Individual Assignment for INT 4843

Applying Statistical Process Control in the Workplace

The application of a statistical process control program is wide open for an individual
that earns his living as a quality engineer in a manufacturing environment. I've been
involved with several attempts to use SPC at more than one company. Every effort winds
up with the same conclusion. All the data gathering, chart generation and information are
great, but how does it improve the process?
Anyone that has even the most general understanding of SPC realizes that the data
gathering phase of statistical process control does not improve a process. A view of the
process is provided in the initial phase. Improving the process comes from acting on the
information that gathering data provides.
For the purpose of this assignment, I intend to explain how I applied SPC to a recent
process improvement initiative that I became involved with at the Alcoa-Danville plant.
The project emerged from a customer complaint and request for corrective action. The
gist of the situation was that a stamping facility that Alcoa-Danville supplies with
aluminum sheets that are to become automobile hoods had received shipments with less
that the amount of material stated on the shipping labels. The customer wasn't getting all
the material that was being paid for. My assignment was to determine if the automated
counting system was working correctly and to devise a control method to assure that the
customer would receive the proper amount of material in future shipments.
To complete the first part of the assignment I decided to establish a confidence level
with the automated counting system. In order to do this I used a very simple form of
statistical process control. I manually counted the sheets of aluminum as they were
stacked on the skids by the automated stacker and counted by the automated counter. In
every instance, the manual count and the automated count agreed. With this data, there
was really no point in performing the mental gymnastics to figure a confidence interval.
The counting system was working. The error was not in the mechanical process.
The next step of the assignment was to devise a control method to assure the customer
would be receiving the prescribed amount of material. There were some factors to
consider. Inspection samples were removed from the stacks. The samples may not be
accounted for. Also, partial skids remain from the end of the run of a particular product.

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 Individual Assignment for INT 4843
Applying Statistical Process Control in the Workplace

These partials are reintroduced in subsequent production runs of that product. The count
on these partial skids might be in question if some of the sheets are removed for samples
or to top off a reworked skid.
Note: the partials are now controlled by sealing the skids with plastic banding
before leaving the operation for storage.
To establish a means to assure the integrity of the product count delivered to the
customer, a stack height check was instituted at the enclosing station. The stack height is
determined by multiplying the thickness of one sheet by the number of sheets in the
stack. The sheet thickness is obtained by measuring with a micrometer. The stack height
is obtained by measuring with a caliper. The results of each measurement are recorded on
a check sheet to provide historical data of the operation. The stack height will then be
entered into an Xmr chart. For this operation, X bar and R charts are not the most
appropriate tools.
The first step in implementing the SPC program was to perform gage R&R on the
measuring instruments. For the micrometer, 10 sheets of aluminum that provided a range
through the measurement sizes were used. A two operator, 10 piece sample, three trial
method was employed. The outcome of the study was a % R&R of 19.83. This is an
acceptable result. A % R&R of 10 or less is desirable. A % R&R of 10 to 30 is
acceptable. The caliper was tested in the same fashion. The % R&R for the caliper was
16.24. The gage studies indicated that operator technique was influencing the
measurements. In order to have confidence in the stack height check as a process control,
the operator technique would require improvement.
The next step was to establish the capability of the sheet thickness. A 30 piece capability
study was performed to establish the Cp and Cpk of the thickness feature. The result of
this study was a Cp of 2.00 and a Cpk of 1.83. These readings indicate that thickness is a
stable feature. The spread or distribution of the process is very good (Cp of 2.00) and the
location of the readings between the specification limits is also very good (Cpk of 1.83).
A capability index of 1.67 is generally used in the automotive industry. A capability
index of 1.33 can also be acceptable.

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 Individual Assignment for INT 4843
Applying Statistical Process Control in the Workplace

These preliminary studies indicated that Alcoa had adequate gauging, the thickness of the
sheet was in control and the automated counting system was reliable. With these facts in
hand, the process to control the stack height (certified stock) to the customer was
initiated. The data from this process was to be reviewed to establish the reliability of the
piece count.
The stack height measurements were based on a target dimension and an upper limit
dimension. This unilateral measuring plan was designed to assure that the stack would
never be short on piece count. The results of the stack height measurement revealed
some shortcomings of the measurement design. The stack could have less than the target
value of height and still have the correct number of pieces. In order to ever display a
capable control method Alcoa had two options. Either count all the stacks individually or
establish upper and lower limits to show the stack height to be in control. Alcoa chose to
use the upper and lower specification limits while exploring the possibility of using a
laser-type device to count each skid. Refinement of the charting system indicates that the
stack height is in control.
Looking at the stack height data with the intent of establishing a control revealed a
more stable process than using the arbitrary limits. Based on the process data, the upper
control limit of the stack height check would 15.766" and the lower control limit would
be 15.634". The data points are all within the control limits.
When using stack height specification limits based on the tolerance of the blank
thickness, the stack height is well in control. The lower specification limit would be
15.045" (.0354" x 425 blanks) and the upper specification limit would be 16.065" (.0378"
x 425 blanks).
The stack height check will continue to be used as a process control. The check is to
remain a 100% check for the affected product. This check cannot be used to determine if
the process is in control. The check will indicate a sudden change in stack height and
trigger the operator to institute the reaction plan (manual count) to determine if the stack
has the correct amount of pieces.

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 Individual Assignment for INT 4843
Applying Statistical Process Control in the Workplace

Note: the true root cause of the sheet shortage was determined to be a mechanical
issue. From time to time, sheets fall off the stack. The automated counter counts the
sheet as it falls, but the sheet doesn't land in the proper place or ends up on the
floor. The operator has to remove the errant piece. When this situation occurs too
often, the operators become frustrated and fail to replace the damaged pieces. The
true corrective action is improved maintenance to the belts of the stacker. The stack
height check is a valid control. If the stack is sent to enclosing with several pieces
absent, the height check will catch the shortage.

Conclusion
The use of the statistical process control tools led to the realization that the current
process was in control to the current specification limits and calculated control limits.
Studying the process indicated that several variables effect the stack height of the
aluminum blanks (i.e. thickness, shape, air, etc.). Improved process controls and
improved preventative maintenance are the two key factors Alcoa needs to use in order to
deliver the proper amount of pieces to the customer. Charting the stack height on a Xmr
chart can give an indication to trigger maintenance on the automated stacking system. In
that regard, using statistical process control will help to improve the results of the
counting process and avoid future dissatisfaction at the customer.
The Hawthorne Effect also played a role in improving the process. The operators and
the maintenance technicians both became aware that the process was under review. The
increased attention helped to increase the overall awareness of the employees involved in
the stacking / counting process. Also, the shortage of blanks at the customer triggered a
management response to the mechanical issues of the stacker. That is what the operators
wanted in the first place.