7 spc2

Variable SPC – Part 2
Breakthrough Management Group January 16, 2002
Notes:
© November 01, Breakthrough Management Group. Unpublished proprietary work available only under license. All rights reserved. January 16, 2002 Pg 1
Interpreting Control Charts
Control charts are powerful tools for detecting Control charts should be plotted for
special cause variation. If a special cause is found: only one purpose: to generate actions to
1. If the out of control condition is part of a trend, mark control and improve the process. When
the beginning and end of the trend a control chart has not shown any out of
control (OOC) conditions for a long
2. Analyze the process to determine the cause of the time, eliminate it.
OOC condition
3. Correct the condition and prevent it from recurring
4. Recalculate the control limits omitting the OOC
values from the calculations
5. Re-evaluate the chart according to the new limits
Control limits are only recalculated when the
causes for the OOC conditions have been identified
and corrected
Notes:
Interpreting Range Charts
Range charts are interpreted first OOC range data directly impacts the
In Range charts, a single OOC point is often caused believability of the associated X-bar data
points. If the range is very high or very
by miscalculation, mis-plotting, or mis-measurement. low, the accuracy of that x-bar point is in
Verify the accuracy of the data first. question.
Trends in the Range data can be caused by:
Real changes in the variability of the process
Changes in the measurement system
Identify the cause of the OOC and recalculate the
control limits, excluding the OOC point
If a point is excluded for the range calculations,
exclude it from the X-bar calculations, also.
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Notes:
Interpreting X-bar Charts
The Interpretation of control charts is based on the
statistical probability of a particular pattern occurring Interpretation is the crucial action
by complete chance (or being caused by random for control charts. Charts exist for
interpretation and for acting on those
variation). interpretations. They must be
All of the tests identify events that have a less than 0.3 interpreted to be of any use.
% chance of occurring by random chance (these The control chart rules or tests are
events are outside of the 3σ zone, or 3σ limits) similar (nearly identical) to the original
Western Electric rules.
Control charts are divided into sigma zones above and
below the average line
Zone C is < 1σ from the mean
Zone B is between 1σ and 2σ
Zone A is between 2σ and 3σ
Beyond Zone A is > 3σ
Notes:
Tests 1 & 2
Test 1. One Point Beyond Zone A
x Test 2
UCL The following rules are from Journal of
A Caused by a process mean Quality Technology, October, 1984 and
B shift are used by Minitab.
C
Test 1 is the test most often used. A
C
single point more than three standard
B
A deviations from the centerline has a
LCL Test 2. Nine Points in a Row probability of being randomly caused
x on One Side of the Center Line only 0.3% of the time. This is so
Test 1 – the basic test. UCL unlikely to have occurred by random
A chance that we must ACT ON IT.
Caused by a large change
B
in the process. C
Requires immediate action. C
B x
A
LCL
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Notes:
Tests 1 & 2 – Demonstration
X-bar
Rule
LCL #2 UCL
Rule
#1
σ σ σ σ σ σ
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Notes:
Tests 3 & 4
Test 3. Six Points in a Row Steadily Test 4 – Alternating Patterns
Increasing or Decreasing Over adjustment
The number of tests can be increased as
Shift-to-Shift variation
UCL
A the stability of the process increases.
Machine-to-machine variation When there are no longer any points
B x
outside the three sigma limits, it is time
C
to use some more subtle tests. When
C
Test 4. Fourteen Points in a Row the process varies outside the upper and
B
A x Alternating Up and Down lower control limit often, it is of little
LCL value to look for the fourteen alternating
UCL
A points in a row test. The Black Belt has
Test 3 – Trends up or down B bigger fish to fry.
Caused by C
Mechanical wear C x
Chemical depletion B
Increasing contamination A
LCL
Etc.
Notes:
Test 3 – Demonstration
X-bar
Rule
#3
LCL UCL
σ σ σ σ σ σ
Notes:
Test 4 – Demonstration
X-bar
Rule
#4
LCL UCL
σ σ σ σ σ σ
Notes:
Tests 5 & 6
Test 5. Two Out of Three Points in
Test 6
a Row in the same Zone A or Beyond Sometimes Test 5 is included with
x x Another test for shifts
UCL Test 1 for evaluation. Sometimes even
A Test 1, 5, 6 are related and Test 6. The idea is to look for process
B show conditions of high excursions far out from the middle.
C special cause variability
The problem with adding tests is that the
C
Test 6. Four Out of Five Points in chance of having a false positive
B
a row in the same Zone B and Beyond increases ~ 0.3% with each added test.
A
LCL If all eight tests are used, the rate is
x UCL
A x 2.4%, or approximately 1 out of 50.
Test 5 B Be judicious in your selection of
The second basic test C tests. False positives are often
C interpreted as true positives without an
High variation w/o exceeding
the 3σ limit B x assignable cause. This can be a very
A frustrating experience.
Major special-cause variation LCL
?
Notes:
Test 5 & 6 – Demonstration
X-bar
Rule Rule
#6 #5
LCL UCL
σ σ σ σ σ σ
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Notes:
Tests 7 & 8
Test 7. Fifteen Points in a Row in Zone C
Test 8 – Alternating Means
(Above and Below Centerline)
Mixtures
Test 7 can be caused by control
UCL Over control
A limits that need recalculation or by a
Two different processes on very high range chart, that is, the within
B x the same chart
C group variation is larger then the
C between variation. Check the range
B Test 8. Eight Points in a Row on Both Sides chart to help differentiate. High
A of Centerline with None in Zone C variation in the Range chart and low
LCL
variation in the X-bar chart usually
UCL
A indicates an irrational basis for selecting
Test 7 – The Whitespace Test x subgroups. Reformulate the subgroup
B
Occurs when within subgroup selection to answer the desired
C
variation is large compared to questions.
between group variation or, C
B
Old or incorrectly calculated A
limits LCL
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Notes:
Test 7 & 8 – Demonstration
X-bar
Rule
#7
Rule
#8
LCL UCL
σ σ σ σ σ σ
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Notes:
Interpretation Exercise – Page 1
X-bar Chart for Length
5.5 Interpret the following

3.0SL=5.357
control charts according the
Sample Mean
2.0SL=5.233
5.0
1.0SL=5.109
X=4.985
the previous eight rules.
-1.0SL=4.861
-2.0SL=4.738
X-bar Chart for Length
-3.0SL=4.614
4.5 5.3
0 5 10 15 20 25 3.0SL=5.232
5.2
Sample Number 2.0SL=5.149
5.1
Sample Mean
1.0SL=5.066
5.0 X=4.983
Are there any out of control 4.9 -1.0SL=4.900
conditions? Which rule? 4.8 -2.0SL=4.818
-3.0SL=4.735
4.7
4.6
0 5 10 15 20 25
Sample Number
Notes:
Interpretation Exercise – Page 2
X-bar Chart for Run 1 - Run 5
6
Interpret the following
3.0SL=5.909
control charts according the
2.0SL=5.610
the previous eight rules.
Sample Mean
1.0SL=5.311
5 X=5.012
-1.0SL=4.713
-2.0SL=4.414 X-bar Chart for Run 1 - Run 5

-3.0SL=4.115 5.5
4
5.4 3.0SL=5.424
0 5 10 15 20 25
5.3 2.0SL=5.278
Sample Number
5.2
Sample Mean
1.0SL=5.132
5.1
5.0 X=4.985
4.9
-1.0SL=4.839
4.8
4.7 -2.0SL=4.692
4.6
-3.0SL=4.546
4.5
0 5 10 15 20 25
Sample Number
Notes:
Taking Action – Special Causes
Taking action is the point of control charts.
Actions generated by special cause
Otherwise they are just a waste of time and money variation are the easiest to take. It is
If actions are required by the data and never taken, the beneficial to drive the actions to the
charts are just feel-good wallpaper. “Look, we have SPC!” lowest practical level. This decreases
Actions are based on increasing process knowledge the response time. As actions are taken
by the technical staff, they should be
Identify the root cause of the variation and fix it documented in a troubleshooting guide
Document on the chart what the problem was and the to enable the operators to act next time.
resulting fix
Document the problems and actions into a troubleshooting
guide so actions can be taken locally
Recalculate the control limits only if the special causes
have been identified and eliminated
Notes:
Taking Action – Common Causes
Compare the natural process limits to the Common cause variation reduction is
specification limits. usually a bigger project, even a Black
Belt project. Hopefully the Black Belt
Determine the process capability from the control limits
has reduced the variation in the Improve
and compare to the specification limits. Is the process phase of the project. Control charts in
capable? that instance are for additional
improvement and monitoring.
Reducing the natural process variation is the point of
Calculate the population standard
most Six Sigma projects. In the Control phase, the deviation from the d2 constants as
common cause variation should be well within the described earlier.
specification limits.
Don’t recalculate the control limits unless a known
process change explains a short term shift
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Notes:
Summary – Average and Range Charts
Used mostly in machine-dominated processes OCAP stands for Out of Control Action
Used when data can be sub grouped rationally Plan.
Powerful tool for differentiating between special cause

and common cause variation
Its power comes from the power of variable data vs.
attribute data. Remember sample size calculations?
Easily indicates trends, process shifts, and other non-
random variation
Enables a quick estimate of process capability
Notes:
CCVar.mtw
Example – Constructing Charts in Minitab

In Minitab, open sample worksheet CCVar.mtw Minitab has routines for 18 different
From the menu select Stat > Control Charts > Xbar-R… control charts. All of them are
documented in the help system and in
Select data the Minitab manuals. In the next
columns module, we will introduce charts for
attribute data. In the previous module
C1-C5 we introduced a flow chart to ease in
selecting the appropriate charting
system.
Notes:
Example: Control Chart Tests
Press the Tests… Button Even though all eight tests are
Select the tests to run. Tests 1 & 5 are best when available, as discussed before, unless the
special cause variation is subtle, start
searching for gross special causes. with tests 1 and 5. When those
Press the Help variations are eliminated, add further
tests.
button for
explanations of
each of the tests
Notes:
X-bar & R Chart – Minitab Output
Xbar/R Chart for Sample 1-Sample 5
While Minitab provides a nice output
1
3.0SL=5.583 for analysis and calculating, it doesn’t
5.5 5
take the place of charts being filled in by
Sample Mean
5.0 X=5.029
the operators or by a real-time computer
system. After-the fact analysis loses
4.5 -3.0SL=4.475
much of the power of control charts, that
is, the power to act on the process as
Subgroup 0 5 10 15 20 25
soon as the signal is received.
2 3.0SL=2.030
Sample Range
1 R=0.9602
0 -3.0SL=0.00E+00
Notes:
Recalculating Control Limits
After identifying the cause for the out-of-control points
Do not exclude points when the
they can be removed from the control limit calculations cause of the OOC condition is not or
In the previous example points 9, 11, & 24 can be cannot be identified.
removed from the control limit calculations
Press the Estimate button on the X-bar & R chart form
and enter the
offending data
?
Notes:
Modified Minitab Output
Notice the small changes in the control limits:
5.7 1
5 3.0SL=5.552
Sample Mean
5.2
X=4.964
4.7
-3.0SL=4.375
4.2
Subgroup 0 5 10 15 20 25
3.0SL=2.158
2
Sample Range
1 R=1.021
0 -3.0SL=0.00E+00
Notes:
Plotting Data With Existing Limits
Minitab can also plot and evaluate the data if historical This is useful when analyzing data
data is known and verified to be accurate for a process that has an established SPC
system. The historical constants can be
Enter the implemented for analysis of the most
historical recent data.
data in the
main form:
Notes:
Minitab Results with Historical Data
When analyzed with historical limits, notice the number
of out of control points, now:
6.0 3.0SL=6.021
Sample Mean
5.5
X=5.350
5.0
2
5 2 2
5 2 -3.0SL=4.679
1 5
4.5
Subgroup 0 5 10 15 20 25
3.0SL=2.459
Sample Range
R=1.163
1
0 -3.0SL=0.00E+00
Notes:
gageaiag.mtw
Control Charts & Minitab Gauge Studies

Conduct a gauge study on the data in Minitab worksheet
Minitab uses control charts in its
gageaiag.mtw, found in the Minitab examples directory
automated gauge study analysis.
Select Stat > Quality Tools > Gage R&R Study
Select Xbar and R for the Method of Analysis
Notes:
Gauge Study Results
Gage name:
Date of study :
Gage R&R (Xbar/R) for Response Reported by :
Tolerance:
Misc: In the gauge study analysis, the
1.1
Xbar Chart by Operator
1 2 3 1.1
Operator*Part Interaction
Operator ranges are repeat measurements of the
1.0 1.0 1
same part. For a capable gauge, the
Sample Mean
0.9 3.0SL=0.8796 0.9
Average
2
0.8 X=0.8075
repeatability of the gauge, i.e. the

-3.0SL=0.7354 0.8 3
0.7
0.7
0.6
0.6
variation caused by the gauge, should be

0.5
0.5
0.4
0.3 0.4
Part 1 2 3 4 5 6 7 8 9 10
much smaller than the part-to-part
R Chart by Operator Response by Operator
0.15 1 2 3 1.1 variability. In other words, the control
1.0
Sample Range
3.0SL=0.1252
0.10 0.9
0.8
limits, calculated from the gauge
0.05
R=0.03833
0.7
0.6
repeatability, should be very narrow and
0.00 -3.0SL=0.00E+00
0.5
0.4 most of the parts should fall outside of
Components of Variation
Operator 1
Response by Part
2 3
the the control limits of the X-bar chart.
1.1
100
%Total Var
%Study Var
1.0
0.9
Conversely, the range chart should
be in control, meaning the gauge
Percent
0.8
50 0.7
0.6
0.5 repeatability is stable over the range of
parts measured.
0 0.4
Gage R&R Repeat Reprod Part-to-Part Part 1 2 3 4 5 6 7 8 9 10
?
Notes:
Another Chart – X-bar & S (std. dev)
X-bar and S charts have control limits calculated This chart, as the next example
directly from the standard deviations of the subgroups shows, provides almost identical results
to the X-bar and R chart. The estimates
Used when of sigma are more precise than those
Data are recorded and charted by a computer where calculated from the range. However,
real-time calculations of σ are easily integrated these charts are really reserved for
automatic systems. Using a hand
Large numbers of samples in a subgroup (> 10). This calculator, even if it has standard
often occurs with measuring equipment that deviation capability, becomes
automatically measures and reports the data. cumbersome when the number of points
exceeds 10.
Minitab has a program for automatically constructing
X-bar and S charts.
Notes:
Example – Using Minitab for X-bar & S
In Minitab select Stat > Control Charts > Xbar-S…
Compare this chart with the output
Compare the Xbar/S Chart for Sample 1-Sample 5 from the X-bar and R chart. In this
X-bar/S 1
chart, the process average control limits
chart with 5.5 5
3.0SL=5.595
are a little wider, while the control limits
Sample Mean
for variation are slightly narrower. This
the X-bar/R 5.0 X=5.029
is not always the case, but the two charts
chart. 4.5 -3.0SL=4.462
usually provide similar data.
See any Subgroup 0 5 10 15 20 25
differences? 0.9
0.8
1
3.0SL=0.8290
0.7
Sample StDev
0.6
0.5
0.4 S=0.3968
0.3
0.2
0.1
0.0 -3.0SL=0.00E+00
Notes:
CAMSHAFT.mtw
Camshaft Exercise
Suppose you work at an automobile manufacturer in a department
that assembles engines. One of the parts, a camshaft, must be 600
mm ±2 mm long to meet engineering specifications. There has been
a chronic problem with camshaft length being out of specification—a
problem which has caused poor-fitting assemblies down the
production line and high scrap and rework rates. Your supervisor
wants to run X-bar and R charts to monitor this characteristic, so for a
month, you collect a total of 100 observations (20 samples of 5
camshafts each) from all the camshafts used at the plant (column C1,
Length), and 100 observations from each of your suppliers (columns
C2 and C3, Supp1 and Supp2). First you will look at camshafts
produced by Supplier 2.
Open the file CAMSHAFT.MTW in the Minitab Data directory.
Construct an X-bar & R using Supp2 data with a subgroup size of 5.
Be prepared to share your conclusions with the class.
Compare the results to those from Supplier 1 (Supp1 data).
What would you recommend?
Notes:
A Word About Rational Subgroups
In X-bar charts, the control limits are set by the within
group variation. Subgroups are required in order to
use X-bar & R or X-bar & S charts.
Data must be grouped by a rational basis There must be a reasonable, rational
Examples of rational bases: basis for sub grouping data. The within
subgroup variation (R-bar or S) is used
Parts within the same batch in a batch process to calculate the control limits of the X-
Parts produced within a short time span bar chart. There must be a reasonable
expectation that the within-group
Examples of irrational bases: variation has some predictive value on
Multiple measurements of the same part the group-to-group variation. The
Parts grouped by measurement order instead of process following example shows the effect of
order. subgroup selection on the data analysis.
If you cannot explain your subgroup strategy in plain

English, the chart will probably have little value.
Notes:
Rational Subgroups – Example
Injection molding is used to make a type of socket, four pieces at a time, one piece
per slot. Measurements of the sockets consist of thickness values in excess of
5.00 millimeters. The gauges measure in hundredths of a millimeter.
Four times a day the supervisor would go to the press and gather up the parts
produced by five consecutive cycles of the press. Since each cycle produced four
parts, he would have 20 parts to measure every two hours. The supervisor kept
track of the cycle and the cavity from which each part came.
Cycle A Cycle B Cycle C Cycle D Cycle E The supervisor wrote his twenty
S1 S2 S1 S2 S1 S2 S1 S2 S1 S2
S3 S4 S3 S4 S3 S4 S3 S4 S3 S4 measurements (per every 2
hours) in an array like this.
Cycle A Cycle B Cycle C Cycle D Cycle E
S1 S2 S1 S2 S1 S2 S1 S2 S1 S2 A B C D E
S3 S4 S3 S4 S3 S4 S3 S4 S3 S4
S1 18 19 20 19 21
S1 S2 S1 S2 S1 S2 S1 S2 S1 S2 S2 13 16 14 13 13
S3 S4 S3 S4 S3 S4 S3 S4 S3 S4
S3 10 11 13 10 13
S1 S2 S1 S2 S1 S2 S1 S2 S1 S2 S4 11 12 13 13 13
S3 S4 S3 S4 S3 S4 S3 S4 S3 S4
The supervisor wanting to use SPC to analyze his data had to choose how he
would organize the data into subgroups, and how to organize the subgroups into
control charts.
Notes:
SocketData.mtw
Rational Subgroups
The data can be organized in three different ways: by row, by
column and by sample Describe verbally what each of the
sub grouping strategies is attempting to
Time 1 Time 2
A B C D E X-bar R A B C D E X-bar R
evaluate.
S1 18 19 20 19 21 19.4 3 S1 16 21 18 18 18 18.2 5
S2 13 16 14 13 13 13.8 3 S2 12 13 14 11 12 12.4 3 Is this reasonable? Why or why not?
S3 10 11 13 10 13 11.4 3 S3 10 14 13 13 12 12.4 4
S4 11 12 13 13 13 12.4 2 S4 13 16 16 13 12 14 4
X-bar 13 15 15 14 15 14.25 X-bar 13 16 15 14 14 14.25
R 8 8 7 9 8 11 R 6 8 5 7 6 11
Time 3 Time 4
A B C D E X-bar R A B C D E X-bar R
S1 15 15 16 16 14 15.2 2 S1 18 19 20 17 16 18 4
S2 9 9 9 9 10 9.2 1 S2 14 16 14 16 11 14.2 5
S3 7 8 7 7 9 7.6 2 S3 12 12 9 11 13 11.4 4
S4 7 7 8 7 8 7.4 1 S4 12 13 14 12 8 11.8 6
X-bar 9.5 10 10 9.8 10 9.85 X-bar 14 15 14 14 12 13.85
R 8 8 9 9 6 9 R 6 7 11 6 8 12
Lets analyze the data in Minitab. Open worksheet SocketData.mtw

(The data was stacked for convenience)
?
Notes:
Allocation of Variation
Group by rows (slot): Source of Variation Allocation In an X-bar chart, there are two types
Hour-to-Hour Between Subgroup of variation: between subgroup and
Cycle-to-Cycle Within Subgroup within subgroup variation. Each chart
allocates the variation into one of the
Slot-to-Slot Between Subgroup
groups or the other.
Source of Variation Allocation The question is always to ask which
Group by columns Hour-to-Hour Between Subgroup variation should be allocated and where.
(cycle): Cycle-to-Cycle Between Subgroup In this example, each of the three
scenarios (and there are more) allocates
Slot-to-Slot Within Subgroup
the variation in different ways.
Source of Variation Allocation
Group by sample (time): Hour-to-Hour Between Subgroup
Cycle-to-Cycle Within Subgroup
Slot-to-Slot Within Subgroup
Notes:
X-bar & R Chart – Grouped by Sample
In Minitab construct an X-bar & R chart to analyze the
variation by sample
How many
subgroups
will you
have?
What is the
subgroup
size?
Notes:
X-bar & R Chart – Grouped by Sample
Minitab Results:
Socket Data Grouped by Sample
15
3.0SL=14.70
14
Sample Mean
13 X=12.80
12
11 -3.0SL=10.89
1 1
10
1
Subgroup 0 10 20
3.0SL=16.80
15
Sample Range
10 R=10.60
5 -3.0SL=4.396
?
Notes:
Grouped by Cycle (Column)
Construct an X-bar & R chart to analyze the variation by
cycle
How many
subgroups
will you
have?
What is the
subgroup
size?
Notes:
Grouped by Cycle (Column) - Results
Minitab Results:
Socket Data Grouped by Cycle
20
3.0SL=18.54
Sample Mean
15
X=12.80
10
-3.0SL=7.054
Subgroup 0 50 100
20
3.0SL=17.98
Sample Range
10
R=7.880
0 -3.0SL=0.00E+00
?
Notes:
Grouped by Slot (Row)
First sort the data by Sample, Slot, & Cycle
Manip > Sort
Notes:
Grouped by Slot (Row)
Construct an X-bar & R chart to analyze the variation by
slot
How many
subgroups
will you
have?
What is the
subgroup
size?
Notes:
Grouped by Slot (Row) – Results
Minitab Results:
Socket Data Grouped by Slot
1 1
20 1 1 1
1 1 1 1 1 1 1 1
1 1 1
Sample Mean
1 1
1 1
15 3.0SL=14.71
X=12.80
-3.0SL=10.88
10 1 1 111 11 11 1
1 1 1 1
1 1 11 1 11
11 11
1
Subgroup 0 10 20 30 40 50 60 70 80
8
7 3.0SL=7.004
Sample Range
6
5
4
3 R=3.313
2
1
0 -3.0SL=0.00E+00
?
Notes:
Grouped by Slot (Row) – Alternative 1
Resort data by Slot, Sample, Cycle & Replot
1 1
20 1 11 11
11 1 1 1 1
1 11
Sample Mean
1 1
11
15 3.0SL=14.71
X=12.80
-3.0SL=10.88
10 1 1 11 1 111 1 1 11 1 1
1 11 1 1 1
1 1 1
1 11
Subgroup 0 10 20 30 40 50 60 70 80
8
7 3.0SL=7.004
Sample Range
6
5
4
3 R=3.313
2
1
0 -3.0SL=0.00E+00
?
Notes:
Replot the data, grouping by Slot.
Press the Estimate Parameters by Groups In… button on
the X-Bar & R form
Notes:
Minitab Results:
S2 S3 S4
1
20
Sample Mean
15 1
11 1 1
1 1 11
3.0SL=12.77
X=10.95
10
1 -3.0SL=9.133
1
1 1 1
1 11
Subgroup 0 10 20 30 40 50 60 70 80
S2 S3 S4
9
8
7 1
Sample Range
3.0SL=6.661
6
5
4
3 R=3.150
2
1
0 -3.0SL=0.00E+0
?
Notes:
Other Analyses
What other types of analyses might be tried on the
socket data?
Box plots
ANOVA
Analysis of means
Multi-Vari
Others?
Notes:
What If Sub Grouping Is Irrational?
Individuals (I & MR) Charts
For use when there is no rational basis for sub grouping or when If you cannot find a rational basis for
the measurements are expensive and/or destructive subgroups, don’t use them. Use an
Individuals Chart. If you collect 100
MR stands for Moving Range. The moving range is calculated by points per day in groups of 5 for an X-
recording the differences between successive pairs of Bar Chart or 100 individuals for an
measurements Individuals Chart, the out of control data
Control limits are calculated as follows: signals will occur at approximately the
same time. An Individuals Chart is only
UCLMR = D 4 MR really less powerful when the amount of
n 2 3 4 5 6 7 8 9 10 data collected is significantly less.
LCLMR = D 3 MR D4 3.27 2.57 2.28 2.11 2.00 1.92 1.86 1.82 1.78
D3 * * * * * 0.08 0.14 0.18 0.22
UCLX = X + E 2 MR
E2 2.66 1.77 1.46 1.29 1.18 1.11 1.05 1.01 0.98
LCLX = X − E 2 MR
σ
d2 1.13 1.69 2.06 2.33 2.53 2.7 2.85 2.97 3.08
X = MR / d 2
Notes:
Exh_qc.mtw
Practice & Homework – I & MR charts
Open Minitab data file Exh_qc.mtw

Construct an I & MR chart from the Weight
column
What are your conclusions?
Turn on all the tests.
What are your conclusions now?
For Homework, repeat the analysis on the Length
column
Notes:
Notes:
Pre-control systems are not really
control charts, but pre-control systems are
Appendix - Pre-control Systems useful in controlling a process to ensure
zero defects. Some processes do not vary
normally around a mean; they have
systematic variation. Some processes
have non-normal batch-to-batch variation
or gradual tooling wear or gradual
chemical depletion. These processes that
require periodic adjustment can benefit
from pre-control.
Breakthrough Management Group January 16, 2002
Notes:
Pre-control
When to use it?
Some processes need adjustment and cannot run in a steady-state
control mode (or cannot run, yet, in a steady-state mode)
Batch processes with incoming raw material differences
Processes with light sources that degrade with time
Machining processes that need to compensate for tool wear
Some processes run in control and only need to be monitored
To maintain improvements in Y until controls on X can be
implemented through mistake-proofing or SPC
To monitor processes that are in control and have been determined
to be capable
Traditional Pre-control charts are constructed using Specification
Limits to judge goodness.
An Alternative method of constructing Pre-control charts uses the
natural process limits
Notes:
Constructing a Pre-control Chart
LSL PC LINE PC LINE USL
1. Divide the total
specification Pre-control charts are guidelines for
judging the condition of the process.
tolerance by four
Plotting is never done on a pre-control
to determine the chart. Pre-control charts are only visual
zone width. cues for judging whether to run the
2. Construct the process as it is, adjust the process, or
Red Yellow Green Green Yellow Red center “green” stop the process. All of these decisions
zone by are made by referencing the specification
establishing the limits, not any natural process limits.
PC line limits as
± one zone width.
50% PRINT 3. Plot the USL and
TOLERANCE LSL as shown
100% PRINT
TOLERANCE
Notes:
Using Pre-control
For setup and qualification:
Take five samples It is critical to have a documented
action plan. These charts are most useful
If all five are in the green zone,
for local control. Operators can judge
Red Yellow Green Green Yellow Red process is qualified, in control
whether the process is qualified and can
and capable
If one or more fall into the
be run, without engineering intervention.
In the following charts, other tests are
yellow or red zones:
illustrated that are intended to be judged
Process is not in control local to the process.
Find the cause and/or adjust
the process according to the
documented reaction plan.
Red Yellow Green Green Yellow Red Take another five samples
and test for qualification
Notes:
Using Pre-control For Process Monitoring
Take two samples at
some frequency (more on Even though data are not recorded on
the pre-control charts, for most quality
frequency later) systems measurements must be recorded
Red Yellow Green Green Yellow Red
as evidence that they were made. A run
1. Two in green zone log is usually sufficient for recording the
–process OK, continue production data. A simple run chart, described in
the previous SPC module is a very useful
companion to a pre-control system.
Judgments on the process are made
according to the pre-control criteria, but
2. One in green, one in yellow trends can be discerned from the run
Red Yellow Green Green Yellow Red –continue production charts.
Notes:
Using Pre-control For Process Monitoring
3. Both in the same yellow zone – One of the problems with pre-control
Adjust process settings per the systems is false signals received when
documented action plan processes have poor capability. An
alternating pattern in a companion run
4. Parts in different yellow zones chart will help determine if an over
or either part in a red zone control situation is being caused by the
– Stop production and pre-control system.
investigate the cause of
variation.
Sample frequency is
determined by dividing the
average time period between
work stoppages by 6.
Notes:
Advantages of Pre-control
Simple to understand, training is easy A documented action plan is crucial
to a successful pre-control system. The
An economical method to monitor output
most common signal that the operators
variables (Y’s) will receive is for an adjustment. The
Requires only 2 samples at specified operators need to know the procedures
for adjusting the process.
frequency
Applicable to short production
runs as well as long runs
No recording, calculating, or plotting of data
An OCAP (Out of Control Action Plan) is easy to define
and implement
Notes:
Disadvantages of Pre-control
The philosophy of pre-control is contrary to Six Sigma
A pre-control system may seem like
It uses the “Between the specs. is good enough” hearsay to a Black Belt, but in some
Six Sigma is focused on achieving the target limited applications, it can be a very
Monitoring techniques are not very useful in diagnosing problems useful tool. Some of the gradually
varying processes mentioned earlier are
High likelihood of false signals for poorly capable processes
good examples of an advantageous
For process that are poorly capable, the likelihood of a false signal application of pre-control. In fact, other
from the pre-control chart is high. than automatic control, it is one of the
If Cpk = 1, there would be a probability of ~2% that a purely random only systems that enable the operators to
signal would initiate an action reliably control a gradually varying
For processes that are poorly capable, the likelihood of a false process.
negative is also high.
If Cpk = 1 and we had a sudden process change that shifted the mean to
the USL (generating 50% defects), there would be a ~6.5% chance of not
detecting it in the next two samples
Notes:
Pre-control and False Signals
Probability of false signals from pre-control charts The first line (solid, blue) shows the
Type II error based on a shift of the mean to the USL (50% failure rate) likelihood of a Type I false signal, either
24%
two in yellow zones or one in a red
22%
zone, as a function of process capability
P ro b a b ilit y o f f a ls e s ig n a l
20%
18% (Cpk). The worse the capability, the
16%
14% more likely that the tails of a process
12% distribution will fall in the yellow or red
10%
8%
zones. The second line (broken, red)
6% shows the likelihood of missing a signal
4%
2%
when, in fact it is true. Assume the
0% process mean shifts all the way to the
0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 upper specification limit (which would
Process Cpk be a 50% failure rate). For a process
Type I Error Type II Error
with large variation (and small Cpk)
there is a high likelihood that at least
one point is in a green zone and one in a
yellow zone.
Notes:
Example – Defining a Pre-control System
Define a pre-control system where the process mean is 100 and
the specification limits are ± 15 One purpose of this exercise is to
Each group: generate a “process” in Minitab of 25 pairs of random investigate the impact of process
normal data as follows: capability on pre-control. Since we are
Group 1: Mean 100, s = 5.00 inventing the process data, we know that
Group 2: Mean 105, s = 5.00 the data is all normal, varying around the
Group 3: Mean 100, s = 7.50 mean. Evaluate the results of each group
and try to establish general observations
Group 4: Mean 100, s = 3.75
about pre-control, process capability and
Group 5: Mean 105, s = 2.50
targeting the mean.
Assume the process has been qualified
Assume a pair of data is collected every two hours
How many adjustments were made, what is the average length of
time between adjustments, and what would be the sample
frequency?
Save your data for another example later
Notes:
Pre-control – An Alternative Method
LSL PC LINE PC LINE USL
1. Set the Green zone
This alternative method of pre-
as the natural, ± 3σ control works well if the variation in the
process limits, process is small. If the variation is too
centered on the large, there will not be any yellow zones.
target mean. In a process with a Cp of 1.0, there is no
2. The yellow zones yellow zone at all.
Red Yellow Green Green Yellow Red are the spaces
between the 3σ
limits and the
specification limits
3. As in the traditional
3σ PROCESS chart, the red zone
TOLERANCE is beyond the
100% PRINT specification limits
TOLERANCE
Notes:
Pre-control – Summary
Pre-control is simple to understand and easy to train
feedback system
It is effective for processes that do not run in steady-
state and require occasional adjustment
A pre-control system must include a documented
reaction plan
Pre-control should only be used when Cpk’s are > 1.0
or the α and β error might cause confusion
Using natural process limits for the green zone
reduces this error, but the process capability must be
even better
Notes:
Exercise – Homework
Using the previous example data:
Set up a pre-control system using the alternative 3σ limits
instead of ½ the specification tolerance limits
Using your group’s data, re-evaluate each pair of
observations
Answer the following questions:
How many adjustments were made?
What is the average length of time between adjustments?
What would be the sample frequency?
Compare the results to the results of the traditional pre-
control results
Notes:

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Variable SPC – Part 2

Breakthrough Management Group January 16, 2002

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

5.5  Interpret the following

 Are there any out of control 4.9 -1.0SL=4.900

conditions? Which rule? 4.8 -2.0SL=4.818

Variable SPC – Part 2

-2.0SL=4.414 X-bar Chart for Run 1 - Run 5

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

 Powerful tool for differentiating between special cause

Variable SPC – Part 2

Example – Constructing Charts in Minitab

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Control Charts & Minitab Gauge Studies

Variable SPC – Part 2

0.9 3.0SL=0.8796 0.9

repeatability of the gauge, i.e. the

variation caused by the gauge, should be

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

 If you cannot explain your subgroup strategy in plain

Variable SPC – Part 2

Variable SPC – Part 2

 Lets analyze the data in Minitab. Open worksheet SocketData.mtw

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Variable SPC – Part 2

Practice & Homework – I & MR charts

 Open Minitab data file Exh_qc.mtw

5.5 Interpret the following

Are there any out of control 4.9 -1.0SL=4.900

Powerful tool for differentiating between special cause

If you cannot explain your subgroup strategy in plain

Lets analyze the data in Minitab. Open worksheet SocketData.mtw

Open Minitab data file Exh_qc.mtw