How to interpret the Control Charts?
• Whether a process is in the controlled state or not is
judged by the following criteria from the control
chart.
• Control charts are divided into sigma zones above
and below the average line.
• Zone C is < 1 sigma from the mean.
• Zone B is between 1 sigma and 2 sigma
• Zone A is between 2 sigma and 3 sigma.
• Beyond Zone A is > 3 sigma
1
A Process Is in Control If …
1. No sample point lies outside limits
2. Most points near process average
3. About equal number of points above and
below centerline
4. Points appear randomly distributed
The next slides mention Nelson’s 8 rules (all are
attributed to special causes)
2
Control Chart Interpretation : Nelson’s 8 Rules and also as per SPC Manual
Test:1 One point beyond zone A
x
UCL
A
B
C
CL
C
B
A
LCL
x
• Startup pcs/improper set up.
• Sudden failure of power/cooling/heating/vacuum/steam system.
• Machine or tool breakage.
• New operator introduced.
• Other spl causes not listed above.
3
Control Chart Interpretation
Test: 2 Seven points in a row on one side of center line.
UCL
A
B
C
CL
C
B x
A
LCL
• Improper set up.
• Excessive tool wear/damaged tool
• Big change in humidity/temperature
• New operator/inadequate training/distraction/fatigue.
• New/incorrect process parameters.
4
Control Chart Interpretation
Test: 3 Six in a row steadily increasing or decreasing
UCL
A
B
C x
CL
C
B x
A
LCL
• Operator fatigue/distraction
• Excessive wear
• Coolant/lubricant depletion
• Gradual failure of support system (Cooling/heating/compressed air/steam etc).
5
Control Chart Interpretation
Test: 4 Fourteen points in a row alternating up& down
UCL
A
B
C
CL
C x
B
A
LCL
• Intermittent support system failure (cooling, heating,
compressed air, vacuum, steam, etc.
• Equipment not being warmed up, at the shift’s start..
• Operator over adjusting the process.
6
Control Chart Interpretation
Test: 5 Two out of three points in a row in the same zone A or beyond
x x
UCL
A
B
C
CL
C
B
A x
LCL
• This is also called large shift, due to a major special cause.
• Sudden changes in temperature.
• 4 M change (any one of the 4 Ms)
• Operator interrupted or distracted, shift change
• Mixed raw materials
7
Control Chart Interpretation
Test: 6 Four out of five points in a row in the same zone B and beyond
UCL
A x
B
C
CL
C
B x
A
LCL
• Considered a smaller shift
• Reasons are same : special causes of lower magnitude.
8
Control Chart Interpretation
Test:7 Fifteen points in a row in zone C (Above & below center line)
UCL
A
B
x
C
CL
C
B
A
LCL
• Also called Whitespace Test (whitespace in zone B and C).
• May be the operator has purposefully truncated the measurements.
• May be the limits were wrongly calculated.
• May be the process has improved significantly due to better tooling etc.
and now the limits need to be recalculated
9
Control Chart Interpretation
Test 8 Eight points in a row on both sides of center line with none in zone C
UCL
A
B x
C
CL
C
B
A
LCL
• Mixture (production of various shifts, machines, materials mixed)
• Too much over control.
10
Towards Personal Development and Personality Development
• Yash Khetrapal, the founder of KCC, started his career with Mukand Iron
and Steel in 1982. After a stint of 2 years, he moved over to Maruti Suzuki
where he worked for the next 38.5 years in various capacities.
• After his superannuation as HOD Training from Maruti, he established KCC.
• KCC is a team of senior trainers, who deliver trainings on 100+ topics.
• Please send us your love and your training enquiries at :
yash@khetrapalconsulting.com (from your workplace mail ID only).
• Or feel free to at 9811801111 (If there is no immediate response, it
will mean that a session is going on. So please leave a message.
• Glimpses of our sessions can be seen at : Yash Khetrapal
• Connect with us at : Yash Khetrapal for the latest updates.
• Visit us at www.khetrapalconsulting.com
Learn Earn Return 11
