Chapter 8: Statistical Quality Control

2007 Pearson Education

Variation

Common causes variation resulting from process factors such as people, materials, methods, and measurement systems Special causes variation that occurs sporadically and can be identified or explained

Statistical Process Control

When only common causes of variation are present, a process is in control. If special causes of variation occur, the process is out of control. SPC is focused on identifying when special causes are present, or if a process is in control.

SPC Methodology
1. 2. 3.

4.
5. 6.

7.

Select a sample of observations from a process Measure a quality characteristic Record data Calculate key statistics Plot statistics on a control chart Examine the chart for out-of-control conditions Determine the cause and take corrective action

Run Charts and Control Charts

Run chart a line chart where the independent variable is time and the dependent variables is the value of a sample statistic Control chart a run chart with control limits that describe limits of common cause variation

Control Chart Structure

x- and R-charts

Thex-chart monitors the centering of a process over time as measured by the mean of each sample The R-chart monitors the variability in data as measured by the range of each sample

Example

Run Chart of Sample Means

Run Chart of Sample Ranges

Control Limit Calculations

UCLR = D4R
LCLR = D3R

UCLx = x + A2R
LCLx = x - A2R

PHStat Tool: Control Charts

PHStat menu > Control Charts > R & Xbar Charts

Enter sample size and specify data range for ranges

Select type of chart; for R and Xbar, specify data range for means Note: You must first compute ranges and means in your worksheet

Example: R-Chart

Example:x-Chart

In-Control Indicators

No points outside control limits Number of points above and below center line about the same Points fall randomly above and below center line No steady upward or downward trends Most points, but not all are near the center line; only a few are close to control limits

Out-of-Control Indicator: Shift

Out-of-Control Indicator: Cycles

Out-of-Control Indicator: Trend

Out-of-Control Indicator: Hugging the Center Line

Out-of-Control Indicator: Hugging the Control Limits

Illustration of Mixture

p-Chart

p-Chart monitors the fraction nonconforming (fraction defective) for attribute data Control limits UCLp = p + 3s
s

LCLp = p - 3s
p(1 p) n

PHStat Tool: p-Chart

PHStat menu > Control Charts > p-Chart

Enter data range Specify sample size; if variable, enter range of data

Example: Room Inspection.xls

PHStat p-Chart Output

p-Charts With Variable Sample Sizes

One approach: compute the average sample size and use this for calculating the standard deviation

Acceptable as long as the sample sizes fall within 25 percent of the average.

Statistical Issues in Control Chart Design

Selection of sample data Rational subgroups Sample size Size influences the ability to detect different size shifts in processes Frequency of sampling Economic trade-offs

Process Capability Analysis

Compare the distribution of process output to design specifications when only common causes are present. Process capability is measured by the proportion of output that can be produced within design specifications.

Capable Process

Marginally Capable Process

Incapable Process

Process Capability Index

USLLSL Cp 6s
Cp is the ratio of the specification range to the natural variability of the process as measured by the standard deviation

Example: Syringe Data.xls

Specifications of syringe lengths are 4.950 0.030 inches

Cp = (4.98 - 4.92)/(0.039) = 1.54