STATISTICAL PROCESS

CONTROL

VARIABLE AND ATTRIBUTE CHARTS

Presented By :
Surya Bakshi
 Statistical Process Control is
 a technique used within the TQM framework
 Aims to reduce variation in processes
 control, manage, analyze and improve the
performance
 eliminates special causes of variation
 defective products,
 operator error,
 errors in measurements
CONCEPTS
 PROCESS
 Is a set of interrelated or interacting activities which
transform inputs into outputs.
 VARIATION
 No two products are exactly alike due to sources of
variability
 Sources of variation : speed of the operator, accuraccy,
procedure followed, variation over time.
Advantages of maintaining a state
of Statistical Control
 Variation( inherent) is restricted to common causes

 Since variability exhibits a regularity in pattern,

the process is repeatable

 Since process is repeatable, quality of future

production can be predicted.
SPC is a strategy of Defect prevention which aims
 To increase the knowledge about any process

 To steer a process to behave in the desired way

 To reduce variation in the product or in other ways

to improve performance of the process

 To reduce cost and increase profit by improving the

performance of the process

 Increase consistency of the process
 Periodic sampling of products from the process and
inspecting them for characteristic under
cosideration
 Computing a suitable index of quality for each
statistic
 Taking actions to detect and eliminate special
causes wherever control limits are exceeded
 Leaving the process alone when there’s no
evidence of “out of control”
 Control charts or graphical trend analysis are
used to understand changes in the process
mean and process standard deviation.

 Process variation
 adds needless cost to the product
 reason why a product does not comply with
specifications
 are a graphical device to aid in process control
 Control chart consists of:
 Points representing a quality characteristic in
samples under observation
 A Centre line, drawn at the process characteristic

mean, which is calculated from the data.

 Upper and Lower Control Limits that indicate the

threshold at which the process output is

considered statistically 'unlikely'.
 Control Chart technique can be used for both
Variable and Attributes.
 Measurement or Variables
 quality characteristics which can be measured
 Attribute
 quality characteristics that can be evaluated with a
discrete response
 not measurable on the quantitative scale
 Data obtained by classification or counting are called
 There are four types of attribute charts used for
 non measurable defect controlling and
 defectives controlling

 N and NP Charts for the control of number of

defectives or non- conforming
 C and U – Charts for the control of the defects or non-
conformities
• Used at places where
▫ various defects could occur in a single product that is being
manufactured

• Fixed sample size , 13 in this case as per 2.5 AQL

• The proportion of defectives are
▫ plotted and
▫ analyzed for improvement of the process
 The graph is made from the quality checks done in the front
section of Jackets Line 3 for three consecutive days

 The plotting shows that the process is shown to be

 within limits and
 very much stabilized
 the UCL is far beyond the fraction of defectives that have been
plotted.

 Hence if this chart is applied it will

 not solve the purpose
 identifying the process instability is difficult.
 Used at places where
 various defects could occur
 product wise checking

 variable sample size

 The UCL and LCL are calculated
 on hourly basis
 on the last hour’s data available
 The chart is
 very time taking to be prepared
 The Quality Checker has to be trained
 Follow up to let them know how to prepare it.
 The same problem of data always show within control
persists

 Hence, the chart cannot be used.

 The two chart applicable to check no. of defectives

is ruled out.
 The C Chart and the U chart are used to assess defects
occurring in the product individually.

 The U chart is used at places where

 The defects are checked to be present as per a specific unit,
 For example is carpet making
 The defect per square unit area is checked in this case.

 There is no such unit that can segregate the garment

defects hence U chart is also not applied in this case.
• The C chart loses its characteristic of showing

▫ the no. of defects present

▫ the fractional values are plotted

• The C Chart previously

▫ Was used for several defects

▫ It is difficult to asses as to which defect led to the inconsistency
▫ Hence should be used for a single defect.
 Preparation of separate chart for different defect
that has to be checked

 The no. of defects instead of fractions should be

plotted on hourly basis

 the UCL and LCL for the next day to be calculated

on the basis of the last day’s data

 THE NEW CHART proposed to be implemented.

 The new chart
 shows the situations out of control where the defect
needs to be checked
 makes it easier to identify the root cause of the defect
 when it happened
 where it happened
 who did it and
 proper steps can be taken to mend it, and
 record is maintained for the future reference