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Process Variability Reduction Through Statistical Process Control For Quality Improvement
Process Variability Reduction Through Statistical Process Control For Quality Improvement
UDK- 005.6.642.2
Short Scientific Paper (1.03)
1.
Abstract: Quality has become one of the most important customer decision
factors in the selection among the competing product and services.
Consequently, understanding and improving quality is a key factor leading to
business success, growth and an enhanced competitive position. Hence
quality improvement program should be an integral part of the overall
business strategy. According to TQM, the effective way to improve the
Quality of the product or service is to improve the process used to build the
product. Hence, TQM focuses on process, rather than results as the results
are driven by the processes. Many techniques are available for quality
improvement. Statistical Process Control (SPC) is one such TQM technique
which is widely accepted for analyzing quality problems and improving the
performance of the production process. This article illustrates the step by
step procedure adopted at a soap manufacturing company to improve the
Quality by reducing process variability using Statistical Process Control.
Keywords: Statistical Process Control; Process Capability Indices; Six
Sigma; Variable control chart; Attribute control chart; Cause and effect
diagram.
LITERATURE REVIEW
193
3.
194
2.
4.
Pareto chart
5. PROCEDURE FOR
AND U CHART
and r chart
Where,
= the average of the measurements
within each subgroup.
Xi = the individual measurements within a subgroup.
195
6.
production unit.
5.2 Procedure for u chart
The procedure followed to construct the u-chart for
Table 1 Sample Data Collection Sheet
SL NO
CHARACTERISTICS
LINE 6
LINE 7
LINE 8
LINE 9
Weight in gms.
Color
Perfume
Specks
Blisters
Grits
Stamping
196
= OK
1
75.3
75.2
74.8
76
75
75.2
75.2
75.3
75.2
74.8
75
75.3
75.3
76
75.1
75.1
75.2
75.2
75.1
75
OBSERVATION
3
4
75.2
75
75.8
75.5
75.2
75.4
76
75
75.8
75.3
76
74
76
75
75
75
75.46
75.36
75.28
75.2
R
1
0.8
1.2
2
76
75.2
75.4
75.2
75
76
75.8
75.2
75.5
75
75
75
75.1
75.2
75.6
76
74
75.3
75.3
75
75.2
75.2
75.3
75.2
75
75
75.3
75.2
75.3
75.1
75
75.1
76
75.3
76
75
75
75.3
75.4
74
75.5
75.6
75.2
75.3
75.6
75
75.2
75.3
75.2
75.2
75.42
75.3
75.16
75.3
75.22
75.02
75.3
75.3
75.16
75.2
75.24
75.18
75.38
75.2
2
0.3
0.8
1
0.4
1.2
0.4
1.4
0.5
1
0.3
0.3
0.6
0.4
1
1.4
75
75
75.2
76
75.4
75.2
75.2
75.4
75.2
75.2
75.2
75.4
75
75.4
76
74.6
R CHART
= R / N
Where N = Total number of subgroups
= 18/20 = 0.9
CLR = = 0.9
UCLR = D4 * = 2.115 * 0.9 = 1.9035
LCLR = D3 * = 0 * 0.9 = 0
From the data, it seen that 2 subgroup i.e. sub group
number 4 & 5 are crossing upper control limit which
indicate the presence of assignable cause. So
homogenization is necessary.
Revised 1 = 18-2-2 = 0.778
20-2
Revised control limits:
UCLR1 = D4 * 1 = 2.115 * 0.778 = 1.645
LCLR1 = D4 * 1 = 2.115 * 0 = 0
Hence now from the data it is seen that all points fall
within control limits.
FOR CHART
= / N = 1505.08 / 20 = 75.254
CONTROL LIMITS:
CLX =
UCLx =
75.703.
= 75.254
+ A2 *
1=
PROCESS CAPABILITY
CALCULATION
USL = 77.25
LSL = 75
s1 = R1 / d2 = 0.778 / 2.326 = 0.3345
6s1 = 6 * 0.3345 = 2.007
6s1 (2.007) < USL - LSL
Hence the process is capable of meeting the
specification limits.
Process capability ratio = CP = USL LSL = 77.25
75 = 1.12107
6s1
6 * 0.3345
Cpk = Min (Cpu, Cpl)
= Min (Cpu = (USL - m) / 3s, Cpl = ( m - LSL) /
3s ) = Min (1.98, 0.25) = 0.25.
The percentage of soaps not meeting the specification
197
limits
p = P ( x < 75) + P ( x > 77.25).
= P ( 75 75.254/ 0.3345) + P ( 77.25 75.254/
0.3345) = 0.2236 + 0 = 0.2236 i.e 22.36% .
The percentage of the specification band that the
process uses up
= ( 1/ Cp ) * 100 = (1/ 1.12107) * 100 = 89.207%
The process is using about 90% of the specification
band.
Fig 2
198
NUMBER OF
INSPECTED n
8
10
7
10
12
11
12
10
10
9
7
8
10
10
12
9
10
11
12
12
NUMBER
OF
DEFECTS c
16
10
21
12
15
22
36
15
20
17
15
19
20
19
25
15
20
25
26
24
CALCULATION
_
u = c / n = (392 / 200) = 1.96
Specimen calculation for sample number 2
_
_
UCL = u + 3* (u / ni ) = 1.96 + 3*(1.96/10) = 3.288
u=c/n
2
1
3
1.2
1.25
2
3
1.5
2
1.9
2.14
2.375
2
1.9
2.08
1.67
2
2.27
2.16
2
UCL
3.445
3.288
3.547
3.288
3.172
3.226
3.172
3.288
3.288
3.362
3.547
3.445
3.288
3.288
3.172
3.362
3.288
3.226
3.172
3.172
LCL
0.475
0.631
0.372
0.631
0.747
0.694
0.747
0.631
0.631
0.561
0.372
0.475
0.631
0.631
0.747
0.561
0.631
0.694
0.747
0.747
_
_
LCL = u - 3* (u / ni ) = 1.96 - 3*(1.96/10) = 0.631
From the data, it is observed that all the points are
falling with in control limit. So, the process is under
control.
199
CUMULATIVE
FREQUENCY
196
294
%
FREQUENCY
50
25
333
363
392
10
7.7
7.3
85
92.7
100
200
% CUMULATIVE
FREQUENCY
50
75
7.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
201
6
7
8
9
1.1207
1.0273
1.1274
1.1574
1.1546
1.0712
1.1803
1.1785
3.02
4.27
4.69
1.82
Cpk
BEFORE
AFTER
0.250
0.164
0.263
0.288
0.261
0.170
0.272
0.295
PERCENTAGE
IMPROVEMENT
IN Cpk VALUE
4.4
3.6
3.4
2.4
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Received:
20.01.2010
Accepted: 15.06.2010
1 Year
203