Statistical Process

Control
(STAT-807)

Dr. Muhammad Younas Majeed

Dimensions of Quality
Performance
Reliability
Durability
Serviceability
Aesthetics
Features
Perceived Quality
Conformance to Standards
 Quality characteristics/
Critical-to-quality (CTQ)

Time
Physical Sensory
Orientation
• Length • Taste • Reliability
• Weight • Appearance • Durability
• Voltage • Color • Serviceability
• Viscosity • Touch & • Scalability
Feel • Portability
 Quality Characteristics/
Critical-to-Quality (CTQ)
Lower specification limit (LSL)
• The smallest allowable value for a quality characteristic

Nominal/Target Value
• Value of a measurement that corresponds to the desired value for that QC.

Upper specification limit (USL)

• The largest allowable value for a quality characteristic
 Operational

Quality
Engineering

Engineering Managerial

to ensure that the quality characteristics of a product

are at the nominal or required levels and that the
variability around these desired levels is minimum.
7 QC TOOLS
 Check Sheets

Used to collect data in real time at

the location where the data is
generated. The data it captures can be
quantitative or qualitative.
Check Sheets
Attribute Data
 Check List
Helps to ensure consistency and
completeness in carrying out a task.

A basic example is the "to do list".

A schedule, which lays out tasks to be

done according to time of day or other factors
 Flow Chart
Flowcharting is typically used to map a process flow
showing the beginning of a process, decision points, and
the end of the process.

this tool is used to find redundant or unnecessary steps in

a process that improve the process efficiency when
eliminated.
Flow Chart
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
Cause & Effect (Fishbone ) Diagram
PARETO CHART

Bar graph

Lengths of the bars represent

frequency/cost/time / money etc.

Longest bars on the left and the

shortest to the right
Visually depicts which situations are
more significant
When to Use PARETO CHART
Analysing data about the frequency of
problems or causes in a process

There are many problems/causes & you want

to focus on the most significant

Analysing broad causes by looking at their

specific components

Communicating with others about your data

How to Construct PARETO CHART
What categories you will use to group items

what measurement is appropriate

what period of time the Pareto chart will cover

Collect data, recording the category each time, or
assemble data that already exist
Subtotal the measurements for each category

Determine appropriate scale for measurements

Construct & label bars for each category; Descend..

Examples; PARETO CHART
CONTROL CHART
CONTROL CHART
CONTROL CHART
CONTROL CHART
CONTROL CHART
CONTROL CHART
Hours
Out of Control Actin Plan (OCAP)
Flow Chart/text-based description
Sequence of activities after detecting OC signals
Check points; which are assignable causes
Terminators; actions to resolve OC conditions
Preferably by eliminating the assignable causes
Analysis of Prior Failure Modes can be helpful
OCAP is a living document; modified over time
an initial OCAP; when a control chart introduced
Out of Control Actin Plan (OCAP)
Types & Control Chart Selection
 Types & Control Chart Selection

Normal Distribution/
Central Limit Theorem

Binomial Distribution Poisson Distribution

 Design of Control Chart
The selection of

The sample size; Five measurements

Control limits; Three-sigma

Frequency of sampling; Every hour

 Design of Control Chart
Increasing Sample size will decrease Type II error, thus
enhancing chart’s ability to detect out of control signal

Cost of sampling

Losses from allowing defective product to be produced

Costs of investigating out-of-control signals that are

really false alarms
Type of variability exhibited by process
Type of variability exhibited by process