Introduction to Quality Assurance

255323

2
.....


( Quality Characteristics)
variables (continuous)

Variable control charts (
)

attributes

(discrete)

Attribute control charts (
(




Variable control charts

Variable control charts

)
(
(continuous)

- Quality characteristic

- Central tendency ( ) (e.g. mean)
- measure of variability () (e.g. R or SD)
- X R Chart, X S Chart

Control Charts for

and R

X chart ()
R Chart

()

Choice of control limits

control limits
(k-sigma limits)
3 control limits

+3
-3

The use of 3 control limits is a

widespread practice.
x 3 x
0.997

0 997 (99.73%)
(99 73%)
x 2 x
0.9545 (95.45%)
x 1 x
0.6826 ((68.26%))
- The # of items between 3 = 99.73%
- It is expected that over 997 times out of 1000,
1000 the subgroup
values will fall between the upper and lower limits, and when
this occurs, the process is considered to be in control.

Subgroup Data with Unknown

and
Center line

Average
range

Phase
ase I Application
pp cat o oof x aandd R CCharts
a ts

m subgroups
20-25 subgroups
g p
subgroup (sample size, n) 3 5

Trial
T i l control
t l lilimits
it
out-of-control
assignable causes
assignable causes
trial control limits
out of control control
charts
control charts
control11 charts out of control

 (N
(Note
t
in
i control
t l

out of control
assignable causes trial control
limits )
in control
control limits

assignable
g
causes , 2
1.
2. control limits

-25 samples,
each of size 5
-time between
subgroup = 1hr

13

 R
chart control limits
on the X chart process
variability process
variability in
control X chart
control,

Revision of Control Limits and Center Lines

control charts

control limits and center lines

25,50 or 100
samples

Phase II Operation of Charts

control limits

control chart
(monitoring)

Out of control

 ((Douglas
g C. Montgomery,
g y, 2005))
- R chart
- R chart out of control assignable
cause R
- R control limits X R chart
- out of control
assignable cause

Control vs. Specification

p
Limits
Control limits

((natural pprocess variability)

y)

subgroup
Specification limits

qualityy
characteristic

control limits 22specification limits

 x R Charts


R chart

in control
(( assignable
g
causes R chart )

Cyclic patterns

x chart
h t

(operator fatigue)

( regular rotation of
operators/mc)
R chart

(maintenance schedules),
(operator fatigue)

Mixture

control limits ,

center line

2

overcontrol
overcontrol

(
(process
adjustment)
dj t t) ,

Shift in process
level

Trend

(operator fatigue)

(Seasonal influences)

Stratification

control charts
1
5

 X-chart
X h andd MR
MR-chart
h
Sample size, n = 1
-
-

-
continuous process



C t l chart
Control
h t ffor iindividual
di id l

Moving range of 2 successive observations

31

Control chart for individual observations (X-chart)

Moving Range Chart (MR-chart)

(X-chart)

(MR-chart)


(Process standard deviation)

MR
=
d2

n = 2, d2 = 1.128

Process Capability Analysis

(
(
specification)
ifi ti )

Cp, Cpkk

In control

(Lower Natural Tolerance

Limit)

(Upper Natural Tolerance

Limit)

Process Capability
The uniformity of the process
The true process capability cannot be determined until the
pprocess is in control.
Process capability = 6
can be obtained from control charts

Capability Index or Process Capability Ratio

(PCR)
The larger,
the better

From Example 5.1

51
Spec 1.50 0.50 microns
From X bar R chart


Cp 1.33

Assume that
processed is centered
p of the
at the midpoint
specification band.
43

If Cp = 1.00
2 process capability is
equal to tolerance
Cp > 1.00 1 process capability is less
than tolerance (Most wanted!)
Cp < 1.00
3 process capability is
greater
t th
than ttolerance
l

- Cp process is centered.
( process mean
specification
ifi ti (nominal))
( i l))
-
spread of specification
6
spread in the process
-Cp doesnt measure process performance in terms of the
nominal or target value.

CCp does not take process centering

into account
It is a measure of potential
capability, not actual capability

(Process potential
capability)

Process Capability Ratio for

an Off-Center Process

 Use Cpk if the process mean differs from the spec

medium value.
value
Guideline
Cpk 1.0: Insufficient process capability
Cpk 1.33: No major problem with the
process capability

Cp = Cpk Process is centered at the midpoint of specification

Cpk < Cp Process is off-center.

Cp measures potential capability

Cpk measures actual capability
Potential improvement that would be
possible by centering the process

 Since LSL = 200

7-5 strength
PCR (one
(one sided)

1.45

Attribute control charts

 quality characteristic
Variable control charts (
)
(Continuous Value)

Attribute control charts ()


(Discrete Value)

quality characteristic

/
(C f i /
(Conforming/nonconforming)
f i )

 (# of nonconforming on a unit of product)

Go no go gage
spec

Go
no go gage is on left, finished
59
part to be checked is on right

 Attribute control charts

np Chart, p Chart (control charts for

fraction nonconforming)
c Chart,
Ch u Chart
Ch (control
(
l charts
h ffor
nonconformities (defects))

np Chart, p Chart


p Chart
(p
(proportion)
p
)
(sample or subgroup)
np Chart

(# nonconforming)
p Chart np Chart


p Chart
() ,

Binomial distribution (success/failure, pass/fail, heads/tails)



1.
R (or S) Chart (
)
(Variables)
x Chart ()
2. np Chart ( )
(Attributes)
p Chart ( )
c Chart ()
u Chart ()

p Chart
p Chart

(proportion)
(sample or subgroup)

n (sample size) m (subgroups)

n (

20, 50, 100 )
(D)

(The average proportion nonconforming)

 p-chart
p-chart quality characteristics
Trial central line and
control limits (3 control limits)

 LCL

0

c Chart, u Chart
(Defects)
1


c Chart
(count of nonconformities (defects))
u Chart
(count of nonconformities per unit)

c Chart u Chart

u Chart
Poisson distribution

 c-chart
Subgroup size
= 1 inspected unit,
unit
subgroup 25
1 inspected unit =

1000 feet
f 2

 Trial control limits

LCL 0

Inspection unit

 subgroup


n =1 Inspection unit = 100 boards
1 Inspection unit = 250 boards 2.5
(n =2.5 Inspection units )
Control limits

nc 3 nc
CL = (2
(2.5)(19.67)
5)(19 67) = 49.18
49 18
Control limits = 49.18 3 49.18
LCL = 28.14, UCL = 70.22