS FROM PART (A) AND DRAW CONCLUSIONS.
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• PROBLEM 6.16
• RECONSIDER THE DATA PRESENTED IN EXERCISE 6.15.
(A) REWORK BOTH PARTS (A) AND (B) OF EXERCISE 6.15 USING
THE X AND S CHARTS.
(B) DOES THE S CHART DETECT THE SHIFT IN PROCESS VARIABILITY
MORE QUICKLY THAN THE R CHART DID ORIGINALLY IN PART (B) OF
EXERCISE 6.15?
•
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• PROBLEM 6.33
• SPECIFICATIONS ON A CIGAR LIGHTER DETENT ARE 0.3220 AND
0.3200 IN. SAMPLES OF SIZE 5 ARE TAKEN EVERY 45 MIN WITH THE
RESULTS SHOWN IN TABLE 6E.17 (MEASURED AS DEVIATIONS FROM
0.3210 IN 0.0001 IN.).
• (A) SET UP AN R CHART AND EXAMINE THE PROCESS FOR
STATISTICAL CONTROL.
60 8
40 45 5
7
50 45 50 8
6
40 50 55 6
5
55 60 0
30 4
60 65 1
20 3 90
2
10
1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 0