SPC Basics: Presented By: Tariq Khurshid
SPC Basics: Presented By: Tariq Khurshid
SPC Basics: Presented By: Tariq Khurshid
LSL
NOMINAL
USL
UCLx X LCLx
Slide: 1
PEOPLE
MACHINES
MEASUREMENT
Identify key process elements & variables (i.e., inputs & outputs)
PROBLEM
Brainstorm Ideas!!
MATERIAL
METHODS
ENVIRONMENT
UCLx X LCLx
CONTROL:
CAPABILITY:
CENTERING:
Measure process capability. Can we meet requirements (i.e., Cpk > 1.33)?
No
Yes
UCLx X LCLx
We win this round. Use SPC as a defect prevention tool for sustaining control of quality.
Provides factual information about the process, operation, product, cause, problem or improvement
Eliminates guesswork Changes problem solving from dealing with OPINIONS to dealing with FACTS People can usually agree on facts
5 What is the PLAN? Who, what, when, where and how? 6 How will the data be analyzed and presented? 7 Should we measure the entire POPULATION or a SAMPLE of the population?
8 Should the sample data consist of random measurements or consecutive measurements? 9 How much data is needed?
EXERCISE: Which bullseye represents: Accuracy & No Precision _____ Precision & No Accuracy _____ Accuracy & Precision _____ No Accuracy & No Precision _____
A small variation not targeted can be adjusted to hit the bulls eye. A large variation not targeted must be improved before it can hit the bull seye.
X-bar (X)
The measure of the average (mean and/or accuracy) of a set of data.
Range
Range = R = high value - low value Sigma = S = n-1 = more precise measure of variation than the range
* Sigma is used to make predictions about a process performance * Sigma is calculated using all data from a sample, not just the high and low values n-1 = S = sample standard deviation *
Standard Deviation
Measures of Variation (cont.)
Standard deviation is the square root of the average squared deviation of each measurement from the mean.
Sx =
x x x x x x x x x x
11 12 13 14
X = 15
4 3 2 1 0 1 2 3 4 Distance from X
M
x x x x x x x x
x x x x x x x x x x
16 17 18 19
Data = 12, 14, 13, 15, 18, 16, 18, 16, 14, 14
M
Sx =
i
Xi = 150 n = 10 150 = 10
(Xi - X)2 =
X =
Xi n
asks:
X LCLx
LSL
NOMINAL
USL
asks:
Can I meet the required engineering tolerance from the B/P or operation sheet 100% of the time.
X
CENTERING (Cpk, Ppk) Measures: Accuracy Key parameter: Xbar, the Mean
asks:
LSL
NOMINAL
USL
POPULATION
SAMPLE
SAMPLE
Refers to a portion of the population.
Samples are taken to represent the population. Samples save time, money, or product when seeking information about the population.
LESS TIME
- Urgency - Lead time
Too small a sample size increases the risk of not getting a true picture of the population. Too small a subgroup may not detect a change in the process. Sampling tables based on the laws of probability are used for evaluation of lots.
If the proper sampling method is used, 20 subgroups of data provides a representative picture of most populations (20 subgroups of data should be the minimum collected).
COMMON CAUSES
- Predictable - Stable over time - Accounts for 85% of process problems (Deming) - Can only be removed by changing the system
EXAMPLE: Cutting fluids breakdown, temperature changes, tool wear, etc.
SPECIAL CAUSES
- Unpredictable - Local in nature - Specific to a certain tool, person, fixture, etc. - Accounts for 15% of process problems (Deming) - Can be identified and removed at the local level
EXAMPLE: Power surges, tool breaks, power outage, out-of-round bushing, etc.
SMALL VARIATION
TIME
LARGE VARIATION
TIME
TIME
TIME
Process Capability - Cp
Cp = Process Potential Index Formula: Cp = Engineering Tolerance (ET)/Natural Tolerance (NT) Where: ET = Upper Specification Level - Lower Specification Level NT = Natural Tolerance = 6 X Sigma Sigma = Average Range/d2 What's it used for: Measures the short-term process precision for a given Key Characteristic essentially it measures Machine Capability Short-term process capability is computed using the short-term process variation (Rbar/d2). This is the machine and gage variation at a certain moment in time (last 2030 pieces made) If the gauge variation, as measured by a gauge capability study, is less than 20%..... .....we can conclude the key process input driving the variation in the shortterm is the machine. What question does Cp ask? Does the process have the precision to potentially make every part 100% to blueprint specification at this moment in time?
Cpu
Cpk = Minimum
or
What's it used for: Measures the short-term process accuracy for a given Key Characteristic - essentially it measures how close to the targeted value the process is running at. Cpk is the smaller of Cpl or Cpu, depending which side of the tolerance the process is shifted towards. Cpk should be compared to Cp. The closer Cpk is to Cp, the more centered the process is running. Cpk is affected by different operators, shifts, raw materials, tool adjustments as well as machine and gage error. What questions does Cpk ask? Is the process targeted to the NOMINAL dimension, i.e.., is the process centered? If a shift is present within the process, should I be concerned?
GOAL: Cpk greater than or equal to 1.33 (equates to a 63 DPM rate or better).
USL
Cp & Cpk
LSL
ET = USL - LSL
USL
Cp MEASURES PRECISION OF A PROCESS
Cp > 1.0
X NT = 6o
USL - X 3o
Cp RATIO ANSWERS THE QUESTION: "CAN I MEET THE ENGINEERING TOLERANCE 100% OF THE TIME?" Cpk RATIO ANSWERS THE QUESTION: "AM I TARGETED TO THE NOMINAL DIMENSION?"
Cp NOTES:
If Cp = 1.0 then the process is capable (but barely!).
If Cp < 1.0, then the process is not capable. If Cp > 1.0, then the process is more than capable. GOAL: Cp greater than or equal to 1.33. Cp tells us if the process is capable of meeting specs. However it does not tell us if the process is centered in the middle of the specs.
Cpk NOTES:
Cpk can never be greater than Cp (mathematically impossible).
If Cpk = Cp, then the process is centered in the middle of the specs. If Cpk < Cp, then the process is not centered. If Cpk > 1.0, then even if the process is not centered properly nothing will be out-of-spec. GOAL: Cpk greater than or equal to 1.33.
X
CONVENTIONAL CONTROL CHART CAPABILITY ANALYSIS:
Cp
USL - LSL 6 )
Cpk = MINIMUM { Cpl, Cpu }, where: Cpl = X - LSL 3 and Cpu = USL - X 3
=R (Where d2
X CAPABILITY ANALYSIS: Now it is time to change the rules for Cpk analysis as illustrated for Bilateral tolerances. Since it is assumed smaller values are always superior to larger values, the most meaningful capability index for MAXIMUM tolerances will be:
Cpu ANSWERS: Is there a probability of making product beyond the Maximum tolerance allowed?
Cpu = USL - X 3
EXAMPLES:
Cpl = X - LSL 3
UCLx X LCLx
Control Charts...
are a graphic representation of a process.
show plotted values of some statistic gathered from that process. have one or two control limits.
Control limits define the maximum and minimum values expected to be produced by the process.
The maximum value expected to be seen. The average value expected to be seen. The minimum value expected to be seen.
TIME
Plotted points from an in-control process will behave in a statistically predictable manner.
Control limits define the amount of variation to be expected in plotted points if the process is consistent over time.
How does management react to processes that are out-of-control or not capable?
Will the data collected on the Control Chart answer the questions people have about the process? What other groups will utilize this Control Chart data for constructive purposes?
Problem areas (initiated from QCPC turnbacks, high scrap & rework).
Critical locating dimensions.
Ones goal in life is not to wallpaper the walls of our companys manufacturing and office areas with charts.
Control chart also tells the Operator when to leave the process alone or there will be a risk of incurring the following losses due to over-correcting:
1. The labor required to make the adjustments and the downtime of the assembly area. 2. Unnecessary adjustments will increase the variability of a stable process. An excessive number of adjustments (over-correcting or knob twiddling) can increase the 6-sigma (natural) tolerance by up to 41%.
Shift Distribution from Unnecessary Adjustments Original Distribution LSL NOMINAL USL
X
Original 6-Sigma Spread
Control Chart Interpretation Below summarizes the patterns on a control chart that might indicate a Special Cause of variation may be present in the process. Investigate for a special cause if one of these patterns should develop on a control chart you are using to monitor a process.
SEVEN POINTS IN A ROW STEADILY INCREASING (OR DECREASING) POSSIBLE CAUSES Gradual deterioration of equipment Operator Fatigue Tool Wear Etc. STRATIFICATION - POINTS HUGGING THE CENTERLINE POSSIBLE CAUSES Inadequate Gauge Resolution Improvement to Process Gauge Sticking Etc.
A B C
X
LCLx
C B A
RUN OF EIGHT POINTS ON THE SAME SIDE OF THE CENTER LINE POSSIBLE CAUSES Sticky Gauge Worn Die Drift in Controls Etc. FOURTEEN POINTS IN A ROW ALTERNATING UP & DOWN POSSIBLE CAUSES Over adjustment of the process Control of two or more processes on the same chart Fixtures or holders not holding work in position Etc.
Quick Review of Some SPC Basics WHAT ARE THE THREE "C's OF SPC?
asks:
X LCLx
LSL
NOMINAL
USL
asks:
Can I meet the required engineering tolerance from the B/P or operation sheet 100% of the time?
X
CENTERING (Cpk, Ppk) Measures: Accuracy Key parameter: Xbar, the Mean
asks:
LSL
NOMINAL
USL
Collect at least 20 subgroups of data prior to calculating control limits. Plotted points are the average values from each subgroup measured. The Range Chart is independent of the Averages Chart.
Range = High value - low value (for each subgroup).
X Chart UCL
X LCL
Averages variation is due to long-term, between subgroup sources that include Temperature, Raw Material., People, Shift, Method, Measurement System, Tooling, etc.
R Chart UCLR
Range variation is due to short-term, within subgroup sources that include the Measurement System and the Machine.
An out-of-control range chart (problem of PRECISION) situation is a more difficult problem to resolve than an out-of-control averages chart (problem of ACCURACY) situation.
METHODS
MEASUREMENT
USE WRIST BAND? LENGTH OF ARMSWING SCOREKEEPER - MANUAL OR AUTO
PROBLEM:
ACHIEVE HIGHER BOWLING SCORES
TYPE OF WRIST BAND AUTO PINSETTER SHOES USED LANE OIL BALL CLEANER
RAG CLEAN
MACHINES
MATERIALS
ENVIRONMENT
Chart No.: __ of __
5/9
5/16 5/23
1-2 1 2 3 5
3-4
5-6
7-8
3 195 210 215 212 203 205 202 198 193 196 205 210 188 211 210
130 140 125 155 160 165 157 160 125 134 188 190 210 158 157 148 162 158 162 171 165 136 151 210 220 225 157 165 160 170 172 168 168 172 120 103 195 200 205
150 10 1
455 152 30 2
445 462 433 487 490 495 496 497 381 388 593 610 640 613 627 593 611 609 148 154 144 162 163 165 165 166 127 129 198 203 213 204 209 198 204 203 28 25 35 15 14 6 14 12 16 7 918 14 3 4 5 6 7 8 9 10 11 48 12 22 13 30 14 20 15 20 16 17 19 23 20
CHANGED STYLE (Can't make spares, getting lots of strikes)
160
140 120 40 30 20 10 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ELIMINATED POOR FIRST GAME
(R) RANGE
15
16
17
18
19
20
SPC
2) Wrap core with two layers of wool and polyester yarn 3) Wrap with thin, white cotton cord KC: 3.75 +/- .05
1) Prepare Core
SPC is used to monitor the 3.75 +/- .05 diameter Key Characteristic at Operation #3, Final Winding Process. The Operator measures the diameter of four balls every hour and records the results on an Xbar-R Chart as seen on the next page.
Sample Mean
Based on the Xbar-R Chart results for 25 subgroups of 4 balls each (total of 100 balls), answer the following questions: 1) Does the process appear to be in control? YES _____ NO _____
1 1
Subgroup 0.10
10
15
20
Sample Range
UCL=0.09125
2) What patterns seem to be present? Check all that apply. __ Saw tooth __ Trend __ 2 of three points near Zone A __ Points outside the 3-sigma control limits
0.05 R=0.04
0.00
LCL=0
Attribute Model
Collect Qualitative Data
Turnbacks
Y C-Chart
NP-Chart
Certify
RRCA
Mistake Proofing
SPC Terms
Company Confidential
Slide: 47
SPC Terms
Company Confidential
Slide: 48
Attribute Chart
Company Confidential
Slide: 49
Company Confidential
Slide: 50