SPC at Hyderabad - 27.02 PDF

23-Feb-20
Statistical process control (SPC)

• Statistical process control (SPC) is a method of quality control in
which statistical methods are employed.
• SPC is applied in order to monitor and control a process.
• Monitoring and controlling the process ensures that it operates at its
full potential.
• At its full potential, the process can make as much conforming
product as possible with a minimum (if not an elimination) of waste
(rework or scrap).
• SPC can be applied to any process where the "conforming product"
(product meeting specifications) output can be measured
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• SPC must be practiced in 2 phases:

• The first phase is the initial establishment of the process, and the
second phase is the regular production use of the process.
• In the second phase, a decision of the period to be examined must
be made, depending upon the change in 5M&E conditions (Man,
Machine, Material, Method, Measurement, Environment) and
• wear rate of parts used in the manufacturing process (machine
parts, jigs, and fixture)
Advantages
• An advantage of SPC over other methods of quality control,
such as "inspection", is that it emphasizes early detection
and prevention of problems, rather than the correction of
problems after they have occurred.
• In addition to reducing waste, SPC can lead to a reduction
in the time required to produce the product.
• SPC makes it less likely the finished product will need to be
reworked or scrapped.
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Why SPC?
• Manufacturing companies today are facing ever increasing competition.
• At the same time raw material costs continue to increase.
• These are factors that companies, for the most part, cannot control.
• Therefore companies must concentrate on what they can control: their
processes.
• Companies must strive for continuous improvement in quality, efficiency
and cost reduction.
• Many companies still rely only on inspection after production to detect
quality issues.
• The SPC process is implemented to move a company from detection
based to prevention based quality controls.
• By monitoring the performance of a process in real time the operator can
detect trends or changes in the process before they result in non-
conforming product and scrap.
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History
• SPC was pioneered by Walter A Shewhart at Bell Laboratories in
the early 1920s.
• Shewhart developed the control chart in 1924 and the concept of a
state of statistical control.
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Common Causes and Special Causes

• 1) "Common Causes" - sometimes referred to as non
assignable, normal sources of variation. It refers to many
sources of variation that consistently acts on process.
These types of causes produce a stable and repeatable
distribution over time.
• 2) "Special Causes" - sometimes referred to as assignable
sources of variation. It refers to any factor causing variation
that affects only some of the process output. They are often
intermittent and unpredictable.
Common Causes
• Variation in material properties within specification
• Seasonal changes in ambient temperature or humidity
• Normal machine or tooling wear
• Variability in operator controlled settings
• Normal measurement variation
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Special Causes
• Failed controllers
• Improper equipment adjustments
• A change in the measurement system
• A process shift
• Machine malfunction
• Raw material properties out of design specifications
• Broken tool, punch, bit, etc.
• Inexperienced operator not familiar with process
Process Variation
• In manufacturing, quality is defined as conformance to
specification.
• However, no two products or characteristics are ever
exactly the same, because any process contains many
sources of variability.
• In mass-manufacturing, traditionally, the quality of a finished
article is ensured by post-manufacturing inspection of the
product.
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Process Variation
• In manufacturing, quality is defined as conformance to
specification.
• However, no two products or characteristics are ever
exactly the same, because any process contains many
sources of variability.
• In mass-manufacturing, traditionally, the quality of a finished
article is ensured by post-manufacturing inspection of the
product.
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Application of SPC
• The application of SPC involves three main phases of
activity:
• Understanding the process and the specification limits.
• Eliminating assignable (special) sources of variation, so that
the process is stable.
• Monitoring the ongoing production process, assisted by the
use of control charts, to detect significant changes of mean
or variation.
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Definitions-Mean, Median, Mode, Range

• The "mean" is the "average" you're used to, where you add up all
the numbers and then divide by the number of numbers.
• The "median" is the "middle" value in the list of numbers. To find the
median, your numbers have to be listed in numerical order from
smallest to largest, so you may have to rewrite your list before you
can find the median.
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Definitions-Mean, Median, Mode, Range

• The "mode" is the value that occurs most often. If no
number in the list is repeated, then there is no mode for the
list.
• The "range" of a list a numbers is just the difference

between the largest and smallest values.
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Exercise-Mean, Median, Mode, Range

• Find the mean, median, mode, and range for the
following list of values:
• 13, 18, 13, 14, 13, 16, 14, 21, 13
• Find the mean, median, mode, and range for the

following list of values:
• 8, 9, 10, 10, 10, 11, 11, 11, 12, 13
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Definitions-Standard Deviation
• Standard deviation is a measure of the dispersion of a set
of data from its mean.
• It is calculated as the square root of variance by
determining the variation between each data point relative
to the mean.
• If the data points are further from the mean, there is higher
deviation within the data set.
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Definitions-Cp, Cpk
• Cp= Process Capability. A simple and straightforward
indicator of process capability.
•
Cpk= Process Capability Index. Adjustment of Cp for the
effect of non-centered distribution.
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Definitions-Cp, Cpk
• Cpk measures how close you are to your target and how consistent
you are to around your average performance.
• A person may be performing with minimum variation, but he can be
away from his target towards one of the specification limit, which
indicates lower Cpk, whereas Cp will be high.
• On the other hand, a person may be on average exactly at the
target, but the variation in performance is high (but still lower than
the tolerance band (i.e., specification interval).
• In such case also Cpk will be lower, but Cp will be high.
• Cpk will be higher only when you r meeting the target consistently
with minimum variation.”
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Control Charts
• The data from measurements of variations at points on the process
map is monitored using control charts.
• Control charts attempt to differentiate "assignable" ("special")
sources of variation from "common" sources.
• "Common" sources, because they are an expected part of the
process, are of much less concern to the manufacturer than
"assignable" sources.
• Using control charts is a continuous activity, ongoing over time.
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Stable process
• When the process does not trigger any of the control chart
"detection rules" for the control chart, it is said to be
"stable".
• A process capability analysis may be performed on a stable
process to predict the ability of the process to produce
"conforming product" in the future.
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Control Charts
• Variable data
• Individual – Moving Range chart: to be used if your data is individual
values
• X – R chart: to be used if you are recording data in sub-groups of 8
or less
• X – S chart: to be used if your sub-group size is greater than 8
• Attribute data
• P chart – For recording the number of defective parts in a group of
parts
• U chart – For recording the number of defects in each part
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Control Charts
• One of the most widely used control charts for variable data is the
X-bar and R chart.
• X-bar represents the average or “mean” value of the variable x.
• The X-bar chart displays the variation in the sample means or
averages.
• The Range chart shows the variation within the subgroup.
• The range is simply the difference between the highest and lowest
value.
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Calculating σ
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Normal Distribution Bell Curve
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6 σ Concept
1σ 68.2689492%
2σ 95.4499736%
3σ 99.7300204%
4σ 99.993666%
5σ 99.9999426697%
6σ 3.4 DPMO 99.9999998027%
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Statistical Process Control
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LECTURE OUTLINE
• Basics of Statistical Process Control
• Control Charts
• Control Charts for Attributes
• Control Charts for Variables
• Control Chart Patterns
• SPC with Excel
• Process Capability
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Basics of Statistical Process Control
• Statistical Process Control (SPC)

• monitoring production process to detect
and prevent poor quality UCL
• Sample
• subset of items produced to use for
inspection
• Control Charts LCL
• process is within statistical control limits
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Variability
• Random • Non-Random
• common causes • special causes
• inherent in a process • due to identifiable factors
• can be eliminated only through • can be modified through operator
improvements in the system or management action
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SPC in TQM
• SPC
• tool for identifying problems and make improvements
• contributes to the TQM goal of continuous improvements
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Quality Measures
• Attribute
• a product characteristic that can be evaluated with a discrete response
• good – bad; yes - no
• Variable
• a product characteristic that is continuous and can be measured
• weight - length
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Applying SPC to Service

• Nature of defect is different in services
• Service defect is a failure to meet customer requirements
• Monitor times, customer satisfaction
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Applying SPC to Service (cont.)

• Hospitals
• timeliness and quickness of care, staff responses to requests, accuracy of lab tests,
cleanliness, courtesy, accuracy of paperwork, speed of admittance and checkouts
• Grocery Stores
• waiting time to check out, frequency of out-of-stock items, quality of food items,
cleanliness, customer complaints, checkout register errors
• Airlines
• flight delays, lost luggage and luggage handling, waiting time at ticket counters and check-
in, agent and flight attendant courtesy, accurate flight information, passenger cabin
cleanliness and maintenance
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Applying SPC to Service (cont.)

• Fast-Food Restaurants
• waiting time for service, customer complaints, cleanliness, food quality, order accuracy,
employee courtesy
• Catalogue-Order Companies
• order accuracy, operator knowledge and courtesy, packaging, delivery time, phone order
waiting time
• Insurance Companies
• billing accuracy, timeliness of claims processing, agent availability and response time
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Where to Use Control Charts

• Process has a tendency to go out of control
• Process is particularly harmful and costly if it goes out of
control
• Examples
• at the beginning of a process because it is a waste of time and
money to begin production process with bad supplies
• before a costly or irreversible point, after which product is difficult
to rework or correct
• before and after assembly or painting operations that might cover
defects
• before the outgoing final product or service is delivered
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Control Charts
• A graph that establishes • Types of charts
control limits of a process • Attributes
• Control limits • p-chart
• c-chart
• upper and lower bands of
a control chart • Variables
• range (R-chart)
• mean (x bar – chart)
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Process Control Chart

Out of control
Upper
control
limit
Process
average
Lower
control
limit
1 2 3 4 5 6 7 8 9 10
Sample number
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Normal Distribution
95%
99.74%
-3σ
σ -2σ
σ -1σ
σ µ=0 1σ
σ 2σ
σ 3σ
σ
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A Process Is in Control If …
1. … no sample points outside limits

2. … most points near process average
3. … about equal number of points above and
below centerline
4. … points appear randomly distributed
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Control Charts for Attributes
 p-charts
 uses portion defective in a sample
 c-charts
 uses number of defects in an item
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p-Chart
UCL = p + zσ
σp
LCL = p - zσ
σp
z = number of standard deviations from process average

p = sample proportion defective; an estimate of process average
σp = standard deviation of sample proportion
p(1 - p)
σp =
n
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p-Chart Example
NUMBER OF PROPORTION
SAMPLE DEFECTIVES DEFECTIVE
1 6 .06
2 0 .00
3 4 .04
: : :
: : :
20 18 .18
200
20 samples of 100 pairs of jeans
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p-Chart Example (cont.)

total defectives
p= = 200 / 20(100) = 0.10
total sample observations
p(1 - p) 0.10(1 - 0.10)

UCL = p + z = 0.10 + 3
n 100
UCL = 0.190
p(1 - p) 0.10(1 - 0.10)

LCL = p - z = 0.10 - 3
n 100
LCL = 0.010
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p-Chart Example (cont.)

0.20
0.18 UCL = 0.190
0.16
Proportion defective
0.14
0.12
p = 0.10
0.10
0.08
0.06
0.04
0.02 LCL = 0.010
2 4 6 8 10 12 14 16 18 20
Sample number
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c-Chart
UCL = c + zσ
σc
σc = c
LCL = c - zσ
σc
where
c = number of defects per sample
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c-Chart (cont.)
Number of defects in 15 sample rooms
NUMBER
OF
SAMPLE DEFECTS 190
1 12 c= =15
12.67
2 8
3 16 UCL = c + zσ
σc
= 12.67 + 3 12.67
: : = 23.35
: :
15 15 LCL = c + zσ
σc
190 = 12.67 - 3 12.67
= 1.99
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c-Chart (cont.)
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UCL = 23.35
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Number of defects
c = 12.67
15
12
3 LCL = 1.99
2 4 6 8
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10 12 14 16
Sample number
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Control Charts for Variables
 Mean chart ( x -Chart )

 uses average of a sample
 Range chart ( R-Chart )
 uses amount of dispersion in a sample
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x-bar Chart
x1 + x2 + ... xk
x==
k
= =
UCL = x + A2R LCL = x - A2R
where
x = average
= of sample means
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x-bar Chart Example

OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15
Example 15.4
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x- bar Chart Example (cont.)
x 50.09
x== = = 5.01 cm
k 10
UCL = x + A=2R = 5.01 + (0.58)(0.115) = 5.08
LCL = x - A=
2R = 5.01 - (0.58)(0.115) = 4.94
Retrieve Factor Value A2

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x- bar Chart Example (cont.)
5.10 –
5.08 – UCL = 5.08
5.06 –
5.04 –
Mean
= x = 5.01
5.02 –
5.00 –
4.98 –
LCL = 4.94
4.96 –
4.94 – | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
4.92 – Sample
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R- Chart
UCL = D4R LCL = D3R
R
R=
k
where
R = range of each sample
k = number of samples
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R-Chart Example
OBSERVATIONS (SLIP-RING DIAMETER, CM)
SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15
Example 15.3
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R-Chart Example (cont.)
R 1.15 UCL = D4R = 2.11(0.115) = 0.243

R= = = 0.115
k 10 LCL = D3R = 0(0.115) = 0
Retrieve Factor Values D3 and D4
Example 15.3
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R-Chart Example (cont.)
0.28 –
0.24 –
UCL = 0.243
0.20 –
Range
0.16 – R = 0.115
0.12 –
0.08 –
0.04 – LCL = 0
0– | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number
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Using x- bar and R-Charts Together
 Process average and process variability must be in

control.
 It is possible for samples to have very narrow ranges,
but their averages is beyond control limits.
 It is possible for sample averages to be in control, but
ranges might be very large.
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Control Chart Patterns

UCL
UCL
LCL
Sample observations
consistently below the LCL
center line
Sample observations
consistently above the
center line
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Control Chart Patterns (cont.)

UCL
UCL
LCL
Sample observations
consistently increasing LCL
Sample observations
consistently decreasing
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Zones for Pattern Tests

UCL =
3 sigma = x + A2R
Zone A
= 2
2 sigma = x + 3 (A2R)
Zone B
= 1
1 sigma = x + 3 (A2R)
Zone C
Process =
x
average
Zone C
=
1 sigma = x - 1 (A2R)
3
Zone B
=
2 sigma = x - 2 (A2R)
3
Zone A
=
LCL 3 sigma = x - A2R
| | | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12 13
Sample number
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Control Chart Patterns
 8 consecutive points on one side of the center line

 8 consecutive points up or down across zones
 14 points alternating up or down
 2 out of 3 consecutive points in zone A but still inside the
control limits
 4 out of 5 consecutive points in zone A or B
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Performing a Pattern Test

SAMPLE x ABOVE/BELOW UP/DOWN ZONE
1 4.98 B — B
2 5.00 B U C
3 4.95 B D A
4 4.96 B D A
5 4.99 B U C
6 5.01 — U C
7 5.02 A U C
8 5.05 A U B
9 5.08 A U A
10 5.03 A D B
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Sample Size
 Attribute charts require larger sample
sizes
 50 to 100 parts in a sample
 Variable charts require smaller samples

 2 to 10 parts in a sample
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SPC with Excel
UCL=0.19
LCL=0.01
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SPC with Excel: Formulas
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Process Capability
• Tolerances
• design specifications reflecting product requirements
• Process capability
• range of natural variability in a process what we measure
with control charts
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Process Capability
Design
Specifications
(a) Natural variation exceeds

design specifications; process
is not capable of meeting
specifications all the time.
Process
Design
Specifications
(b) Design specifications and

natural variation the same;
process is capable of meeting
specifications most of the time.
Process
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Process Capability (cont.)

Design
Specifications
(c) Design specifications greater

than natural variation; process is
capable of always conforming to
specifications.
Process
Design
Specifications
(d) Specifications greater than

natural variation, but process off
center; capable but some output
will not meet upper specification.
Process
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Process Capability Measures
Process Capability Ratio
tolerance range
Cp = process range
upper specification limit -

lower specification limit
=
6σ
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Computing Cp
Net weight specification = 9.0 oz ± 0.5 oz

Process mean = 8.80 oz
Process standard deviation = 0.12 oz
upper specification limit -

lower specification limit
Cp =
6σ
9.5 - 8.5
= = 1.39
6(0.12)
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Process Capability Measures
Process Capability Index
= x - lower specification limit

3σ
σ ,
Cpk = minimum
upper specification limit - x =
3σ
σ
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Computing Cpk
Net weight specification = 9.0 oz ± 0.5 oz

Process mean = 8.80 oz
Process standard deviation = 0.12 oz
=
x - lower specification limit
,
Cpk = minimum 3σ
=
upper specification limit - x
3σ
8.80 - 8.50 9.50 - 8.80

= minimum , = 0.83
3(0.12) 3(0.12)
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Appendix:
Determining Control Limits for x-bar and R-Charts
SAMPLE SIZE FACTOR FOR x-CHART FACTORS FOR R-CHART
n A2 D3 D4
2 1.88 0.00 3.27

3
4
Fact 1.02
0.73
0.00
0.00
2.57
2.28
5
6
ors 0.58
0.48
0.00
0.00
2.11
2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.44 0.18 1.82
10 0.11 0.22 1.78
11 0.99 0.26 1.74
12 0.77 0.28 1.72
13 0.55 0.31 1.69
14 0.44 0.33 1.67
15 0.22 0.35 1.65
16 0.11 0.36 1.64
17 0.00 0.38 1.62
18 0.99 0.39 1.61 Return
19 0.99 0.40 1.61
20 0.88 0.41
4-73 1.59
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SPC
CALCULATION
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SPC
Basic Statistical Concepts
&
Statistical Process Control
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SPC
AVERAGE AND RANGE CHARTS X & R
STATISTICAL PROCESS CONTROL :
The use of statistical techniques such as control

charts to analyze a process or its output so as to
take appropriate actions to achieve and maintain
a state of statistical control and to improve the
process capability.
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SPC

ISO/TS 16949:2009 QMS REQUIREMENTS FOR
SPC,
7.4.3.1 Incoming product quality (8.6.4-a receipt &
Evaluation of statistical data provided by the
supplier to the organization)
The organization shall have a process to assure
the quality of purchased product (see 7.4.3) utilizing
one or more of the following methods:
receipt of, and evaluation of, statistical data
by the organization;
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SPC

SPC,
(8.5.1.1 Control plan - e)
7.5.1.3 Verification of job set-ups (8.5.1.3-C)
Job set-ups shall be verified whenever performed,

such as an initial run of a job, material changeover or
job change. Work instructions shall be available for
set-up personnel. The organization shall use statistical
methods of verification where applicable.
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SPC

SPC,
7.6.1 Measurement system analysis (7.1.5.1.1)
Statistical studies shall be conducted to analyse the

variation present in the results of each type of measuring
and test equipment system. This requirement shall apply to
measurement systems referenced in the control plan. The
analytical methods and acceptance criteria used shall
conform to those in customer reference manuals on
measurement systems analysis. Other analytical methods
and acceptance criteria may be used if approved by the
customer.
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SPC
ISO/TS 16949:2009 QMS REQUIREMENTS FOR SPC,
8.1 General
The organization shall plan and implement the monitoring,
measurement, analysis and improvement processes needed
a) to demonstrate conformity of the product,
b) to ensure conformity of the quality management system, and
c) to continually improve the effectiveness of the quality
management system.
This shall include determination of applicable methods,
including statistical techniques, and the extent of their use.
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SPC

SPC,
Clause 8.1.1 :- Identification of statistical tools (9.1.1.2 &

9.1.1.3 Application of statistical Concept)
Appropriate statistical tools for each process shall be

determined during advance quality planning and included in
the control plan.
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SPC

SPC,
Clause 8.1.2 :- Knowledge of basic statistical

concepts
Basic statistical concepts, such as variation, control

(stability), process capability and over-adjustment shall
be understood and utilized throughout the
organization.
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SPC
Clause 8.2.3.1 :- Monitoring and measurement of

manufacturing processes (9.1.1.1 )
The organization shall perform process studies on all new
manufacturing (including assembly or sequencing)
processes to verify process capability and to provide
additional input for process control. The results of process
studies shall be documented with specifications, where
applicable, for means of production, measurement and test,
and maintenance instructions.
These documents shall include objectives for manufacturing
process capability…..
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SPC

SPC,
The organization shall maintain manufacturing process

capability or performance as specified by the customer part
approval process requirements.
Significant process events, such as tool change or machine
repair, shall be recorded.
A corrective action plan shall then be completed by the
organization, indicating specific timing and assigned
responsibilities to assure that the process becomes stable
and capable.
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SPC
Clause 8.5.1.2 :- Manufacturing process improvement

(10.3.1 Continual improvement – Supplemental)
Manufacturing process improvement shall continually focus
upon control and reduction of variation in product
characteristics and manufacturing process parameters.
NOTE 1 Controlled characteristics are documented in the
control plan.
NOTE 2 Continual improvement is implemented once
manufacturing processes are capable and stable, or product
characteristics are predictable and meet customer
requirements.
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SPC
SPECIAL CHARACTERISTICS:
Product characteristics or manufacturing process

parameters which can affect safety or compliance
with regulations, fit, function, performance or
subsequent processing of product.
( Refer Customer Specific Requirements )
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43
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SPC
PROCESS :
The combination of people, equipment,

materials, methods, measurement and
environment that produce output – a given
product or service
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SPC
Process Capability:
It is determined by the variation that comes from

common causes. It generally represents the best
performance of the process itself. This is
demonstrated when the process is being operated in
a state of statistical control regardless of the
specification.
(Cp,Cpk)
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44
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SPC
Process Performance:
The overall output of the process and how it is

related to their requirements ( defined by
specification ), irrespective of the process
variation.
(Pp,Ppk)
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SPC
VARIATION :
The inevitable differences among individual outputs
of a process.
The sources of variation can be grouped into two

major classes,
Common causes & Special causes.
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45
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SPC
Controlled Variation
Time
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SPC
AVERAGE AND RANGE CHARTS
X&R
Time
Uncontrolled Variation
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46
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SPC

Indirect Material People
Tools
Equipment Training
Machines Skill
Coolant
Fixtures Motivation
Bushings
Gauges/Masters Communication
Lubricants
Spindles/Collects Attitude
Chemicals
Trust
Direct Material Product Quality
Hardness
Machiniability
Pick up points
Orders Methods
Clarity Facilities Specification
Timeliness Temperature Speeds
Adequacy Cleanliness Feeds
Product mix Humidity Process Documentation
Quantity Noise
Central coolant system
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SPC
NORMAL DISTRIBUTION:
A continuous, symmetrical, bell-shaped frequency

distribution for variables data that is the basis
for the control charts for variables.
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47
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SPC
50% 50%
“Balanced”
Normal Distribution
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SPC
COMMON CAUSE :
A source of variation that affects all the individual

values of the process output being studied
This is the source of the inherent process
variation.
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SPC
Common Causes:
1. Plenty in numbers
2. Results in less variation
3. Part of the process
4. Variation due to Limitations in 5M
( Man, Machine, Material, Method, Measurement
and Environment )
5. Results in constant variation
6. Predictable
7. Management Controllable
8. Statistics shall apply
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SPC

Examples of Common Causes,
Man: Difference in Competency ( setting, operating &

inspection )of Employees working in shifts.
Machine: Difference in Quality of Product when Production
of same Part is being carried out on 2 different
machines having same pecifications. Preventive
Maintenance being carried out as per plan. UPS
provided for Electrical supply
Material: Difference in Mechanical & Chemical Properties in
2 different lots of raw Material of same grade
received from suppliers ( Raw material
Manufacturers )
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49
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SPC
Examples of Common Causes,
Method: Setting of Process Parameters at different

levels within the defined specifications.
Tool wear & tear.
Measurement: Use of 2 different Vernier of same type,
L.C. & Range
Environment: Change in Temperature, Humidity at
different times during a day
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SPC
SPECIAL CAUSE :
A source of variation that affects only some of the
output of the process; it is often intermittent and
unpredictable. A Special cause is some times
called assignable cause. It is signaled by one
or more points beyond the control limits or a
non-random pattern of points within the control
limits.
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50
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SPC
Special Causes:
1. Few in numbers
2. Results in large variation
3. Visitors to the process
4. Variation due to external factors
5. Fluctuating variation
6. Unpredictable
7. Operating personnel Controllable
8. Statistics shall not apply
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SPC
Examples of Special Causes,

Man: Untrained Employee working on the Machine
Machine: Production of Product on Conventional Lathe
machine where Product Run out
requirement is 2 microns. Major &
frequent Breakdowns of Machine. Frequent
Power Failures.
Material: Use of different grade of raw material
Method: Setting of Process Parameters which are not
proven. Tool Breakage
Measurement: Use of Micrometer having range of 0-25 mm
to check O.D. of 25 mm +/- 0.1 mm
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51
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SPC
Examples of Special Causes,
Environment:
Precision grinding process being carried out in open
shop floor where tolerance for OD is +/- 1 micron and as
per Machine Manufacturer’s Instruction Grinding machine
need to be kept in A.C. cabin and temperature
requirement is
22*C +/- 2*C
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SPC

1 1 P o in t m o re th a n 3 s ta n d a rd d e v ia tio n s fro m c e n te rlin e
2 7 P o in ts in a ro w o n s a m e s id e o f C e n e rlin e
3 6 P o in ts in a ro w , a ll in c re a s in g o r a ll d e c re a s in g
4 1 4 P o in ts in a ro w , a lte rn a tin g u p & D o w n
5 2 o u t o f 3 p o in ts > 2 s ta n d a rd d e v ia tio n s fro m c e n te rlin e ( s a m e s id e )
6 4 o u t o f 5 p o in ts > 1 s ta n d a rd d e v ia tio n s fro m c e n te rlin e ( s a m e s id e )
7 1 5 p o in ts in a ro w w ith in 1 s ta n d a rd d e v ia tio n o f c e n te rlin e ( e ith e r s id e )
8 8 P o in ts in a ro w > 1 S ta n d a rd d e v ia tio n fro m c e n te rlin e ( e ith e r s id e )
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SPC
SPECIFICATION:
The Engineering requirement for judging acceptability of

a particular characteristic. A specification must never
be confused with a control limit. Ideally, a
specification ties directly to or is compatible with the
Customer’s ( internal and/or external ) requirements
and expectations.
USL = Upper Specification Limit
LSL = Lower Specification Limit
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SPC
BILATERAL SPECIFICATION:
A bilateral specification identifies requirements at both
extremes of the process range. Often referred to as
a two-sided specification or tolerance.
UNILATERAL SPECIFICATION:
A unilateral specification identifies requirements at only
one extreme of the process range. Often referred to
as a one-sided specification or tolerance.
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SPC
CONTROL LIMIT:
A line ( or lines ) on a control chart used as a basis for
judging the stability of process. Variation beyond a
control limit is evidence that special causes are
affecting the process. Control limits are calculated
from process data and are not to be confused with
engineering specifications.
( Control Limits cannot be decided they need to be
calculated )
UCL = Upper Control Limit
LCL = Lower Control Limit
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SPC
CONTROL CHART:
A graphic representation of a characteristics of a

process, showing plotted values of some statistic
gathered from that characteristic, a centerline, and
one or two control limits. It has two basic uses: as a
judgment to determine if a process has been
operating in statistical control, and to aid in
maintaining statistical control.
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SPC
VARIABLE DATA :
Quantitative data, where measurements are used

for analysis. Examples include the diameter of
bearing in millimeters.
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SPC
ATTRIBUTES DATA :
Qualitative data that can be categorized for recording

and analysis. Examples are characteristics that are
inherently measurable (i.e. could be treated as
variables data), but where the results are recorded
in a simple yes/no fashion, such as acceptability of
shaft diameter when checked on a go/no-go gauge.
Attribute data are usually gathered in the form of
nonconforming units or of nonconformities.
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SPC
Preparation for SPC Study,

1. Identify Product Special Characteristics for which SPC Study is
to be carried out.
2. Confirm Cpk requirement of Customer or Organization.
3. Please ensure MSA Study of Gauges to be used for SPC
Study.
4. Please ensure qualification of personnel who are going to
conduct SPC study.
5. Collect Data from running production and Plot Histogram and
ensure Normal Distribution Curve.
6. Data collection should be done when process is running under
Natural working conditions ( 5M )
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7. Process should be free from Variation due to Special Causes
111
SPC
WHEN,
In Control Chart:- All points are within control limits or there is
no obvious run or non-random pattern of points within the
control limits.
&
In Histogram:- Inverted bell shape is observed ( i.e. Normal
Distribution Curve – NDC )
ONLY THEN,
Continue SPC Study.
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SPC

During SPC Study make sure that,
1. 5Ms & 1 E are set at natural working conditions.

2. No over adjustment, No special setting.
3. Decide sub group size and no. of sub groups and frequency
of sample collection.
4. Event Logging to monitor relation between cause and
variation.
5. Proper data collection, calculations, analysis & action
6. Review of SPC study results by Cross Function Team &
action plan to improve Process Capability.
7. Retain samples for reference.
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SPC

CONTROL CHARTS FOR VARIABLES :
Average and Range Chart ( X bar & R ):
For Mass Production ( M/c. Shop )
Median & Range Chart :
For Mass Production ( M/c. Shop )
Average and Standard Deviation Chart ( X bar & S ):
For Mass Production(M/c. Shop)
Individual and moving range Chart :
Applicable for Batch Production ( Paint Viscosity )
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SPC
CONTROL CHARTS FOR ATTRIBUTES:
P Chart : To collect % of non-conformities. Not to focus on

no. of defects. Sample size is constant .
nP Chart : Defectwise monitoring. Sample size is constant.

OD undersize 3 nos., ID oversize 4 nos. out of
500 nos.
u chart
c chart
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SPC
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58
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SPC
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SPC
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59
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SPC
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SPC
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60
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SPC
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SPC
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SPC

MEAN: A measure of location. The average of values in a
group of measurements.
RANGE: A measure of process spread. The difference between
the highest and lowest values in a subgroup, a sample, or a
population
MEDIAN: A measure of location. The middle value in a group of
measurements, when arranged from lowest to highest. If the
number of values is even, by convention the average of the
middle two values is used as the median.
STANDARD DEVIATION: A measure of the spread of the
process output or the spread of a sampling statistics from
the process.
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SPC

OTHER TYPES OF CHARTS,
Spot Light Chart : Green, Yellow & Red zone in the chart.
Pre Control Chart ( Defined Controls ) : Zone defined based on ½ &
¼ of Tolerance.
Short Run Chart : Used for different products having same
dimension.
Cusum Chart : For Continuous Production such as Chemical / Paint
Industry. Small Changes will be monitored.
Regression control chart : To monitor 2 different parameters such as
Product cost vs. weight, Output vs. cycle time, Temp. vs.
Pressure
Auto Regression Chart : Applicable for Heat Treatment process.
Temp. vs. Hardness, Time vs. Hardness.
Zone Chart : Control Charts divided in Zones.
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SPC

Types of SPC Study,
1. Short Term SPC Study :- Short term SPC study is being

carried out at the time of initial study / PPAP. Normally
continuous production of 50/100/300 nos. is being taken for
this study.
( Comply to CSR ) – Pp & Ppk
2. Long Term SPC Study:- Long term SPC study is being

carried out for a long run of production. A complete lot
production, covering all shifts, all operators and all types of
variations need to be captured in this study.
- Cp & Cpk
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SPC

Cp = Process Capability
Represents Precision of the Process
Potential Process Capability
For Routine Production
Process Capability w.r.t. Control Limits
Cpk = Process Capability Index

Actual Process Capability
Represents Accuracy & Precision of the Process
Centering of the process
Cp is equal or greater than Cpk ( In case of Bilateral Tolerance)

Cp is less, equal or greater than Cpk (In case of Unilateral Tolerance)
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SPC
Pp = Process Performance
Potential Process Performance
For Initial Studies
Process Capability w.r.t. Specification Limits
Ppk = Process Performance Index

Actual Process Performance
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SPC

CALCULATION METHOD FOR Cp & Cpk (Bilateral Tolerance)
STANDARD DEVIATION () = R bar / d2
Cp=USL – LSL / 6 = Tolerance / 6
Cpu= (USL – Xdbar) / 3 Cpl= (Xdbar - LSL) / 3
In case of bilateral specification, calculate both the values and

take minimum of two as Cpk.
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SPC

How to calculate Control Limits In X bar & R Chart,
Centerline for X bar chart = X dbar
UCL = X dbar + A2*R bar
LCL = X dbar - A2*R bar
Centerline for R chart = R bar

UCL = D4*R bar
LCL = D3*R bar
(Refer Table from SPC Manual for A2,D2,D3 & D4 value based
on subgroup size)
(Formulas for calculation of Standard Deviation (S) for Pp & Ppk
is different)
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SPC
AVERAGE AND RANGE X&R
CHARTS
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SPC

Case Study,
Diameter of Part
USL = 23.5 mm & LSL = 21.5
Sample Size = 125 nos.
Subgroup Size = 5 nos.
No. of Subgroups = 25
X dbar = 22.5308
R bar = 0.4184
D2 = 2.326
Calculate,
1. Standard Deviation
2. Cp
3. Cpk
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SPC
Standard Deviation = 0.179880
Cp = 1.85
Cpk = 1.80
( Cpl = 1.91 & Cpu = 1.80 )
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SPC
Cp = 1.0
= 3 sigma Process
= 2700 PPM
= 0.27% Rejection possibility
= Process variation covers100% band of Tolerance
= Process does not meet the acceptance criteria
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SPC

Cp = 1.33
= 4 sigma Process
= 64 PPM
= Process variation covers 75% band of Tolerance
= Process Centered, may be Acceptable
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SPC

Cp = 1.67
= 5 sigma Process
= 10 PPM
= Process meets the acceptance criteria
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SPC
Cp = 2.0
= 6 sigma Process
= 3.4 PPM
= Process is performing good.
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SPC
Let’s Go Ahead
Thank You
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69

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23-Feb-20

Statistical process control (SPC)

• SPC must be practiced in 2 phases:

Common Causes and Special Causes

Definitions-Mean, Median, Mode, Range

Definitions-Mean, Median, Mode, Range

• The "range" of a list a numbers is just the difference

Exercise-Mean, Median, Mode, Range

• Find the mean, median, mode, and range for the

Normal Distribution Bell Curve

Statistical Process Control

Basics of Statistical Process Control

• Statistical Process Control (SPC)

Applying SPC to Service

Applying SPC to Service (cont.)

Applying SPC to Service (cont.)

Where to Use Control Charts

Process Control Chart

1. … no sample points outside limits

Control Charts for Attributes

z = number of standard deviations from process average

20 samples of 100 pairs of jeans

p-Chart Example (cont.)

p(1 - p) 0.10(1 - 0.10)

p(1 - p) 0.10(1 - 0.10)

p-Chart Example (cont.)

0.18 UCL = 0.190

0.02 LCL = 0.010

Control Charts for Variables

 Mean chart ( x -Chart )

x-bar Chart Example

x- bar Chart Example (cont.)

UCL = x + A=2R = 5.01 + (0.58)(0.115) = 5.08

Retrieve Factor Value A2

x- bar Chart Example (cont.)

5.08 – UCL = 5.08

UCL = D4R LCL = D3R

R-Chart Example (cont.)

R 1.15 UCL = D4R = 2.11(0.115) = 0.243

Retrieve Factor Values D3 and D4

R-Chart Example (cont.)

Using x- bar and R-Charts Together

 Process average and process variability must be in

Control Chart Patterns

Control Chart Patterns (cont.)

Zones for Pattern Tests

Control Chart Patterns

 8 consecutive points on one side of the center line

Performing a Pattern Test

 Variable charts require smaller samples

SPC with Excel

SPC with Excel: Formulas

(a) Natural variation exceeds

(b) Design specifications and

Process Capability (cont.)

(c) Design specifications greater

(d) Specifications greater than

Process Capability Measures

Process Capability Ratio

upper specification limit -

Net weight specification = 9.0 oz ± 0.5 oz

upper specification limit -

Process Capability Measures