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Process Capability Analysis in Minitab - Manual PDF
Process Capability Analysis in Minitab - Manual PDF
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Process Capability
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Process Capability Overview
Note
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Process Capability
Capability Sixpack (Normal) combines the following charts into a single display,
along with a subset of the capability statistics:
an X (or Individuals), R or S (or Moving Range), and run chart, which can be used
to verify that the process is in a state of control
a capability histogram and normal probability plot, which can be used to verify
that the data are normally distributed
a capability plot, which displays the process variability compared to the
specifications
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Process Capability Overview
Capability Sixpack (Weibull) combines the following charts into a single display,
along with a subset of the capability statistics:
an X (or Individuals), R (or Moving Range), and run chart, which can be used to
verify that the process is in a state of control
a capability histogram and Weibull probability plot, which can be used to verify
that the data come from a Weibull distribution
a capability plot, which displays the process variability compared to the
specifications
Although the Capability Sixpack commands give you fewer statistics than the Capability
Analysis commands, the array of charts can be used to verify that the process is in
control and that the data follow the chosen distribution.
Note
Capability statistics are simple to use, but they have distributional properties that are not
fully understood. In general, it is not good practice to rely on a single capability statistic
to characterize a process. See [2], [4], [5], [6], [9], [10], and [11] for a discussion.
Capability Analysis (Poisson) is appropriate when your data take the form of the
number of defects per item. The report draws a U chart, which helps you to verify
that the process is in a state of control. The report also includes a chart of the
cumulative mean DPU (defects per unit), histogram of DPU, and a defect rate plot.
Capability statistics
Process capability statistics are numerical measures of process capabilitythat is, they
measure how capable a process is of meeting specifications. These statistics are simple
and unitless, so you can use them to compare the capability of different processes.
Capability statistics are basically a ratio between the allowable process spread (the
width of the specification limits) and the actual process spread (6). Some of the
statistics take into account the process mean or target.
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Process Capability
Capability statistics
For more information, see Capability statistics on page 14-9, Capability statistics on page
14-21, and Capability statistics on page 14-26.
Many practitioners consider 1.33 to be a minimum acceptable value for the process
capability statistics, and few believe that a value less than 1 is acceptable. A value less
than 1 indicates that your process variation is wider than the specification tolerance.
Here are some guidelines for how the statistics are used:
This statistic
is used when
Definition
Cp or Pp
Cpk or Ppk
Note
CPU or PPU
USL - / 3
CPL or PPL
- LSL / 3
If the process target is not the midpoint between specifications, you may prefer to use
Cpm in place of Cpk, since Cpm measures process mean relative to the target rather than
the midpoint between specifications. See [9] for a discussion. You can calculate Cpm by
entering a target in the Options subdialog box.
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Non-normal data
When you have non-normal data, you can either transfom the data in such a way that
the normal distribution is a more appropriate model, or choose a Weibull probability
model for the data.
To transform the data, use Capability Analysis (Normal), Capability Sixpack (Normal),
Capability Analysis (Between/Within), or Capability Sixpack (Between/Within) with
the optional Box-Cox power transformation. See Box-Cox Transformation for
Non-Normal Data on page 12-6.
To use a Weibull probability model, use Capability Analysis (Weibull) and Capability
Sixpack (Weibull).
Weibull model
Which method is better? The only way to answer that question is to see which model
fits the data better. If both models fit the data about the same, it is probably better to
choose the normal model, since it provides estimates of both overall and within process
capability.
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Process Capability
performance. The report can be used to visually assess whether the data are normally
distributed, whether the process is centered on the target, and whether it is capable of
consistently meeting the process specifications.
A model which assumes the data are from a normal distribution suits most process data.
If your data are very skewed, see the discussion under Non-normal data on page 14-6.
Data
You can use individual observations or data in subgroups. Individual observations
should be structured in one column. Subgroup data can be structured in one column,
or in rows across several columns. When you have subgroups of unequal size, enter the
data in a single column, then set up a second column of subgroup indicators. For
examples, see Data on page 12-3.
If you have data in subgroups, you must have two or more observations in at least one
subgroup in order to estimate the process standard deviation.
To use the Box-Cox transformation, data must be positive.
If an observation is missing, MINITAB omits it from the calculations.
h To perform a capability analysis (normal probability model)
1 Choose Stat Quality Tools Capability Analysis (Normal).
When subgroups or individual observations are in one column, enter the data
column in Single column. In Subgroup size, enter a subgroup size or column of
subgroup indicators. For individual observations, enter a subgroup size of 1.
When subgroups are in rows, choose Subgroups across rows of, and enter the
columns containing the rows in the box.
3 In Lower spec or Upper spec, enter a lower and/or upper specification limit,
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Options
Capability Analysis (Normal) dialog box
Note
enter historical values for (the process mean) and (the process potential standard
deviation) if you have known process parameters or estimates from past data. If you
do not specify a value for or , MINITAB estimates them from the data.
estimate the process standard deviation () various wayssee Estimating the process
variation on page 14-10.
use the Box-Cox power transformation when you have very skewed datasee Use
the Box-Cox power transformation for non-normal data on page 12-68.
calculate the capability statistics using an interval other than six standard deviations
wide (three on either side of the process mean) by entering a sigma tolerance. For
example, entering 12 says to use an interval 12 standard deviations wide, six on
either side of the process mean.
perform only the within-subgroup analysis or only the overall analysis. The default is
to perform both.
display the capability analysis graph or not. The default is to display the graph.
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Process Capability
store your choice of statistics in worksheet columns. The statistics available for
storage depend on the options you have chosen in the Capability Analysis (Normal)
dialog box and subdialog boxes.
Capability statistics
When you use the normal distribution model for the capability analysis, MINITAB
calculates the capability statistics associated with within variation (Cp, Cpk, CPU, and
CPL) and with overall variation (Pp, Ppk PPU, PPL). To interpret these statistics, see
Capability statistics on page 14-4.
Cp, Cpk, CPU, and CPL represents the potential capability of your processwhat your
process would be capable of if the process did not have shifts and drifts in the subgroup
means. To calculate these, Minitab estimates within considering the variation within
subgroups, but not the shift and drift between subgroups.
Note
When your subgroup size is one, the within variation estimate is based on a moving
range, so that adjacent observations are effectively treated as subgroups.
Pp, Ppk, PPU, and PPL represent the overall capability of the process. When calculating
these statistics, MINITAB estimates overall considering the variation for the whole study.
Each small curve
represents within (or
potential) variation, or
variation for one
subgroup (one
moment in time).
The large curve
represents overall
variationthe
variation for the
whole study.
Overall capability depicts how the process is actually performing relative to the
specification limits. Within capability depicts how the process could perform relative to
the specification limits, if shifts and drifts could be eliminated. A substantial difference
between overall and within variation may indicate that the process is out of control, or it
may indicate sources of variation not estimated by within capability.
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click Estimate.
For subgroup sizes greater than one, to base the estimate on:
the average of the subgroup rangeschoose Rbar.
the average of the subgroup standard deviationschoose Sbar. To not use an
unbiasing constant in the estimation, uncheck Use unbiasing constants.
the pooled standard deviation (the default)choose Pooled standard
deviation. To not use an unbiasing constant in the estimation, uncheck Use
unbiasing constants.
For individual observations (subgroup size is one), to base the estimate on:
the average of the moving range (the default)choose Average moving
range. To change the length of the moving range from 2, check Use moving
range of length and enter a number in the box.
the median of the moving rangechoose Median moving range. To change
the length of the moving range from 2, check Use moving range of length
and enter a number in the box.
the square root of MSSD (mean of the squared successive differences)choose
Square root of MSSD. To not use an unbiasing constant in the estimation,
uncheck Use unbiasing constants.
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Process Capability
3 Click OK.
e Example of a capability analysis (normal probability model)
box.
Graph
window
output
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Suppose you work for a company that manufactures floor tiles and are concerned about
warping in the tiles. To ensure production quality, you measure warping in ten tiles each
working day for ten days.
A histogram shows that your data do not follow a normal distribution, so you decide to
use the Box-Cox power transformation to try to make the data more normal.
First you need to find the optimal lambda () value for the transformation. Then you will
do the capability analysis, performing the Box-Cox transformation with that value.
1 Open the worksheet TILES.MTW.
2 Choose Stat Control Charts Box-Cox Transformation.
3 In Single column, enter Warping. In Subgroup size, type 10. Click OK.
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Process Capability
Graph
window
output
The best estimate of lambda is 0.449, but practically speaking, you may want a lambda
value that corresponds to an intuitive transformation, such as the square root (a lambda
of 0.5). In our example, 0.5 is a reasonable choice because it falls within the 95%
confidence interval, as marked by vertical lines on the graph. So you will run the
Capability Analysis with a Box-Cox transformation, using = 0.5.
1 Choose Stat Quality Tools Capability Analysis (Normal).
2 In Single column, enter Warping. In Subgroup size, enter 10.
3 In Upper spec, enter 8.
4 Click Options.
5 Check Box-Cox power transformation (W = Y**Lambda). Choose Lambda = 0.5
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Data
You can use data in subgroups, with two or more observations. Subgroup data can be
structured in one column, or in rows across several columns.
To use the Box-Cox transformation, data must be positive.
Ideally, all subgroups should be the same size. If your subgroups are not all the same
size, due to missing data or unequal subgroup sizes, only subgroups of the majority size
are used for estimating the between-subgroup variation.
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Process Capability
When subgroups are in one column, enter the data column in Single column. In
Subgroup size, enter a subgroup size or column of subgroup indicators.
When subgroups are in rows, choose Subgroups across rows of, and enter the
columns containing the rows in the box.
3 In Lower spec or Upper spec, enter a lower and/or upper specification limit,
Options
Capability Analysis (Between/Within) dialog box
Note
enter historical values for (the process mean) and within subgroups and/or
between subgroups if you have known process parameters or estimates from past
data. If you do not specify a value for or , MINITAB estimates them from the data.
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use the Box-Cox power transformation when you have very skewed datasee Use
the Box-Cox power transformation for non-normal data on page 12-68.
calculate the capability statistics using an interval other than six standard deviations
wide (three on either side of the process mean) by entering a sigma tolerance. For
example, entering 12 says to use an interval 12 standard deviations wide, six on
either side of the process mean.
perform the between/within subgroup analysis only, or the overall analysis only. The
default is to perform both.
display the capability analysis graph or not. The default is to display the graph.
store your choice of statistics in worksheet columns. The statistics available for
storage depend on the options you have chosen in the Capability Analysis (Between/
Within) dialog box and subdialog boxes.
Capability statistics
When you use Capability Analysis (Between/Within), MINITAB calculates both overall
capability statistics (Pp, Ppk, PPU, and PPL) and between/within capability statistics (Cp,
Cpk, CPU, and CPL). To interpret these statistics, see Capability statistics on page 14-4.
Cp, Cpk, CPU, and CPL represents the potential capability of your processwhat your
process would be capable of if the process did not have shifts and drifts in the subgroup
means. To calculate these, Minitab estimates within and between and pools them to
estimate total. Then, total is used to calculate the capability statistics.
Pp, Ppk, PPU, and PPL represent the overall capability of the process. When calculating
these statistics, MINITAB estimates overall considering the variation for the whole study.
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Process Capability
2 To change the method for estimating within, choose one of the following:
3 To change the method for estimating between, choose one of the following:
the average of the moving range (the default)choose Average moving range.
To change the length of the moving range from 2, check Use moving range of
length and enter a number in the box.
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the median of the moving rangechoose Median moving range. To change the
length of the moving range from 2, check Use moving range of length and enter
a number in the box.
4 Click OK.
e Example of a capability analysis (between/within)
Suppose you are interested in the capability of a process that coats rolls of paper with a
thin film. You are concerned that the paper is being coated with the correct thickness of
film and that the coating is applied evenly throughout the roll. You take three samples
from 25 consecutive rolls and measure coating thickness. The thickness must be 50 3
to meet engineering specifications.
1 Open the worksheet BWCAPA.MTW.
2 Choose Stat Quality Tools Capability Analysis (Between/Within).
3 In Single column, enter Coating. In Subgroup size, enter Roll.
4 In Lower spec, enter 47. In Upper spec, enter 53. Click OK.
Graph
window
output
Interpreting results
You can see that the process mean (49.8829) falls close to the target of 50. The Cpk
index indicates whether the process will produce units within the tolerance limits. The
Cpk index is only 1.21, indicating that the process is fairly capable, but could be
improved.
The PPM Total for Expected Between/Within Performance is 193.94. This means that
approximately 194 out of a million coatings will not meet the specification limits. This
analysis tells you that your process is fairly capable.
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Process Capability
Data
You can enter your data in a single column or in multiple columns if you have arranged
subgroups across rows. Because the Weibull capability analysis does not calculate within
capability statistics, MINITAB does not used subgroups in calculations. For examples, see
Data on page 12-3.
Data must be positive.
If an observation is missing, MINITAB omits it from the calculations.
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When subgroups are in rows, choose Subgroups across rows of, and enter the
columns containing the rows in the box.
3 In Lower spec or Upper spec, enter a lower and/or upper specification limit,
respectively. You must enter at least one of them. These limits must be positive
numbers, though the lower spec can be 0.
4 If you like, use any of the options listed below, then click OK.
Options
Capability Analysis (Weibull) dialog box
Note
define the upper and lower specification limits as boundaries, meaning that it is
impossible for a measurement to fall outside that limit. As a result, when calculating
the expected % out-of-spec, MINITAB sets this value to 0 for a boundary.
When you define the upper or lower specification limits as boundaries, MINITAB still
calculates the observed % out-of-spec. If the observed % out-of-spec comes up nonzero,
this is an obvious indicator of incorrect data.
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Process Capability
enter historical values for the Weibull shape and scale parameterssee Weibull family
of distributions on page 14-21.
calculate the capability statistics using an interval other than six standard deviations
wide (three on either side of the process mean) by entering a sigma tolerance. For
example, entering 12 says to use an interval 12 standard deviations wide, six on
either side of the process mean.
Capability statistics
When you use the Weibull model for the capability analysis, MINITAB only calculates the
overall capability statistics, Pp, Ppk, PPU, and PPL. The calculations are based on
maximum likelihood estimates of the shape and scale parameters for the Weibull
distribution, rather than mean and variance estimates as in the normal case.
To interpret these statistics, see Capability statistics on page 14-4.
Pp, Ppk, PPU, and PPL represent the overall capability of the process. When calculating
these statistics, MINITAB estimates overall considering the variation for the whole study.
Because the shape and scale parameters define the properties of the Weibull distribution,
they also define the probabilities used to calculate the capability statistics. If you enter
known values for the parameters, keep in mind that small changes in the parameters,
especially the shape, can have large effects on the associated probabilities.
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click Options.
1 (Exponential)
2 (Rayleigh)
3 In Scale parameter, choose Historical value, and enter a positive value for the scale.
Click OK.
e Example of a capability analysis (Weibull probability model)
Suppose you work for a company that manufactures floor tiles, and are concerned
about warping in the tiles. To ensure production quality, you measured warping in ten
tiles each working day for ten days.
A histogram of the data showed that it did not come from a normal distributionsee
Example of a capability analysis with a Box-Cox transformation on page 14-12. So you
decide to perform a capability analysis based on a Weibull probability model.
1 Open the worksheet TILES.MTW.
2 Choose Stat Quality Tools Capability Analysis (Weibull).
3 In Single column, enter Warping.
4 In Upper spec, type 8. Click OK.
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Process Capability
Graph
window
output
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within and overall capability statistics: Cp, Cpk, Cpm (if you enter a target), and
within; Pp, Ppk, and overall
The X , R, and run charts can be used to verify that the process is in a state of control.
The histogram and normal probability plot can be used to verify that the data are
normally distributed. Lastly, the capability plot gives a graphical view of the process
variability compared to the specifications. Combined with the capability statistics, this
information can help you assess whether your process is in control and the product
meets specifications.
A model that assumes the data are from a normal distribution suits most process data. If
your data are either very skewed or the within-subgroup variation is not constant (for
example, when this variation is proportional to the mean), see the discussion under
Non-normal data on page 14-6.
Data
You can enter individual observations or data in subgroups. Individual observations
should be structured in one column. Subgroup data can be structured in one column,
or in rows across several columns. When you have subgroups of unequal size, enter the
subgroups in a single column, then set up a second column of subgroup indicators. For
examples, see Data on page 12-3.
To use the Box-Cox transformation, data must be positive.
If you have data in subgroups, you must have two or more observations in at least one
subgroup in order to estimate the process standard deviation. Subgroups need not be
the same size.
If a single observation in the subgroup is missing, MINITAB omits it from the calculations
of the statistics for that subgroup. Such an omission may cause the control chart limits
and the center line to have different values for that subgroup. If an entire subgroup is
missing, there is a gap in the chart where the statistic for that subgroup would have
been plotted.
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Process Capability
When subgroups or individual observations are in one column, enter the data
column in Single column. In Subgroup size, enter a subgroup size or column of
subgroup indicators. For individual observations, enter a subgroup size of 1.
When subgroups are in rows, choose Subgroups across rows of, and enter the
columns containing the rows in the box.
3 In Lower spec or Upper spec, enter a lower and/or upper specification limit,
Options
Capability Sixpack (Normal) dialog box
enter your own value for (the process mean) and (the process potential standard
deviation) if you have known process parameters or estimates from past data. If you
do not specify a value for or , MINITAB estimates them from the data.
do your choice of eight tests for special causessee Do tests for special causes on
page 12-64. To adjust the sensitivity of the tests, use Defining Tests for Special Causes
on page 12-5.
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Note
When you estimate using the average of subgroup ranges (Rbar), MINITAB displays
an R chart.
When you estimate using the average of subgroup standard deviations (Sbar),
MINITAB displays an S chart.
When you estimate using the pooled standard deviation and your subgroup size is
less than ten, MINITAB displays an R chart.
When you estimate using the pooled standard deviation and your subgroup size is
ten or greater, MINITAB displays an S chart.
use the Box-Cox power transformation when you have very skewed datasee Use
the Box-Cox power transformation for non-normal data on page 12-68.
change the number of subgroups or observations to display in the run chart. The
default is 25.
enter the process target or nominal specification. MINITAB calculates Cpm in addition
to the standard capability statistics.
calculate the capability statistics using an interval other than six standard deviations
wide (three on either side of the process mean) by entering a sigma tolerance. For
example, entering 12 says to use an interval 12 standard deviations wide, six on
either side of the process mean.
Capability statistics
Capability Sixpack (Normal) displays both the within and overall capability statistics,
Cp, Cpk, Cpm (if you specify a target), and within, and Pp, Ppk, and overall. To
interpret these statistics, see Capability statistics on page 14-4.
Cp, Cpk, CPU, and CPL represents the potential capability of your processwhat your
process would be capable of if the process did not have shifts and drifts in the subgroup
means. To calculate these, Minitab estimates within considering the variation within
subgroups, but not the shift and drift between subgroups.
Pp, Ppk, PPU, and PPL represent the overall capability of the process. When calculating
these statistics, MINITAB estimates overall considering the variation for the whole study.
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Graph
window
output
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The points on the run chart make a random horizontal scatter, with no trends or shifts
also indicating process stability.
If you want to interpret the process capability statistics, your data should approximately
follow a normal distribution. On the capability histogram, the data approximately
follow the normal curve. On the normal probability plot, the points approximately
follow a straight line. These patterns indicate that the data are normally distributed.
But from the capability plot, you can see that the process tolerance falls below the lower
specification limit. This means you will sometimes see camshafts that do not meet the
lower specification of 598 mm. Also, the values of Cp (1.16) and Cpk (0.90) are below
the guideline of 1.33, indicating that Supplier 1 needs to improve their process.
e Example of a capability sixpack with a Box-Cox tranformation
Suppose you work for a company that manufactures floor tiles, and are concerned
about warping in the tiles. To ensure production quality, you measure warping in ten
tiles each working day for ten days.
From previous analyses, you found that the tile data do not come from a normal
distribution, and that a Box-Cox transformation using a lambda value of 0.5 makes the
data more normal. For details, see Example of a capability analysis with a Box-Cox
transformation on page 14-12.
So you will run the capability sixpack using a Box-Cox transformation on the data.
1 Open the worksheet TILES.MTW.
2 Choose Stat Quality Tools Capability Sixpack (Normal).
3 In Single column, enter Warping. In Subgroup size, type 10.
4 In Upper spec, type 8.
5 Click Options.
6 Check Box-Cox power transformation (W = Y**Lambda). Choose Lambda = 0.5
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an Individuals chart
an R chart or S chart
between/within and overall capability statistics; Cp, Cpk, Cpm (if you specify a
target), within, between, and total; Pp, Ppk, and overall.
The Individuals, Moving Range, and R or S charts can verify whether or not the process
is in control. The histogram and normal probability plot can verify whether or not the
data are normally distributed. Lastly, the capability plot gives a graphical view of the
process variability compared to specifications. Combined with the capability statistics,
this information can help you assess whether your process is in control and the product
meets specifications.
A model that assumes that the data are from a normal distribution suits most process
data. If your data are either very skewed or the within subgroup variation is not
constant (for example, when the variation is proportional to the mean), see the
discussion under Non-normal data on page 14-6.
Data
You can enter data in subgroups, with two or more observations per subgroup.
Subgroup data can be structured in one column or in rows across several columns.
To use the Box-Cox transformation, data must be positive.
Ideally, all subgroups should be the same size. If your subgroups are not all the same
size, due to missing data or unequal sample sizes, only subgroups of the majority size
are used for estimating the between-subgroup variation. Control limits for the
Individuals and Moving Range charts are based on the majority subgroup size.
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Process Capability
When subgroups are in one column, enter the data column in Single column. In
Subgroup size, enter a subgroup size or column of subgroup indicators.
When subgroups are in rows, choose Subgroups across rows of, and enter the
columns containing the rows in the box.
3 In Lower spec or Upper spec, enter a lower and/or upper specification limit,
Options
Capability Sixpack (Between/Within) dialog box
enter a historical value for (the process mean) and/or (within-subgroup and/or
between-subgroup standard deviations) if you have known process parameters or
estimates from past data. If you do not specify a value for or , MINITAB estimates
them from the data.
do your choice of the eight tests for special causessee Do tests for special causes on
page 12-64. To adjust the sensitivity of the tests, use Defining Tests for Special Causes
on page 12-5.
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Note
When you estimate using the average of subgroup ranges (Rbar), MINITAB displays
an R chart.
When you estimate using the average of subgroup standard deviations (Sbar),
MINITAB displays an S chart.
When you estimate using the pooled standard deviation and your subgroup size is
less than ten, MINITAB displays an R chart.
When you estimate using the pooled standard deviation and your subgroup size is
ten or greater, MINITAB displays an S chart.
use the Box-Cox power transformation when you have very skewed datasee
Non-normal data on page 14-6.
enter the process target or nominal specification. MINITAB calculates Cpm in addition
to the standard capability statistics.
calculate the capability statistics using an interval other than six standard deviations
wide (three on either side of the process mean) by entering a sigma tolerance. For
example, entering 12 says to use an interval 12 standard deviations wide, six on
either side of the process mean.
Capability statistics
When you use Capability Analysis (Between/Within), MINITAB calculates both overall
capability statistics (Pp, Ppk, PPU, and PPL) and between/within capability statistics (Cp,
Cpk, CPU, and CPL). To interpret these statistics, see Capability statistics on page 14-4.
e Example of a capability sixpack (between/within)
Suppose you are interested in the capability of a process that coats rolls of paper with a
thin film. You are concerned that the paper is being coated with the correct thickness of
film and that the coating is applied evenly throughout the roll. You take three samples
from 25 consecutive rolls and measure coating thickness. The thickness must be 50 3
to meet engineering specifications.
Because you are interested in determining whether or not the coating is even
throughout a roll, you use MINITAB to conduct a Capability Sixpack (Between/Within).
1 Open the worksheet BWCAPA.MTW.
2 Select Stat Quality Tools Capability Sixpack (Between/Within).
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Process Capability
Graph
window
output
Interpreting results
If you want to interpret the process capability statistics, your data need to come from a
normal distribution. This criteria appears to have been met. In the capability histogram,
the data approximately follow the normal curve. Also, on the normal probability plot,
the points approximately follow a straight line.
No points failed the eight tests for special causes, thereby implying that your process is
in control. The points on the Individuals and Moving Range chart do not appear to
follow each other, again indicating a stable process.
The capability plot shows that the process is meeting specifications. The values of Cpk
(1.21) and Ppk (1.14) fall just below the guideline of 1.33, so your process could use
some improvement.
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The X, R, and run charts can be used to verify that the process is in a state of control.
The histogram and Weibull probability plot can be used to verify that the data
approximate a Weibull distribution. Lastly, the capability plot gives a graphical view of
the process variability compared to the specifications. Combined with the capability
statistics, this information can help you assess whether your process is in control and
can produce output that consistently meets the specifications.
When using the Weibull model, MINITAB only calculates the overall capability statistics,
Pp and Ppk. The calculations are based on maximum likelihood estimates of the shape
and scale parameters for the Weibull distribution, rather than mean and variance
estimates as in the normal case. If you have data that do not follow a normal
distribution, and you want to calculate the within statistics (Cp, Cpk, within), see
Capability Analysis (Normal Distribution) on page 14-6 with the optional Box-Cox power
transformation. For a comparison of the methods used for non-normal data, see
Non-normal data on page 14-6.
Tip
To make a control chart that you can interpret properly, your data must follow a normal
distribution. If the Weibull distribution fits your data well, a lognormal distribution would
probably also provide a good fit. To transform your data, use the control chart command
with the optional Box-Cox transformation, entering Lambda = 0(natural log). For more
details, see Use the Box-Cox power transformation for non-normal data on page 12-68.
Data
You can enter individual observations or data in subgroups. Individual observations
should be structured in one column. Subgroup data can be structured in one column or
in rows across several columns. When you have subgroups of unequal size, enter the
subgroups in a single column, then set up a second column of subgroup indicators. For
examples, see Data on page 12-3.
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Process Capability
When subgroups or individual observations are in one column, enter the data
column in Single column. In Subgroup size, enter a subgroup size or column of
subgroup indicators. For individual observations, enter a subgroup size of 1.
When subgroups are in rows, choose Subgroups across rows of, and enter the
columns containing the rows in the box.
3 In Lower spec or Upper spec, enter a lower and/or upper specification limit. You
must enter at least one of them. These limits must be positive numbers, though the
lower spec can be 0.
4 If you like, use any of the options listed below, then click OK.
Options
Options subdialog box
Caution
enter your own value for the Weibull shape and scale parameterssee Weibull family
of distributions on page 14-21. If you do not enter values, MINITAB obtains maximum
likelihood estimates from the data.
When you enter known values for the parameters, keep in mind that small changes in
the parameters, especially the shape, can have large effects on the associated
probabilities.
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change the number of subgroups or observations to display in the run chart. The
default is 25.
calculate the capability statistics using an interval other than six standard deviations
wide (three on either side of the process mean) by entering a sigma tolerance. For
example, entering 12 says to use an interval 12 standard deviations wide, six on
either side of the process mean.
Capability statistics
Capability Sixpack (Weibull) displays the overall capability statistics, Pp and Ppk. These
calculations are based on maximum likelihood estimates of the shape and scale
parameters for the Weibull distribution, rather than mean and variance estimates as in
the normal case.
For information on interpreting these statistics, see Capability statistics on page 14-4.
e Example of a capability sixpack (Weibull probability model)
Suppose you work for a company that manufactures floor tiles, and are concerned
about warping in the tiles. To ensure production quality, you measured warping in ten
tiles each working day for ten days.
A histogram of the data revealed that it did not come from a normal distributionsee
Example of a capability analysis with a Box-Cox transformation on page 14-12. So you
decide to make a capability sixpack based on a Weibull probability model.
1 Open the worksheet TILES.MTW.
2 Choose Stat Quality Tools Capability Sixpack (Weibull).
3 In Single column, enter Warping. In Subgroup size, type 10.
4 In Upper spec, type 8. Click OK.
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Capability Analysis (Binomial)
Use Capability Analysis (Binomial) if your data meet the following conditions:
each item can result in one or two possible outcomes (success/failure, go/no-go)
Capability Analysis (Binomial) produces a process capability report that includes the
following:
Chart of cumulative %defectiveverifies that you have collected data from enough
samples to have a stable estimate of %defective
Defective rate plotverifies that the %defective is not influenced by the number of
items sampled
Data
Use data from a binomial distribution. Each entry in the worksheet column should
contain the number of defectives for a subgroup. When subgroup sizes are unequal,
you must also enter a corresponding column of subgroup sizes.
Suppose you have collected data on the number of parts inspected and the number of
parts that failed inspection. On any given data, both numbers may vary. Enter the
number that failed inspection in one column. If the total number inspected varies, enter
subgroup size in another column:
Failed Inspected
11
1003
12
968
9
897
13
1293
9
989
15
1423
Missing data
If an observation is missing, there is a gap in the P chart where that subgroup would
have been plotted. The other plots and charts simply exclude the missing observations.
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Process Capability
When your sample size is constant, enter the sample size value in Constant size.
When your sample sizes vary, enter the column containing sample sizes in Use
sizes in.
4 If you like, use any of the options listed below, then click OK.
Options
Capability Analysis (binomial) dialog box
enter a historical value for the proportion of defectives. This value must be between 0
and 1.
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Capability Analysis (Binomial)
perform your choice of the four tests for special causessee Do tests for special causes
on page 13-15. To adjust the sensitivity of the tests, use Defining Tests for Special
Causes on page 12-5.
Suppose you are responsible for evaluating the responsiveness of your telephone sales
department, that is, how capable it is of answering incoming calls. You record the
number of calls that were not answered (a defective) by sales representatives due to
unavailability each day for 20 days. You also record the total number of incoming calls.
1 Open the worksheet BPCAPA.MTW.
2 Choose Stat Quality Tools Capability Analysis (Binomial).
3 In Defectives, enter Unavailable.
4 In Use sizes in, enter Calls. Click OK.
Graph
window
output
Interpreting results
The P chart indicates that there is one point out of control. The chart of cumulative
%defect shows that the estimate of the overall defective rate appears to be settling
down around 22%, but more data may need to be collected to verify this. The rate of
defectives does not appear to be affected by sample size. The process Z is around 0.75,
which is very poor. This process could use a lot of improvement.
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Process Capability
the rate of defects per unit of space or time is the same for each item
the number of defects observed in the items are independent of each other
Capability Analysis (Poisson) produces a process capability report for data from a
Poisson distribution. The report includes the following:
U chartverifies that the process was in a state of control at the time the report was
generated
Chart of cumulative mean DPU (defects per unit)verifies that you have collected
data from enough samples to have a stable estimate of the mean
Histogram of DPUdisplays the overall distribution of the defects per unit from the
samples collected
Defect plot rateverifies that DPU is not influenced by the size of the items sampled
Data
Each entry in the worksheet column should contain the number of or defects for a
subgroup. When subgroup sizes are unequal, you must also enter a corresponding
column of subgroup sizes.
Suppose you have collected data on the number of defects per unit and the size of the
unit. For any given unit, both numbers may vary. Enter the number of defects in one
column. If the unit size varies, enter unit size in another column:
Failed Inspected
3
89
4
94
7
121
2
43
11
142
6
103
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Capability Analysis (Poisson)
Missing data
If an observation is missing, there is a gap in the U chart where the subgroup would
have been plotted. The other plots and charts simply exclude the missing
observation(s).
Unequal subgroup sizes
In the U chart, the control limits are a function of the subgroup size. In general, the
control limits are further from the centerline for smaller subgroups than they are for
larger ones. When you do have unequal subgroup sizes, the plot of defects per unit
(DPU) versus sample size will permit you to verify that there is no relationship between
the two. For example, if you tend to have a smaller DPU when more items are sampled,
this could be caused by fatigued inspectors, a common problem. The subgroup size has
no bearing on the other charts, because they only display the DPU.
h To perform a capability analysis (Poisson distribution model)
1 Choose Stat Quality Tools Capability Analysis (Poisson).
When your unit size is constant, enter the unit size value in Constant size.
When your unit sizes vary, enter the column containing unit sizes in Use sizes in.
4 If you like, use any of the options listed below, then click OK.
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Process Capability
Options
Capability Analysis (Poisson) dialog box
enter historical values for (the process mean) if you have known process parameters
or estimates from past data. If you do not specify a value for , MINITAB estimates it
from the data.
enter a target DPU (defects per unit) for the process.
perform the four tests for special causessee Do tests for special causes on page
13-15. To adjust the sensitivity of the tests, use Defining Tests for Special Causes on
page 12-5.
choose to use a full color, partial color, or black and white color scheme for printing.
Suppose you work for a wire manufacturer and are concerned about the effectiveness of
the wire insulation process. You take random lengths of electrical wiring and test them
for weak spots in their insulation by subjecting them to a test voltage. You record the
number of weak spots and the length of each piece of wire (in feet).
1 Open the worksheet BPCAPA.MTW.
2 Choose Stat Quality Tools Capability Analysis (Poisson).
3 In Defects, enter Weak Spots.
4 In Uses sizes in, enter Lengths. Click OK.
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References
Graph
window
output
Interpreting results
The U Chart indicates that there are three points out of control. The chart of cumulative
mean DPU (defects per unit) has settled down around the value 0.0265, signifying that
enough samples were collected to have a good estimate of the mean DPU. The rate of
DPU does not appear to be affected by the lengths of the wire.
References
[1] L.K. Chan, S.W. Cheng, and F.A. Spiring (1988). A New Measure of Process
Capability: Cpm, Journal of Quality Technology, 20, July, pp.162175.
[2] Y. Chou, D. Owen, S. Borrego (1990). Lower Confidence Limits on Process
Capability Indices, Journal of Quality Technology, 22, July, pp.223229.
[3] Ford Motor Company (1983). Continuing Process Control and Process Capability
Improvement, Ford Motor Company, Dearborn, Michigan.
[4] L.A. Franklin and G.S. Wasserman (1992). Bootstrap Lower Confidence Limits for
Capability Indices, Journal of Quality Technology, 24, October, pp.196210.
[5] B. Gunter (1989). The Use and Abuse of Cpk, Part 2, Quality Progress, 22, March,
pp.108, 109.
[6] B. Gunter (1989). The Use and Abuse of Cpk, Part 3, Quality Progress, 22, May,
pp.79, 80.
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Process Capability
[7] A.H. Jaehn (1989). How to Estimate Percentage of Product Failing Specifications,
Tappi,72, pp.227228.
[8] V.E. Kane (1986). Process Capability Indices, Journal of Quality Technology, 18, pp.
4152.
[9] R.H. Kushler and P. Hurley (1992). Confidence Bounds for Capability Indices,
Journal of Quality Technology, 24, October, pp.188195.
[10] W.L. Pearn, S. Kotz, and N.L. Johnson (1992). Distributional and Inferential
Properties of Process Capability Indices, Journal of Quality Technology, 24, October,
pp. 216231.
[11] R.N. Rodriguez (1992). Recent Developments in Process Capability Analysis,
Journal of Quality Technology, 24, October, pp.176187.
[12] T.P. Ryan (1989). Statistical Methods for Quality Improvement, John Wiley & Sons.
[13] L.P. Sullivan (1984). Reducing Variability: A New Approach to Quality, Quality
Progress, July, 1984, pp.15 21.
[14] H.M. Wadsworth, K.S. Stephens, and A.B. Godfrey (1986). Modern Methods for
Quality Control and Improvement, John Wiley & Sons.
[15] Western Electric (1956). Statistical Quality Control Handbook, Western Electric
Corporation, Indianapolis, Indiana.
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References
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