Concept of Process Capability

In 6-sigma

Prof. S. K. Neogy
Indian Statistical Institute
Delhi Centre

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 the time.

Process
 Process Capability
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

Process Capability
• Terminology
– Control limits
• represent the natural variation in a quality
characteristic
– Tolerance limits
• represent variation acceptable to the customer
– Capable Process
• In a capable process, specification limits are well
outside control limits
• The goal is to choose a capable process such that
the natural control limits of the process are within
the specifications of the customer
 Process Capability
Index
• There are several indices that may be
used to measure process capability. We
will examine one.

 X − LSL USL - X 
Cpk = min or 

 3σ 3σ 

Process Capability
Index
 X − LSL USL - X 
Cpk = min or 

 3σ 3σ 

Capability Index shows how well

parts being produced fit into
design limit specifications.

As a production process
produces items small shifts Shifts in Process Mean
in equipment or systems
can cause differences in
production performance
from differing samples.
 Interpreting Process
Capability
• Interpretation of index values
– If Cpk = 1, then the natural control limits
and the customer specification are
exactly equal. The process is just
capable
– If Cpk < 1, the process is not capable
– If Cpk > 1, the process is highly capable
of meeting customer specifications
• Note: If the process is not under
control, then Cpk has no meaning

Process Capability
Measures
Process Capability Ratio

tolerance range
Cp =
process range

upper specification limit -

lower specification limit
=
6σ
 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)

Process Capability
Measures
Process Capability Index

=
x - lower specification limit
,
Cpk = minimum 3σ
=
upper specification limit - x
3σ
 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)

The Statistical Meaning of Six Sigma

Process capability measure
Lower Upper
Specification
USL − LSL
Specification
Limit (LSL) Limit (USL)
Cp =
6σˆ
Process A
(with st. dev σA) xσ Cp P{defect} ppm
1σ 0.33 0.317 317,000
σA
X-3σ σA
X-2σ σA
X-1σ X σ A X+2σ
X+1σ σ σA
X+3σ
2σ 0.67 0.0455 45,500
σ
3σ

3σ 1.00 0.0027 2,700

Process B 4σ 1.33 0.0001 63
(with st. dev σB)
5σ 1.67 0.0000006 0,6
6σ 2.00 2x10-9 0,00
σB
X-6σ X σB
X+6σ

• Estimate standard deviation: σ̂ =R/d2

• Look at standard deviation relative to specification limits
• Don’t confuse control limits with specification limits: a process can be out of
control, yet be incapable
Sigma To Cpk Conversion Table

Sigma Cpk
1.5 0.50

3.00 1.00

3.50 1.17

4.00 1.33

4.50 1.50

5.00 1.67

6.00 2.00

Assumptions
In the above table, we have assumed that the standard sigma shift of 1.5 is appropriate (the
calculator allows you to specify another value), the data is normally distributed, and the
process is stable.