/

1
( )


/
/
(Upper Specification Limited :USL)
(Lower Specification Limited :LSL)

5.1)

 141

5.1
(Standard Lower-Upper Specification Limited)
(Item)
(Appearance)
(Viscosity(250 c))
(Flux Content)
(Chlorine Content)

-
Grey paste
200-230 Pa.s
9.2-9.8 wt%
0 wt%

(Lower-Upper Control Limited)
()
3

5.4
6
(6 )

(Process Capability Index :CP) 5.1

 142

USL LSL
6

Cp =
USL
LSL

(5.1)

(Upper Specification Limit)

(Lower Specification Limit)

(Cp )

Cp < 1 (not capable)

- (USL- LSL) 5.1
UCL
USL
6

LSL
LCL

5.1 Cp < 1
Cp =1 (Capable)
(UCL- LCL)
(USL - LSL) Cp = 1
6 0.27
0.135
5.2
3
3

USL
6
LSL

5.2 Cp = 1

 143

Cp 1

Cp
5.3
USL

10

12

d)
c)
b)
)c
a)
)a
)5.3 Cp

a) LSL

5.3 a) b) c)
d)
a)
6 (Six Sigma)
VICTOR E. KANE (1986) Cp Cp = 1.33

(0.007%) Cp 1.33
Cp 1.33
Cp
Harvery C. Charbonneau Gordon L. Webster (1978)
(Capability Ratio)
C.R.
6
C.R.(%)=
x 100

1
=
X 100
..(5.2)
CP

 144

Cp C.R.(%) Cp C.R.(%)
Cp = 1.00 C.R.(%) = 100%
Cp = 1.33 C.R.(%) = 75%
Cp = 1.66 C.R.(%) = 60% Cp = 2.00 C.R.(%) = 50%

C.R.(%) 67% Cp 1.49
C.R.(%) 75% Cp 1.33

/

3

5.4

Process Capability Analysis

5.4

 145

3
R
S

R S (
)
0
S

0 = 0 =
0 =
d2
C4
C2
Cp

Cp
^

Cp

USL - LSL
6 '0

(5.3)

^
^
^
R
S

=
=
=
C4
d2
C2

Cp =

USL - LSL
^

(5.4)

(C2 C4 d2 )
5.2)

11.95 12.05
21 5 5.2

 146

5.2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

X1

X2

X3

X4

X5

11.95
12.03
12.01
11.97
12.00
11.98
12.00
12.00
12.00
12.02
11.98
11.92
11.98
11.99
12.00
12.00
12.02
12.00
11.97
11.99
12.00

12.00
12.02
12.00
11.98
12.01
11.98
12.01
12.01
12.02
12.00
11.97
11.95
11.93
11.93
11.98
11.98
11.98
12.01
12.03
12.01
11.98

12.03
11.96
11.97
12.00
12.02
12.00
12.03
12.04
11.96
11.97
11.96
11.92
11.94
11.94
11.99
11.97
11.97
12.02
12.00
12.02
11.99

11.98
12.00
11.98
12.03
12.03
12.01
12.00
12.00
12.00
12.05
11.95
11.94
11.95
11.95
11.95
11.96
11.98
12.01
12.01
12.00
11.99

12.01
11.98
12.00
11.99
12.02
11.99
11.98
12.02
11.98
12.00
12.00
11.96
11.96
11.96
11.93
11.99
11.99
11.99
11.99
12.01
12.02

11.994
11.998
11.992
11.994
12.016
11.992
12.004
12.014
11.992
12.008
11.972
11.938
11.952
11.954
11.970
11.980
11.988
12.006
12.000
12.006
11.996

0.031
0.029
0.016
0.023
0.011
0.013
0.018
0.017
0.023
0.030
0.019
0.018
0.019
0.023
0.029
0.016
0.019
0.011
0.022
0.011
0.015

Cp

S=

k
Si
i 1
K

USL - LSL
^
6

S
C4

0.031 0.029 .... 0.015

21

= 0.02

C4 n = 5 C4 = 0.94
^
^
12.05 - 11.95
0.02

= 0.021 C p =
= 0.794
=
6(0.021)
0.94
^

C p
( )

 147

5.3) 30
5
0.0623 0.0630 ( : .0600 .)
5.3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

X1
25
24
22
24
21
28
24
24
27
25
25
30
27
26
28
25
24
28
27
26
27
25
28
25
27
32
30
32
30
32

X2
26
23
25
23
21
26
27
25
28
26
24
28
26
26
27
26
26
27
26
25
26
26
26
31
30
28
28
32
28
31

X3
24
24
23
20
22
25
25
25
26
28
26
27
28
25
26
25
24
28
28
26
28
28
27
30
31
31
31
28
31
30

X4
25
26
25
23
25
26
24
26
25
26
26
25
27
26
25
28
25
26
25
25
25
25
30
28
28
28
28
31
32
28

X5
27
25
26
24
24
27
26
26
27
27
26
27
26
27
26
27
27
30
27
27
27
27
27
27
27
27
27
30
31
28

25
24
24
23
23
26
25
25
27
26
25
27
27
26
26
26
25
27
27
26
27
26
28
28
29
30
29
31
30
30

R
3
3
4
4
4
3
3
2
3
3
2
5
2
2
3
3
3
4
3
2
3
3
4
6
4
5
4
4
4
4

 148

Cp =

USL - LSL
^
6

k
Ri
i 1
K

R
d2

3 + 3 + .... + 4
=3
30
d2 n = 5 d2 =2.326
^
3
=1.289
=
2.326
^
30 - 23
= 1.503
Cp =
6(1.289)
R =

C p
( )
/

X -Chart R-Chart
UCL X = 28.556
LCL X =24.697

UCLR = 7.074
LCLR = 0

5.5 C p

Xbar Chart of thickness

R Chart of thickness

31

30

_
_
X= 26.627

27
26
25
24

LCL= 24.697
1

5
4

_
R= 3.345

3
2
1

23
22

UCL= 28.556

28

Sample Range

UCL= 7.074

29

Sample Mean

12

15
18
Sample

21

24

27

30

LCL= 0
3

12

15
18
Sample

21

24

27

30

5.5

 149

C p
^

5.3 C p
5.6

(P r oc e s s P e r for ma nc e )
a)

b)

c)

a ) P ro ce ss i s h ig h ly ca p a b le (C p > 2)
b ) P ro ce ss i s ca p a b le (C p = 1 to 2)
c) P ro ce ss i s n o t ca p a b le (C p < 1)

5.6 Cp
CP
4.5 a)
CP > 1
4.5 b)
CP > 1

a) cp > 1

b) cp > 1

5.7 C p

 150

5.7 b)

VICTOR E.KANE (1984)

CPU CPL CPU CPL
USL
LSL
6 (6 )
5.8
LSL - =

USL - =

USL

LSL

3 =

3 =

5.8

5.8

CPU =

USL -
CPU =
(5.5)
3

X C PU CPU
^

C PU =

USL - X
^

(5.6)

 151

USL - X
Z( USL )
Z(USL) = ^
3

CPL CPL

C PU

CPL =
CPL =

- LSL
3

(5.7)
^

X C PL CPL
^

C PL

X - LSL
3

.(5.8)

Z( LSL )
; Z(LSL) = X - LSL
3
3

^

C PL

C PU C PL 1.0
0.135
^

2 C PU C PL
^

C PU C PL C PU C PL
^

C pk
^

Min ( C PL , C PU )
.(5.9)
^
Z(min)

=
C pk
3
Cpk
Cpk 1

1.00 Cpk 1.33

1.33 Cpk 1.67

,
Cpk 1.67
,

C pk

 152

b)

a)

C)

Cp = 2
Cpk = 1

C p=2
Cpk =2

Cp = 2
Cpk < 1

a) Process is highly capable CPK > 1.5

b) Process is capable CPK = 1 to 1.5
c) Process is not capable CPK < 1

5.9 CP CPK

5.9 a)
b) c)

1) CP CPK CP > CPK

(Target) (Setting Value)
2) CP = CPK

3) CPK = (1-k)* CP
^

5.4) 5.2) C PK
( X ) = 11.99

C pk

C PU

=
=
=

( C PL , C PU )
USL - X
3

(12.05 - 11.99)
(3)(0.021)

= 0.9523

 153

5
^

C PL

=
=

C pk

X - LSL
3

(11.99 - 11.95)
(3)(0.021)

= 0.635

= ( 0.635 ,0.9523 ) = 0.635

^

C pk 0.635 1 C pk C P ( C P
0.794)

CPm CP

CPm = Cp / 1 + [(- T)/ ] 2 (5.10)

T (Process Target)
( USL + LSL )
T =
2
^

X C pm CPm (5.9)
^
^
C pm = C p / 1 + [( x - T)/ ] 2
(5.11)
^

C pm 1
5.5)
20 1 20

100
19.98 0.189

^
USL - LSL
5.4

Cp =
^
6
(21 - 19)
= 6(0.189)
= 1.76

 154

5.11

C pm

C pk

C PU

= Cp/

= (1.76) / 1 + [(19.98- 20)/0.189]2

= 1.75
^

=
=

C PL

=
=

( C PL , C PU )
USL - X
3
(21 - 19.98)
=1.799
(3)(0.189)
X - LSL
3
(19.98 - 19)
= 1.728
(3)(0.189)

1 + [( x - T)/ ] 2

C pk = (1.799,1.728 ) = 1.728

C p C pk 1

^

C pm
1

C pm

CP

USL LSL
6

C p

C 2P

2
USL LSL (n 1) s

(n 1) 2
6

 155

2
2 (n 1)
USL LSL

6
(n 1)

.(5.12)

(1 - ) 100%
2
P( /2

< 2 12- /2 ) = 1

.(5.13)

5.10

2
1

5.10
P( 2
/2
P(

2
/2
2
S. (n 1)

(n 1) S 2
2

1
2

CP

2
/2 ) 1
2
S. (n 1)

(USL LSL) 2
P
2
/2
36 S 2 (n 1)

/2
P C P
n
1

2 ) 1
/2

(USL LSL) 2
36 2

2
/2
CP
n 1

(USL LSL) 2 2

1 /2
2
36 S (n 1)

(1 - ) 100% C p

C
P

2
/2,
n 1

CP

C
P

2
1 /2,
n 1

.(5.14)

= (n-1)
(n > 50) BISSELL(1990)

(n 1)S 2
2

(1 - ) 100% C p

1
N( n 1, )
2

 156

C

C
P
P /2

1
2f

CP

C

C
P
P /2

1
2f

.........................(5.15)
f f
1
n > 25
f = (n-1)
2
n < 25 f
f

.........................(5.16)
.........................(5.17)

1
(n 1) 2

2 n C 2 2

(1 - ) 100% C PU C PL (5.18)
(5.19) ( . 265-267)

C
PU /2

2
1 C PU

9n
2f

C
PU /2

2
1 C PL

9n
2f

C PU

C
PU /2

2
1 C PU

9n
2f

........................(5.18)

C PU

C
PU /2

2
1 C PL

9n
2f

.........................(5.19)

n (5.12) (5.18)
k (subgroup) nk

(5.16)

f = k(n-1)
(5.17)
f

.........................(5.20)

1
(n 1) 2

C
2
k 2
2
n

.......................(5.21)
3

R
d2

CS
4

C2

(n

1) 2

-1
C
2
(n -1) 2
2
n

.......................(5.22)
( f )

 157

(Process Performance Indicies:PP)

CP
^
R
CP =
d2
(S) PP S

n
2
Xi X
i 1

PP (5.23)
^

Pp

USL - LSL
6S

(5.23)

C PU
C PL
C Pk PPU PPL PPk
(5.24) (5.26)
^

P PU
^

P PL
^

=
=

USL - X
3S
X - LSL
3S

(5.24)
(5.25)

= ( P PL , P PU )
(5.26)

C PU C PL C Pk
P pk

: AIAG(1)(1991 ) P P P pk
(Process is not in control)
MINITAB

5.6)
(Statistical Process Control)

 158

2 (

) 0.2500
0.2500 0.0050
3
4
1 5.4)
5.4) () A

No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

0.250
0.251
0.251
0.249
0.250
0.251
0.251
0.250
0.250
0.248
0.250
0.251
0.250
0.250
0.250

No
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

0.251
0.249
0.249
0.247
0.247
0.252
0.248
0.249
0.247
0.248
0.250
0.249
0.247
0.250
0.247

No
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

0.249
0.249
0.251
0.252
0.250
0.249
0.250
0.249
0.250
0.251
0.250
0.251
0.250
0.249
0.250

No
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

0.250
0.252
0.248
0.248
0.252
0.251
0.250
0.252
0.251
0.253
0.253
0.254
0.251
0.252
0.251

P r o b a b i l i ty P l o t o f th i c k n e s s
No r m a l - 9 5 % C I

9 9 .9
99

nt

95
90
80
70
60

M ean
S tDev
N
AD
P - V a lu e

0 .2 5
0 .0 0 1 5 7 3
60
1 .2 0 5
< 0 .0 0 5

 159

5.11 5.4
5.11 95% 0.25
0.001573 60
(AD(1)) 1.205 P-value 0.005

(AD) P-value
6
(Individual-Chart) (Moving
Range-Chart)
IChart of thickness

MovingRangeChartofthickness
1

0.254

0.005

UCL=0.253651

UCL=0.004486

0.253
0.004

0.251
_
X=0.25

0.250
0.249
0.248

Moving Range

Individual Value

0.252

0.003

0.002
__
MR=0.001373
0.001

0.247
LCL=0.246349

0.246
1

12

18

24 30 36
Observation

42

48

54

60

0.000

LCL=0
1

12 18 24 30 36 42 48 54 60
Observation

Test Results for I Chart of x . One point more than 3.00 standard deviations from center line.Test Failed at points: 57
Test Results for MR Chart of x . One point more than 3.00 standard deviations from center line.Test Failed at points: 21

5.12

 160

5.12 57
21

7
P r oce s s C apability of thickne s s
(using 95.0% confidence)

L SL

T ar ge t

USL

W ithin
O v e r all

P r o c e s s D a ta
L SL
0 .2 4 5 0 0
T ar get
0 .2 5 0 0 0
USL
0 .2 5 5 0 0
S a m p le M e a n 0 .2 5 0 0 0
S a m p le N
60
S tD e v ( W ith in ) 0 .0 0 1 2 5
S tD e v ( O v e r a ll) 0 .0 0 1 5 8

P o te n tia l ( W ith in )
C a p a b ility
Cp
1 .3 3
L o w e r C L 1 .0 9
U p p e r C L 1 .5 7
CPL
1 .3 3
CPU
1 .3 3
C pk
1 .3 3
L o w e r C L 1 .0 8
U p p e r C L 1 .5 8
C C pk
1 .3 3
O v e r a ll C a p a b ility

0 .2 4 6

0 .2 4 8

0 .2 5 0

0 .2 5 2

Pp
L o w e r C L
U p p e r C L
PPL
PPU
P pk
L o w e r C L
U p p e r C L
C pm
L o w e r C L

0 .2 5 4

1 .0 6
0 .8 7
1 .2 4
1 .0 6
1 .0 6
1 .0 6
0 .8 5
1 .2 6
1 .0 6
0 .8 7

5.13

5.13 C P

PP

C P = 1. 33

P PU

P PL

PP

P PK

C PU

C PL

C Pk 1. 33

C pm 1.06

=1.06

C P = C Pk P P = P PK
6

P P P PU
AIAG )

P PL

P PK

 161

5
P r o c e s s C a p a b ility
LSL

T arget

USL
W ith in
O v e r a ll

P r oce ss D
LSL
T arget
USL
S a m p le M e a n
S a m p le N
S tD e v ( W ith in )
S tD e v ( O v e r a ll)

a ta
0 .2
0 .2
0 .2
0 .2

4
5
5
4

5
0
5
9

0
0
0
9
5
0 .0 0 1 1
0 .0 0 1 4

P o te n tia l ( W ith in )
C a p a b ility
Cp
1 .5 1
CPL
1 .4 8
CPU
1 .5 4
C pk
1 .4 8
C C pk
1 .5 1

0
0
0
0
8
0
9

O v e r a ll C a p a b ility
P
P
P
P
C

0 .2 4 6

0 .2 4 8

0 .2 5 0

0 .2 5 2

p
PL
PU
pk
pm

1
1
1
1
1

.1
.1
.1
.1
.1

2
0
4
0
2

0 .2 5 4

5.14

5.14

C P 1.33 1.51 P P
1.06 1.12 21 57

 162

1)

2)
25 4 ()

No. ( X ) (Range) No. ( X ) (Range)
1
2
3
4
5
6
7
8
9
10
11
12
13

50.3
49.6
50.8
50.9
49.8
50.5
50.2
49.9
50.0
50.1
50.2
50.5
50.4

0.73
0.75
0.79
0.74
0.72
0.73
0.71
0.70
0.65
0.67
0.65
0.67
0.68

14
15
16
17
18
19
20
21
22
23
24
25

50.8
50.0
49.9
50.4
50.5
50.7
50.2
49.9
50.1
49.5
50.0
50.3

0.70
0.65
0.66
0.67
0.68
0.70
0.65
0.60
0.64
0.60
0.62
0.60

6 C P C Pk
50 0.5
3) 50
8
50
X i 2000
i 1

50
R i 250
i 1

3.1)
3.2) 41 5.0

4)
30 6
4.1)
4.2) 200 5

 163

4.3) 199

5) ()
25 3

0.0630 0.0015
lot
1
2
3
4
5
6
7
8
9
10
11
12
13

x1

0.0629
0.0630
0.0628
0.0634
0.0619
0.0613
0.0630
0.0628
0.0623
0.0631
0.0635
0.0623
0.0635

x2

x3

0.0636
0.0631
0.0631
0.0630
0.0628
0.0629
0.0639
0.0627
0.0626
0.0631
0.0630
0.0630
0.0631

0.0640
0.0622
0.0633
0.0631
0.0630
0.0634
0.0625
0.0622
0.0633
0.0633
0.0638
0.0630
0.0630

lot
14
15
16
17
18
19
20
21
22
23
24
25

x1

0.0645
0.0619
0.0631
0.0616
0.0630
0.0636
0.0640
0.0628
0.0615
0.0630
0.0635
0.0623

x2

0.0640
0.0644
0.0627
0.0623
0.0630
0.0631
0.0635
0.0625
0.0625
0.0632
0.0629
0.0629

x3

0.0631
0.0632
0.0630
0.0631
0.0626
0.0629
0.0629
0.0616
0.0619
0.0630
0.0635
0.0630

6)
(:) 12 5
(lots)
1
2
3
4
5
6
7
8
9
10
11
12

x1

138.1
149.3
115.9
118.5
108.2
102.8
120.4
132.7
136.4
135.0
139.6
125.3

x2

110.8
142.1
135.6
116.5
123.8
112.0
84.3
151.1
126.2
115.4
127.9
160.2

x3

138.7
105.0
124.2
130.2
117.1
135.0
112.8
124.0
154.7
149.1
151.1
130.4

x4

137.4
134.0
155.0
122.6
142.4
135.0
118.5
123.9
127.1
138.3
143.7
152.4

x5

125.4
92.3
117.4
100.2
150.9
145.8
119.3
105.1
173.2
130.4
110.5
165.1

130.1
124.5
129.6
117.6
128.5
126.1
111.0
127.4
143.5
133.6
134.6
146.7

R
27.9
57.0
39.1
30.0
42.7
43.0
36.1
46.0
46.9
33.7
40.6
39.8

6.1)
6.2)