Process Capability

Evaluate the Process from Accuracy of Parts

Machine Repeatability
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 Process Capability
Process Capability （Cp）
It is defined as ratio of specification range (tolerance) to process range
using ±3σ limits, it is expressed as follows
SD: Standard Deviation
𝑆𝑈− 𝑆𝐿 𝑇𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒
𝐶𝑃 = =
6𝜎 6 × 𝑆𝐷
Cp=1.00 35% of Tolerance
Cp=1.33 25% of Tolerance
Cp=1.67 20% of Tolerance
Cp=2.00 15% of Tolerance
 Standard Deviation (σ）

Work out Standard deviation (σ) in order to figure out

Cp

Standard deviation (SD) is the measure of spread of

number in set of data mean value. In order to figure out
SD (σ）、find “mean” and “variance”, of given number.

Mean is average of set of numbers

Variance is how far a set of numbers is spread out
 Process Capability （Cp）

①Work out mean

We have a data set containing the value X1, X2, ……..Xn

mean is defined by following formula

X 1  X 2  ....... Xn
X
n
 Standard Deviation & Variance
②Now we calculate each data’s difference from mean

If we added up difference (Xi－X) negatives would cancel the positives

It will be “0”

MEAN

Therefore let ‘s figure out squaring each difference

1 n
Variance S   ( Xi  X ) 2
n i 1

Standard
𝜎= 𝑆
Deviation
 Image of Population & Sample
𝑛
1
𝜎2 = ෍(𝑋𝑖 − 𝜇)2
𝑛
Population n σ, μ 𝑖=1
σ:deviation for population data
μ: mean for population data
𝑁
1
𝑠2 = ෍ 𝑋𝑖 − 𝑚 2
Sample N,s,m 𝑁
𝑖=1
s:deviation for sample data
m: mean for sample data

We assume population σ from sample s & m

 Final Standard Deviation
𝑛
1
Population n σ, μ 𝜎2 = ෍(𝑋𝑖 − 𝜇)2
𝑛
𝑖=1

𝑁
1
𝑠2 = ෍ 𝑋𝑖 − 𝑚 2
𝑁
Sample N,s,m 𝑖=1

𝑁
1
𝜎≅ ෍ (𝑋𝑖 − 𝑚)2
𝑁−1
𝑁=1
Normal Distribution Curve
Quincunx
 Normal Distribution Curve
The Normal distribution is common continuous distribution in
statistics.

−𝑢2
1
f(x)= ∙𝑒 2
2𝜋
u=(x-μ)/σとする
μ：MEAN
σ2：Variance
e：Natural Logarithm e

For normal distribution, the values less σ away from mean account
for as follows
μ±σ 68.26％、
μ±2σ 95.44％、
μ±3σ 99.74％
Normal Distribution Curve

68% of values are within ±1σ

95% of values are within ±2σ

99.7% of values are within ±3σ

 Ratio of Tolerance to Cp
tolerance=6σ tolerance=8σ
SL SU SL SU

cp=1.00(99.74%) cp=1.33(99.994%)

tolerance=4σ tolerance=10σ
SL SU SL SU

cp=0.67(95.44%) cp=1.67(99.999･･･%)
 Process Capability
Process Capability Index （Cpk）
Cpk is Process capability Index.
Adjustment of Cp for effect of non centered distribution

SL SU
| ( SU  SL) / 2  m |
K
( SU  SL) / 2 (𝑺𝑼−𝑺𝑳)/𝟐

𝑺𝑼 + 𝑺𝑳
−𝒎
𝟐

SU  SL
Cpk  (1  K ) -5 -4 -3 -2 -1 m0 1 2 3 4 5

6σ
 How to predict Cpk from Cp
SU 𝐶𝑝𝑘 = 1 − 𝐾 𝐶𝑝
SL
a b
𝑆𝐿 +𝑆𝑈
a= −𝑚
2

𝑆𝑈 −𝑆𝐿
b=
2
-6 -4 -2 0 2 4 6
m
The prediction of Cpk is difficult since its amount is varied by K.
In case you are requested Cpk1.33, you should follow the next procedure
to reply customers
1. Find Cp 1.33 can be done on the customer request
2. If it is YES, make sample test cut and seek “a” value.
3. “a” can be compensated by offset or others
 How to predict Cpk from Cp
4. But “a” cannot be compensated to “0” , because there are various
distributions as follows;

5. Cpk =0.75 ～0.80 x Cp due to item 4, even after compensating “a”

Cp=1.33 25.0% of Tolerance
Cpk1.33 20.0% of Tolerance
Cp=1.67 20.0% of Tolerance
Cpk1.67 15.0% of Tolerance
 Cp for Surface roughness
In case of surface roughness and rectangularity

SU
SU
SU

-6 -4 -2 0 2 4 6 -6
m -4 -2
m
0 2 4 6 -6 -4 -2 0
m 2 4 6

Cp>2 0<Cp<2 Cp=0

Cp is defined by following formula

m: mean
𝑆𝑈 −𝑚
Cp= Su: for example Ra 3.2
3𝜎 𝜎 :Standard deviation
Cp, σ, K, Cpk formula

𝑁
1
𝜎≅ ෍ (𝑋𝑖 − 𝑚)2
𝑁−1
𝑁=1

SU  SL
Cp 
6σ

| ( SU  SL ) / 2  m |
K
( SU  SL ) / 2
SU  SL
Cpk  (1  K )
6σ
 Cp & Cpk
Under condition of tolerance Su=10.5, Sl= -10.5

*In case of sample data: 2,2,2,2,2,-2,-2,-2,-2,-2

(10pcs)
Find out Cp

*In case of sample data: 2.5,2.5,2.5,2.5,2.5,-2.5,-

2.5,-2.5, -2.5,-2.5 (10pcs)
Find out Cp

*In case of sample data: 4,4,4,4,4,0,0,0,0,0 (10pcs)

Find out Cp & Cpk