FINAL QM

Mr. D.V.T.SON

Statistical Process Control

Definition Target

Process variation
➔ result of either common causes or special causes.
Control Charts and Variation:
1. Control charts are used to identify and differentiate between common and special causes of
variation.
2. When a process no longer exhibits special variation, but only common variation: process is stable.
3. When only common causes of variation are present in a process: must take action to reduce the
difference between customer needs and process performance by endeavoring to move the centerline of
the process closer to nominal and/or by reducing the magnitude of common variation.
Structure Of Control Chart
Advantages of a Stable process
A stable process is a process that exhibits only common variation or variation resulting from inherent
system limitations. The advantages of achieving a stable process are:
◼ Management knows the process capability and can predict performance, costs, and quality levels.
◼ Productivity will be at a maximum, and costs will be minimized.
◼ Management will be able to measure the effects of changes in the system with greater speed and
reliability.
◼ If management wants to alter specification limits, it will have the data to back up its decision

ZONE
RULES FOR IDENTIFYING OUT-OF-CONTROL POINTS (7 RULES).
CONTROL CHARTS
Attribute chart
There are two basic types of attribute control charts:
Classification Charts Count Charts

1. p Chart. 1. c Chart.
➢ Used to control the fraction of items with the ➢ Used to control the number of times a
characteristic. particular characteristic appears in a constant
➢ Subgroup sizes may remain constant or may area of opportunity.
vary. ✓ For example:
2. np Chart. ❖ defects per air conditioner;
➢ Used to control the number of items with the ❖ accidents per workweek in a factory;
characteristic. ❖ and, deaths per week in a city.
➢ Used only with constant subgroup sizes. 2. u Chart.
➢ Used when the area of opportunity changes
from subgroup to subgroup.
Classification Charts

The centerline for a p-chart is the mean of the fraction defective.

The standard error for the average proportion is:

Where n is the subgroup size.

Using this value, the upper and lower control limits for a p-chart are given by:

Notice that since a negative fraction defective is not possible, the lower control limit is set at 0.00.
The information used is the same as for p-charts with constant subgroup sizes, these two charts are
interchangeable.

EX:
The p-Chart for Variable Subgroup Sizes
Count Charts

c-Charts
Stabilizing a Process:

The process is not in control. Special

causes of variation are present. Let us
assume that the local operators responsible
for the final inspection act so that the
special causes of variation for points 9, 10,
14, 19, 20, 22, and 23 are identified and
the appropriate corrections are made.

The data for points affected by known special causes that have been eliminated are deleted from the
data set, and the centerline and control limits are recomputed:

The new limits are so close to the old limits that the old limits are used for the next 24 machines
produced.
EXAMPLE:

 According to the above calculations, the number of

new accounts generated by a salesman in a six month
period can be predicted to be between 13 and 45 new
accounts. This large amount of variation is attributable to
the sales system.  All salesmen are in the same sales
system, and they all deserve the percentage pay raise. No
one should be rewarded, and no one should be punished.
Sales management should focus their attention on
improvement of he sales system, not on rewarding and
punishing salesmen.
If Fred had generated 66 new accounts (instead of 36) the sales system’s statistics would be
In this scenario, Fred is outside the sales system on the high
side (he is above 51). Investigation by Fred’s manager led to
the realization that Fred had developed a better telephone
procedure for screening potential customers. Fred should
receive special recognition because he is outside the sales
system on the high side and because his efforts provide
guidance for improvement for all salesmen all in the sales
system.
u-Charts
The characteristic used for the control chart, u, is the ratio of the number of events to the area of
opportunity in which the events may occur.

EXAMPLE
Consider the case of the manufacture of a certain grade of plastic. The plastic is produced in rolls,
with samples taken five times daily. Because of the nature of the process, the square footage of each
sample varies from inspection lot to inspection lot.
Limitations of Attribute Control Charts

• As processes improve and defects or defectives become rarer, the number of units that must
be examined to find one or more of these events increases.
• This implies inspecting all of the items and sorting those that conform to some specification
from those that don't. Not only is this inspection costly, but it's equivalent to accepting the fact
that the process is producing a constant fraction of its output as defective and will continue to
do so.
• Hence, attribute control charts are limited in terms of the level of process improvement they
make possible. Additional process improvement is possible with variables control charts.

Variable control charts

• Individuals and moving range charts: only one variables measurement.
• x and R charts: from 2-3, or 4-9 subgroup sizes.
• x and s charts: 10 or more subgroups

Xbar and R chart

EXAMPLE
x- chart
Xbar and s chart

x-portion

EXAMPLE
The value for the averages of these subgroup means and standard deviations are computed :

The s chart must be constructed first, upper and lower control limits :
The zone boundaries:

The average value for x,x bar is 2.12, the upper and lower control limits for the x bar chart:

Individuals and moving range chart

Or

EXAMPLE