SPC & MSA Using Minitab

I Chart for C1
39
3.0SL=37.36

Individual Value
34

X=30.60
29

24 -3.0SL=23.84

0 5 10 15 20 25 30 35
Observation Number

L. GOCH – FEBRUARY 2011

AGENDA
Continuous & Attribute Data
 IMR Charts

 Xbar & R Charts

 Xbar & S Charts SPC & MSA using

Minitab.mtb

MSAs
 Using Xbar & S Charts for MSAs

 Non-Destructive Variable MSAs

(NOTE: Minitab will also Analyze Destructive Variable MSAs &
Attribute MSAs)
THE BASIC CONTROL CHART
KEY COMPONENTS

Control Limits are NOT Spec Limits

UCL
CHARACTERISTIC
MONITORED

Plotted Data

Center Line

LCL

DATA PLOTTED OVER TIME

UCL = Upper Control Limit / LCL = Lower Control Limit

COMMON CAUSES VS SPECIAL
CAUSES
 Individual-X &
Moving Range Chart
 CONTROL CHARTS
INDIVIDUAL /MOVING RANGE
 Use:
 When only have 1 measurement per time period
 When want to chart Counts.
 When want to chart Percentages (%’s).

Do NOT use P-Charts if the values are <10% or subgroup

sample size >100 since it violates basic P-Chart assumptions.
 Need a minimum of 10 data points

 Variation
 Short Term: Measures relatively rapid changes over time ( Moving
Range chart)
chart
 Long Term: Measures relatively gradual changes over
time(Individuals chart)
chart

Charts are Based on a Subgroup Size of 1

I / MR CHART: STAT > CONTROL CHARTS > I-MR
 I-MR Chart analyzes individual data
over time.

Open worksheet
Exh_QC.mtw
I / MR CHART: STAT > CONTROL CHARTS
> RUN CHART

Rule #1
MINITAB EXERCISE
INDIVIDUALS / MOVING RANGE OUTPUT
I-MR Chart of Weight
1050 1 1 1

6 U C L=1010.9
Individual V alue

1000 6

2 2

950 2
2 _
X=936.9
2 2 2 2
2 2 2 2
900 2
6 2 2
6 6 2
5
LC L=862.8
850 1 1

1 5 9 13 17 21 25 29 33 37 41 45
O bser vation

100
U C L=91.0
M ov ing Range

75

50

__
25 M R=27.8

0 LC L=0
1 5 9 13 17 21 25 29 33 37 41 45
O bser vation

Is there a shift at Observation # 25?

MINITAB EXERCISE
INDIVIDUALS / MOVING RANGE OUTPUT

Group
Column
Added
MINITAB EXERCISE
INDIVIDUALS / MOVING RANGE OUTPUT

Press <Ctl> e
 MINITAB EXERCISE
INDIVIDUALS / MOVING RANGE OUTPUT
I-MR Chart of Weight by Group
1 2
1050 U C L=1041.8 5
5
Individual V alue

1000 _
U C L=974.4 X=973.3
950
6
_
X=905 5
900
1 LC L=904.8

850

LC L=835.6
1 5 9 13 17 21 25 29 33 37 41 45
O bser vation

1 2
U C L=85.23 U C L=84.13
80
M oving Range

60

40
__ __
M R=26.09 M R=25.75
20

0
LC L=0 LC L=0
1 5 9 13 17 21 25 29 33 37 41 45
O bser vation
Xbar & R Chart
 CONTROL CHARTS
X BAR / R CHART

 Advantages
Sensitive to changes in data

 Limitation
Unlike the Individual Chart, the Xbar Chart control
limits do not represent the overall data range. They
represent the range of the subgroup averages.
CONTROL CHARTS
X-BAR / R CONTROL CHARTS

 GATHERING DATA
 Define rational basis for subgrouping
 Select sample size for the subgroups
 Select sampling frequency
 Need a minimum of 10 subgroups

 VARIATION
 Short Term: Measures the variation within the Subgroups based on
the subgroup range (Range chart)
 Long Term: Measures the variation between the Subgroups based
on the subgroup average (X Bar chart)
XBAR-R CHARTS: STAT > CONTROL
CHARTS > VARIABLES CHARTS FOR
SUBGROUPS > XBAR-R

Open worksheet
Camshaft.mtw
MINITAB EXERCISE - XBAR / R CHARTS
OUTPUT
Xbar-R Chart of Length
602
U C L=601.722

601
Sample M ean

_
_
600 X=600.072

599

LC L=598.422
598 1

1 3 5 7 9 11 13 15 17 19
Sample

6.0 U C L=6.048
Sample Range

4.5

_
3.0
R=2.860

1.5

0.0 LC L=0
1 3 5 7 9 11 13 15 17 19
Sample

What do the Charts tell us?

We need to look at the individual suppliers.
MINITAB EXERCISE - XBAR / R CHARTS
o Stack Data:
Stack the 2 Suppliers so the data can be
looked at together on the same chart
MINITAB EXERCISE - XBAR / R CHARTS
Xbar-R Chart of Lengths by Supplier
S upp1 S upp2
1
1
U C L=602.474
602
Sample M ean

_
_
U C L=600.321 X=600.23
_
_
600
X=599.548

LC L=598.775
598 6
LC L=597.986
1 5 9 13 17 21 25 29 33 37
Sample

S upp1 S upp2
U C L=8.225
8
Sample Range

6
_
4 R=3.890
U C L=2.835
_
2
R=1.341

0
LC L=0 LC L=0
1 5 9 13 17 21 25 29 33 37
Sample
Xbar & S Chart
 CONTROL CHARTS
X BAR / S CHART

 Advantages
 Very sensitive to changes in data.
 Also, the center line of the S-Chart provides a good
estimate for the data’s standard deviation.

 Limitation
The Xbar Chart control limits do not represent the
overall data range. They represent the range of the
subgroup averages.
CONTROL CHARTS
X-BAR / S CONTROL CHARTS

 GATHERING DATA
 Define rational basis for subgrouping
 An S-Chart is typically used when the subgroup’s
sample size is > 9
 Select sampling frequency
 Need a minimum of 10 subgroups

 VARIATION
 Short Term: Measures the variation within the Subgroups based
on the subgroup stddev (S chart)
 Long Term: Measures the variation between the Subgroups
based on the subgroup average (X Bar chart)
XBAR-S CHARTS: STAT > CONTROL
CHARTS > VARIABLES CHARTS FOR
SUBGROUPS > XBAR-S
Open worksheet
Bloodsugar.mtw
MINITAB EXERCISE - XBAR / S CHARTS
OUTPUT
Xbar-S Chart of Glucoselevel
U C L=130.72

120
Sample M ean

_
_
100 X=101.03

80

LC L=71.35
1 3 5 7 9 11 13 15 17 19
Sample

50 U C L=50.67

40
Sample StDev

_
30
S =28.77

20

10
LC L=6.88
1 3 5 7 9 11 13 15 17 19
Sample

What do the Charts tell us?

We need to look at the individual people.
MINITAB EXERCISE - XBAR / S CHARTS
o Sort Data:
Sort the data by SubjectID & Reading
 MINITAB EXERCISE – I-MR CHARTS
I-MR Chart of Glucoselevel by SubjectID
1 2 3 4 5 6 7 8 9
1

200
Individual Value

6
150 6

1111 1 1
5 6 86 55
5
100
8 1
151 6
65 5
1
66
50 1

1 19 37 55 73 91 109 127 145 163

O bser vation

1 2 3 4 5 6 7 8 9
60 1
1
1
45
M oving Range

1
30 1
1
1 1 1
1
15

1 19 37 55 73 91 109 127 145 163

O bser vation
Xbar & S Charts used
for MSA’s
 MSA: X BAR / S CHART

 Advantages
 Pictorial look at MSA results
 Measurement error can easily be calculated
 % R&R and %P/T can easily be calculated
 Daily Calibration Data can be used

 Limitation
 Will NOT detect measurement that varies by nominal
value (e.g. large parts having more or less measurement error than
small parts)
MSA: X-BAR / S CHART

 GATHERING DATA
 Need Multiple measurements per time period
 Can use 1 or more Parts
 Need a minimum of 10 subgroups

 VARIATION
S Chart: Displays the Measurement Error. A good measurement
system will be in-control
 Xbar Chart: Displays any Drift over time in the average
measurements. A good measurement system will be in-control for
each individual Part.
MSA: X-BAR / S CHART
Open worksheet
Daily Calibration
Data.mtw

 Multiple
Measurements per
Day on most Days.
 1 Calibration Part per
Facility
 3 Facilities
 Sorted by Facility
Date & Time
XBAR-S CHARTS: STAT > CONTROL
CHARTS > VARIABLES CHARTS FOR
SUBGROUPS > XBAR-S
Open worksheet
Daily Calibration
Data.mtw
MSA: X-BAR / S CHART OUTPUT
Xbar-S Chart of Actual Measurement by Facility
DHM DSM GSO

UCL=594.3 UCL=604.2
600
_
UCL=560.2
_
Sample Mean

550 _ X=538.8
_ _
_
X=511.8
X=500.8 LCL=517.5
500 1

450

LCL=429.3
400
LCL=397.4
Nov-02 Nov-09 Nov-19 Nov-29 Nov-04 Nov-13 Nov-26 Nov-03 Nov-09 Nov-16 Nov-23
Date

DHM DSM GSO

1 UCL=101.4
100 1
UCL=89.8

75
Sample StDev

_
50 S=31.0 1
_
S=27.5 UCL=26.2
25
_
S=8.0
0 1 2 2
LCL=0 LCL=0 2 2 LCL=0
Nov-02 Nov-09 Nov-19 Nov-29 Nov-04 Nov-13 Nov-26 Nov-03 Nov-09 Nov-16 Nov-23
Date

Tests performed w ith unequal sample sizes

Need to add the Measurement Error.

MSA: X-BAR / S CHART RESULTS

Facilitly ~Sbar Multiplier ~ Meas Error %P/T

DHM 31.0 2.575 +/- 80 80/50 = 160%
DSM 27.5 2.575 +/- 71 71/50 = 142%
GSO 8.0 2.575 +/- 21 21/50 = 42%

 Comments
 Spec is +/- 50.
 %P/T target is < 30%
 None of Facilities meet the measurement error target
 Daily Calibration Check procedures need investigated
since producing dramatically different results
 Variables MSA
(Non-Destructive Testing)
VARIABLES MSA: STAT > QUALITY TOOLS>
GAGE STUDY > GAGE R&R STUDY (CROSSED)

 Minimum Requirements
Minimum 10 parts: ~3 at low end of spec, ~4
parts in middle of Spec, ~3 parts at high end of
spec (NOTE: some parts should be out of spec)
3 Operators (NOTE: if only 1 operator measures parts, 1
operator may be used for MSA)
3 Repeated Measurements
VARIABLES MSA: STAT > QUALITY TOOLS>
GAGE STUDY > GAGE R&R STUDY (CROSSED)
VARIABLES MSA: STAT > QUALITY TOOLS>
GAGE STUDY > GAGE R&R STUDY (CROSSED)
 VARIABLES MSA: GRAPH RESULTS
Gage R&R (ANOVA) for Measurement
Reported by : Lisa G och
G age name: G age 1 Tolerance: 8-16
Date of study : F eb 18. 2011 M isc:

Components of Variation Measurement by Part

100 96.0% % R&R
14
% P/T
67.1%
Percent

50 12
27.9%
19.5% 18.4% 20.9%
12.9% 14.6%
10
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3 4 5 6 7 8 9 10
Part

R Chart by Operator
Measurement by Operator
A B C
1. 0
14
UCL=0.880
Sample Range

0. 5 _ 12
R=0.342

0. 0 LCL=0 10
A B C
Operator
Xbar Chart by Operator
A B C Operator * Part Interaction
14 Operator
14
A
UCL=12.551 B
Sample Mean

_ C
Average

12 X=12.201 12
LCL=11.852

10
10
1 2 3 4 5 6 7 8 9 10
Part
 VARIABLES MSA: SESSION WINDOW
RESULTS

Both the Part &

the Operator
significantly
effect the part
measurements.

Measurement Error: +/- 0.78

(i.e. 1.55721/2 = 0.78)
SPC/MSA - SUMMARY
The reliability of Control Charts are dependent on the
selection of Rational Subgroups. Pick the wrong
subgroup and the results can be very misleading.

The reliability of MSAs are dependent on the selection

of the actual Parts. Pick Parts with too much or too little
variation between them and the results can be very
misleading.