Six Sigma Green Belt

Part 5

Process Capability

© 2011 IIE and Aft Systems, Inc. 5-1

 Process Capability

• Is the measured, inherent reproducibility of the

product turned out by the process. It can be
quantified from data which, in turn, are the result of
measurements of work performed by the process. It
defines limits we would normally expect virtually all
individuals to fall within.
• By definition a process is “capable” when it is
operating at the three sigma level.

© 2011 IIE and Aft Systems, Inc. 5-2

 Process Capability

• Is the range over which the natural variation of a

process occurs as determined by the system of
common causes.
• It is the ability of the combination of people,
machines, methods, materials, and measurements to
produce a product or service that will consistently
meet design specifications.

© 2011 IIE and Aft Systems, Inc. 5-3

 Measuring Process Capability

• Process capability is measured by the proportion

of output that can be produced within design
specifications-It is a long term prediction.
• It is a measure of the uniformity of the process.

It can be measured only if all special causes

have been eliminated and the process is in a
state of statistical control.

© 2011 IIE and Aft Systems, Inc. 5-4

 Components of Process Capability

• Design specifications
• Centering of natural variation
• Range or spread of variation

© 2011 IIE and Aft Systems, Inc. 5-5

 Capability Measures

• Short term measures show the capability at a

specific instance in time, e.g., 5 out of 90 samples
did not meet customer requirements
• Long term measures show the expected
capability of the process based on statistical
projections using inherent process variability

© 2011 IIE and Aft Systems, Inc. 5-6

 Establishing Process Capability

• Histogram
• Control Chart

These must be performed prior to calculating any

process capability measures

© 2011 IIE and Aft Systems, Inc. 5-7

 Statistics

Green Belts are expected to be able to calculate

the following:

• Percent or proportion Non-Conforming

• Cp Index
• Cpk Index

© 2011 IIE and Aft Systems, Inc. 5-8

 Percent Non-Conforming

• Reflects the proportion of the population that we

normally expect not to meet the process
specifications.
• Corresponds to the
‘tail’ areas on the
normal curve sketch
USL

LSL
LSL
Acceptable

© 2011 IIE and Aft Systems, Inc. 5-9

 Calculating

Use z transform. Values in Normal Curve Table

Uspec - x
zu 
 x is also called the mean
Lspec - x
zl 

R MR
 '  or
d2 d2

Process must be centered somewhere

between the customer requirements.

© 2011 IIE and Aft Systems, Inc. 5-10

Z Value Tail Z Value Tail Z Value Tail Z Value Tail
Prop. Prop. Prop. Prop.
0.01 0.4960 0.31 0.3783 0.61 0.2709 0.91 0.1814
0.02 0.4920 0.32 0.3745 0.62 0.2676 0.92 0.1788
0.03 0.4880 0.33 0.3707 0.63 0.2643 0.93 0.1762
0.04 0.4840 0.34 0.3669 0.64 0.2611 0.94 0.1736
0.05 0.4801 0.35 0.3632 0.65 0.2578 0.95 0.1711
0.06 0.4761 0.36 0.3594 0.66 0.2546 0.96 0.1685
0.07 0.4721 0.37 0.3557 0.67 0.2514 0.97 0.1660
0.08 0.4681 0.38 0.3520 0.68 0.2483 0.98 0.1635
0.09 0.4641 0.39 0.3483 0.69 0.2451 0.99 0.1611
0.10 0.4602 0.40 0.3446 0.70 0.2420 1.00 0.1587
0.11 0.4562 0.41 0.3409 0.71 0.2389 1.01 0.1562
0.12 0.4522 0.42 0.3372 0.72 0.2358 1.02 0.1539
0.13 0.4483 0.43 0.3336 0.73 0.2327 1.03 0.1515
0.14 0.4443 0.44 0.3300 0.74 0.2296 1.04 0.1492
0.15 0.4404 0.45 0.3264 0.75 0.2266 1.05 0.1469
0.16 0.4364 0.46 0.3228 0.76 0.2236 1.06 0.1446
0.17 0.4325 0.47 0.3192 0.77 0.2206 1.07 0.1423
0.18 0.4286 0.48 0.3156 0.78 0.2177 1.08 0.1401
0.19 0.4247 0.49 0.3121 0.79 0.2148 1.09 0.1379
0.20 0.4207 0.50 0.3085 0.80 0.2119 1.10 0.1357
0.21 0.4168 0.51 0.3050 0.81 0.2090 1.11 0.1335
0.22 0.4129 0.52 0.3015 0.82 0.2061 1.12 0.1314
0.23 0.4090 0.53 0.2981 0.83 0.2033 1.13 0.1292
0.24 0.4052 0.54 0.2946 0.84 0.2005 1.14 0.1271
0.25 0.4013 0.55 0.2912 0.85 0.1977 1.15 0.1251
0.26 0.3974 0.56 0.2877 0.86 0.1949 1.16 0.1230
0.27 0.3936 0.57 0.2843 0.87 0.1922 1.17 0.1210
0.28 0.3897 0.58 0.2810 0.88 0.1894 1.18 0.1190
0.29 0.3859 0.59 0.2776 0.89 0.1867 1.19 0.1170
0.30 0.3821 0.60 0.2743 0.90 0.1841 1.20 0.1151
© 2011 IIE and Aft Systems, Inc. 5-11
Z Value Tail Z Value Tail Z Value Tail Z Value Tail
Prop. Prop. Prop. Prop.
1.21 0.1131 1.51 0.0655 1.81 0.0351 2.11 0.0174
1.22 0.1112 1.52 0.0643 1.82 0.0344 2.12 0.0170
1.23 0.1093 1.53 0.0630 1.83 0.0336 2.13 0.0166
1.24 0.1075 1.54 0.0618 1.84 0.0329 2.14 0.0162
1.25 0.1056 1.55 0.0606 1.85 0.0322 2.15 0.0158
1.26 0.1038 1.56 0.0594 1.86 0.0314 2.16 0.0154
1.27 0.1020 1.57 0.0582 1.87 0.0307 2.17 0.0150
1.28 0.1003 1.58 0.0571 1.88 0.0301 2.18 0.0146
1.29 0.0985 1.59 0.0559 1.89 0.0294 2.19 0.0143
1.30 0.0968 1.60 0.0548 1.90 0.0287 2.20 0.0139
1.31 0.0951 1.61 0.0537 1.91 0.0281 2.21 0.0136
1.32 0.0934 1.62 0.0526 1.92 0.0274 2.22 0.0132
1.33 0.0918 1.63 0.0516 1.93 0.0268 2.23 0.0129
1.34 0.0901 1.64 0.0505 1.94 0.0262 2.24 0.0125
1.35 0.0885 1.65 0.0495 1.95 0.0256 2.25 0.0122
1.36 0.0869 1.66 0.0485 1.96 0.0250 2.26 0.0119
1.37 0.0853 1.67 0.0475 1.97 0.0244 2.27 0.0116
1.38 0.0838 1.68 0.0465 1.98 0.0239 2.28 0.0113
1.39 0.0823 1.69 0.0455 1.99 0.0233 2.29 0.0110
1.40 0.0808 1.70 0.0446 2.00 0.0228 2.30 0.0107
1.41 0.0793 1.71 0.0436 2.01 0.0222 2.31 0.0104
1.42 0.0778 1.72 0.0427 2.02 0.0217 2.32 0.0102
1.43 0.0764 1.73 0.0418 2.03 0.0212 2.33 0.0099
1.44 0.0749 1.74 0.0409 2.04 0.0207 2.34 0.0096
1.45 0.0735 1.75 0.0401 2.05 0.0202 2.35 0.0094
1.46 0.0721 1.76 0.0392 2.06 0.0197 2.36 0.0091
1.47 0.0708 1.77 0.0384 2.07 0.0192 2.37 0.0089
1.48 0.0694 1.78 0.0375 2.08 0.0188 2.38 0.0087
1.49 0.0681 1.79 0.0367 2.09 0.0183 2.39 0.0084
1.50 0.0668 1.80 0.0359 2.10 0.0179 2.40 0.0082
© 2011 IIE and Aft Systems, Inc. 5-12
Z Value Tail Z Value Tail Z Value Tail
Prop. Prop. Prop.
2.41 0.0080 2.71 0.0034 3.10 0.00096760
2.42 0.0078 2.72 0.0033 3.20 0.00068714
2.43 0.0075 2.73 0.0032 3.30 0.00048342
2.44 0.0073 2.74 0.0031 3.40 0.00033693
2.45 0.0071 2.75 0.0030 3.50 0.00023263
2.46 0.0069 2.76 0.0029 3.60 0.00015911
2.47 0.0068 2.77 0.0028 3.70 0.00010780
2.48 0.0066 2.78 0.0027 3.80 0.00007235
2.49 0.0064 2.79 0.0026 3.90 0.00004810
2.50 0.0062 2.80 0.0026 4.00 0.00003167
2.51 0.0060 2.81 0.0025 4.10 0.00002066
2.52 0.0059 2.82 0.0024 4.20 0.00001335
2.53 0.0057 2.83 0.0023 4.30 0.00000854
2.54 0.0055 2.84 0.0023 4.40 0.00000541
2.55 0.0054 2.85 0.0022 4.50 0.00000340
2.56 0.0052 2.86 0.0021 4.60 0.00000211
2.57 0.0051 2.87 0.0021 4.70 0.00000130
2.58 0.0049 2.88 0.0020 4.80 0.00000079
2.59 0.0048 2.89 0.0019 4.90 0.00000048
2.60 0.0047 2.90 0.0019 5.00 0.00000029
2.61 0.0045 2.91 0.0018 5.10 0.00000017
2.62 0.0044 2.92 0.0018 5.20 0.00000010
2.63 0.0043 2.93 0.0017 5.30 0.00000006
2.64 0.0041 2.94 0.0016 5.40 0.00000003
2.65 0.0040 2.95 0.0016 5.50 0.00000002
2.66 0.0039 2.96 0.0015 6.00 0.000000001
2.67 0.0038 2.97 0.0015 6.50 0.00000000
2.68 0.0037 2.98 0.0014 7.00 0.00000000
2.69 0.0036 2.99 0.0014 7.50 0.00000000
2.70 0.0035 3.00 0.0013 8.00 0.00000000
© 2011 IIE and Aft Systems, Inc. 5-13
 Example

A process has a mean of

600 and a standard
deviation of 6. Spec
limits are 585 and 615.
1. What is the percent non- Unacceptable USL

conforming? (The total LSL

LSL Unacceptable
proportion in both tails.)
2. What is the DPMO?
3. What is the sigma level?
(The sigma level is the
smaller of the two z
values.)
© 2011 IIE and Aft Systems, Inc. 5-14
 Example

A process has a mean of

100 and a standard
deviation of 4. Spec
limits are 95 and 106.
Unacceptable USL
1. What is the percent non-
LSL
LSL Unacceptable
conforming?
2. What is the sigma level?
3. What is the DPM?

© 2011 IIE and Aft Systems, Inc. 5-15

 Example
Continued

In the preceding example if each incorrect

transaction costs $4 and annual volume is
400,000, what is the cost of the incorrect
transactions?

© 2011 IIE and Aft Systems, Inc. 5-16

 Example
Continued

If in the preceding example the standard

deviation were reduced to 2 via a DMAIIC
Green Belt project. If this were done at a
cost of $100,000 would it be worth it? (One year
payback.)

© 2011 IIE and Aft Systems, Inc. 5-17

 Example
Continued

What would it take (or be worth) to now reduce

the standard deviation to 1?

© 2011 IIE and Aft Systems, Inc. 5-18

 More Practice

• A process has a mean of • Determine

200 and and a standard – Proportion non
deviation of 2. conforming
• Upper specification limit – DPMO
is 212. – Sigma Level
• Lower specification limit
is 188.

Motorola Shift

© 2011 IIE and Aft Systems, Inc. 5-19

 Another Problem

What is the capability of the process, in terms of

proportion defective or sigma level or dpmo, we
collected data on earlier in the course?
(page 4-12)

© 2011 IIE and Aft Systems, Inc. 5-20

 Capability Indices

Show the relationship between the process capability and

the process specifications
Cp measures potential capability assuming that
the process average is equal to the midpoint of
the specification limits and the process is
operating in statistical control. Cpk reflects the
current process mean’s proximity to either
specification limit. (When the process is centered
Cp = Cpk.)
Although the indices are calculated differently,
the interpretation is the same

© 2011 IIE and Aft Systems, Inc. 5-21

Cp or Cpk Less than 1.0

Cp or Cpk Sigma
Value Level
0.33 1
0.67 2

© 2011 IIE and Aft Systems, Inc. 5-22

 -4.5
-4.3
-4
-3.8
-3.5
-3.3
-3.1
-2.8
-2.6
-2.3
-2.1
-1.9
-1.6
-1.4
-1.1
-0.9
-0.7
-0.4
-0.2
0.07
0.31
0.55
0.79
1.03
1.27
1.51
1.75
1.99
2.23
2.47
2.71
2.95
3.19
3.43
3.67
3.91
4.15
4.39

© 2011 IIE and Aft Systems, Inc.

0.67
1.00
0.33
Value
Cp or Cpk
Cp or Cpk Equal to 1.0

3
1
2
Level
Sigma

5-23
 -4.5
-4.3
-4
-3.8
-3.5
-3.3
-3.1
-2.8
-2.6
-2.3
-2.1
-1.9
-1.6
-1.4
-1.1
-0.9
-0.7
-0.4
-0.2
0.07
0.31
0.55
0.79
1.03
1.27
1.51
1.75
1.99
2.23
2.47
2.71
2.95
3.19
3.43
3.67
3.91
4.15
4.39

© 2011 IIE and Aft Systems, Inc.

2.00
0.67

3.00
2.67
2.33
1.67
1.33
1.00
0.33
Value
Cp or Cpk
Cp or Cpk Greater than 1.0

9
8
7
5
4
3
1

6
2
Level

No Motorola Shift
Sigma

5-24
 Calculating Cp

Cp = (Uspec – Lspec)/6

Process must be centered at the midpoint of the

specification limits.

© 2011 IIE and Aft Systems, Inc. 5-25

 Cpk Calculation

Smaller of the following:

Cpku = (Uspec – Mean) / 3
Cpkl = (Mean – Lspec) / 3

Cpk also is equal to the sigma level divided

by 3

Note:
Can also use these for one sided requirements

© 2011 IIE and Aft Systems, Inc. 5-26

 Capability

What is the capability index for the process we

analyzed earlier? (page 4-12)

© 2011 IIE and Aft Systems, Inc. 5-27

 Interpretation
More
Capability Not than
Measure Capable Capable Capable
Proportion
Non More than Less than
Conforming .0027 0.0027 .0027

More than Less than

DPMO 2700 2700 2700
Less than More
Sigma Level 3.0 3.0 than 3.0
Less than More
Cpk 1.0 1 than 1.0

© 2011 IIE and Aft Systems, Inc. 5-28

 Another Cost Study

• A process has customer requirements of 50 and 75. It is in

control with an adjustable mean and a known standard
deviation (based on the Shewhart approximation) of 8.
• Accounting tells us that a “defect” on the low side will
cost of $10 and on the high side $5. (Scrap vs. rework.)
• Engineering has not been able to figure out a way to
reduce variation.
• What is the optimum location for the process centering in
order to minimize cost?

© 2011 IIE and Aft Systems, Inc. 5-29

 Homework Exercise
U-Bolts

• On the following page is

data on U-bolts for the
dimension shown at the
right.
• Determine the capability of
the process regarding the
indicated dimension. (Specs
are 10.70 + .15)

© 2011 IIE and Aft Systems, Inc. 5-30

Sample Observations Average Range
1 10.65 10.70 10.65 10.80 10.55 10.670 0.25
2 10.75 10.85 10.75 10.70 10.65 10.740 0.20
3 10.75 10.80 10.80 10.70 10.75 10.760 0.10
4 10.60 10.70 10.65 10.65 10.90 10.700 0.30
5 10.70 10.75 10.70 10.65 10.65 10.690 0.10
6 10.60 10.75 10.75 10.75 10.70 10.710 0.15
7 10.75 10.80 10.65 10.75 10.45 10.680 0.35
8 10.65 10.80 10.50 10.70 10.80 10.690 0.30
9 10.60 10.70 10.70 10.65 10.60 10.650 0.10
10 10.80 10.75 10.60 10.75 10.65 10.710 0.20
11 10.85 10.70 10.65 10.70 10.65 10.710 0.20
12 10.70 10.75 10.75 10.70 10.65 10.710 0.10
13 10.65 10.70 10.75 10.65 10.50 10.650 0.25
14 10.70 10.80 10.90 10.80 10.70 10.780 0.20
15 10.65 10.80 10.65 10.60 10.65 10.670 0.20
16 10.75 10.70 10.65 10.75 10.65 10.700 0.10
17 10.90 10.70 10.80 10.70 10.75 10.770 0.20
18 10.75 10.65 10.70 10.65 10.55 10.660 0.20
19 10.75 10.60 10.75 10.60 10.90 10.720 0.30
20 10.65 10.55 10.70 10.70 10.65 10.650 0.15
21 10.60 10.65 10.65 10.70 10.65 10.650 0.10
22 10.50 10.60 10.70 10.65 10.75 10.640 0.25
23 10.80 10.70 10.65 10.50 10.65 10.660 0.30
24 10.65 10.65 10.90 10.80 10.65 10.730 0.25

104
© 2011 IIE and Aft Systems, Inc. 5-31
 Statistics

Mean 10.6958

Average Range .2021

Shewhart Standard Deviation .0869

Calculated Standard .0871

Deviation

© 2011 IIE and Aft Systems, Inc. 5-32

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

© 2011 IIE and Aft Systems, Inc. 5-33

 Sample ID

Averages

Ranges

© 2011 IIE and Aft Systems, Inc. 5-34

 Histogram

40

35

30
# Observations

25

20

15

10

0
10.45 10.495 10.54 10.585 10.63 10.675 10.72 10.765 10.81 10.855
to <= to <= to <= to <= to <= to <= to <= to <= to <= to <=
10.495 10.54 10.585 10.63 10.675 10.72 10.765 10.81 10.855 10.9
Class

© 2011 IIE and Aft Systems, Inc. 5-35

 Xbar Chart

10.85 UCL=10.81244
10.8
10.75
CEN=10.69583
10.7
10.65
10.6
10.55 LCL=10.57923
10.5
10.45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

R Chart

0.5
UCL=0.4272
0.4

0.3
CEN=0.20208
0.2

0.1

0
LCL=0.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

© 2011 IIE and Aft Systems, Inc. 5-36

 10.30
10.33
10.35 Cpk = .5600
LSL = 10.55
USL = 10.85

DPM = 84,654
Mean = 10.696

10.38
StdDev = 0.0869

10.40
Sigma Level = 1.6801

10.43
10.45
10.48
10.50
10.53
10.55
10.58
10.60
10.63
10.65
10.68
10.70
10.73
Cpk Analysis

10.75
10.78

© 2011 IIE and Aft Systems, Inc.

10.80
10.83
10.85
10.88
10.90
Process Capability

10.93
10.95
10.97
11.00
11.02
11.05
11.07
5-37