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Quality Control: Mcgraw-Hill/Irwin
Quality Control: Mcgraw-Hill/Irwin
Quality Control
McGraw-Hill/Irwin Copyright © 2007 by The McGraw-Hill Companies, Inc. All rights reserved.
Learning Objectives
List and briefly explain the elements of the
control process.
Explain how control charts are used to
monitor a process, and the concepts that
underlie their use.
Use and interpret control charts.
Use run tests to check for nonrandomness
in process output.
Assess process capability.
10-2
Phases of Quality Assurance
Figure 10.1
Inspection and
Inspection of lots corrective Quality built
before/after action during into the
production production process
10-3
Inspection
Figure 10.2
10-4
Inspection Costs
Figure 10.3
Cost
Total Cost
Cost of
inspection
Cost of
passing
defectives
Optimal
Amount of Inspection
10-5
Where to Inspect in the Process
10-6
Examples of Inspection Points
Table 10.1
Type of Inspection Characteristics
business points
Fast Food Cashier Accuracy
Counter area Appearance, productivity
Eating area Cleanliness
Building Appearance
Kitchen Health regulations
Hotel/motel Parking lot Safe, well lighted
Accounting Accuracy, timeliness
Building Appearance, safety
Main desk Waiting times
Supermarket Cashiers Accuracy, courtesy
Deliveries Quality, quantity
10-7
Statistical Control
10-8
Control Chart
Control Chart
Purpose: to monitor process output to see
if it is random
A time ordered plot representative sample
statistics obtained from an on going
process (e.g. sample means)
Upper and lower control limits define the
range of acceptable variation
10-9
Control Chart
Figure 10.4
Mean
Normal variation
due to chance
LCL
Abnormal variation
due to assignable sources
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample number
10-10
Statistical Process Control
The essence of statistical process
control is to assure that the output of a
process is random so that future output
will be random.
10-11
Statistical Process Control
10-12
Statistical Process Control
10-13
Sampling Distribution
Figure 10.5
Sampling
distribution
Process
distribution
Mean
10-14
Normal Distribution
Figure 10.6
Standard deviation
99.74%
10-15
Control Limits
Figure 10.7
Sampling
distribution
Process
distribution
Mean
Lower Upper
control control
limit limit
10-16
SPC Errors
Type I error
Concluding a process is not in control
when it actually is.
Type II error
Concluding a process is in control when it
is not.
10-17
Type I and Type II Errors
Table 10.2
10-18
Type I Error
Figure 10.8
/2 /2
Mean
10-19
Observations from Sample
Figure 10.9 Distribution
UCL
LCL
1 2 3 4
Sample number
10-20
Control Charts for Variables
Variables generate data that are measured.
(process mean is
shifting upward)
Sampling
Distribution
UCL
UCL
Does not
R-chart
LCL
detect shift
10-22
Mean and Range Charts
Figure 10.10B
Sampling
Distribution (process variability is increasing)
UCL
Does not
x-Chart
LCL
reveal increase
UCL
10-23
Control Chart for Attributes
10-24
Use of p-Charts
Table 10.4
10-25
Use of c-Charts
Table 10.4
10-26
Use of Control Charts
At what point in the process to use
control charts
What size samples to take
What type of control chart to use
Variables
Attributes
10-27
Run Tests
Run test – a test for randomness
Any sort of pattern in the data would
suggest a non-random process
All points are within the control limits -
the process may not be random
10-28
Nonrandom Patterns in Control
charts
Trend
Cycles
Bias
Mean shift
Too much dispersion
10-29
Counting Runs
B A A B A B B B A A B
U U D U D U D U U D
10-30
NonRandom Variation
Managers should have response plans to
investigate cause
May be false alarm (Type I error)
May be assignable variation
10-31
Process Capability
Tolerances or specifications
Range of acceptable values established by
engineering design or customer
requirements
Process variability
Natural variability in a process
Process capability
Process variability relative to specification
10-32
Process Capability
Figure 10.15
Lower Upper
Specification Specification
A. Process variability
matches specifications
Lower Upper
Specification Specification
B. Process variability
Lower Upper
well within specifications Specification Specification
C. Process variability
exceeds specifications
10-33
Process Capability Ratio
If the process is centered use Cp
specification width
Process capability ratio, Cp =
process width
10-34
Limitations of Capability Indexes
1. Process may not be stable
2. Process output may not be normally
distributed
3. Process not centered but Cp is used
10-35
Example 8
Standard Machine
Machine Deviation Capability Cp
A 0.13 0.78 0.80/0.78 = 1.03
B 0.08 0.48 0.80/0.48 = 1.67
C 0.16 0.96 0.80/0.96 = 0.83
10-36
3 Sigma and 6 Sigma Quality
Lower Upper
specification specification
Process
mean
+/- 3 Sigma
+/- 6 Sigma
10-37
Improving Process Capability
Simplify
Standardize
Mistake-proof
Upgrade equipment
Automate
10-38
Taguchi Loss Function
Figure 10.17
Traditional
cost function
Cost
Taguchi
cost function
10-39
Video: Defect Prev.
10-40