Chapter 5a Process Capability

This chapter introduces the topic of process

capability studies. The theory behind
process capability and the calculation of Cp
and Cpk is presented
Specification Limit &
Process Limit
 Look at indv. values and avg. values of x’s
 Indv x’s values n = 84 - considered as population
 Avg’s n = 21 - sample taken
= same
X and(in this
X xcase)

 Normally distributed individual x’s and x avg. values

having same mean, only the spread is different  >
 σ
Relationship σ x = popu. Std. dev. of avg’s
n
 If n = 5 = 0.45  =  x popn std dev of indiv. x’s
 SPREAD OF AVGS IS HALF OF SPREAD FOR INDV.
VALUES
Relationship between
population and sample values
 Assume Normal Dist.
 ‘Estimate’ popu. std. dev.
s

ˆ 
c4
4(n  1)
 c4  4n  3 ; n = 84

  σ̂ 4.16 (c4 = 0.99699)


0.99699

= 4.17
 4.17
x  
n 4
= 2.09
Central Limit Theorem
 ‘If the population from which samples are
taken is NOT normal, the distribution of
SAMPLE AVERAGES will tend toward
normality provided that sample size, n, is at
least 4.’
 Tendency gets better as n
 Standardized normal for distribution of
averages Z = x μ
σ n
 Central Limit Theorem
is one reason why
control chart works
 No need to worry about
distribution of x’s is not
normal, i.e. indv.
values.
 Averages distribution
will tend to ND
Control Limits &
Specifications
 Control limits - limits for
avg’s, and established
as a func. of avg’s
 Specification limits -
allowable variation in
size as per design
documents e.g. drawing
  for individual values
 estimated by design
engineers
 Control limits, Process spread, Dist of
averages, & distribution of individual values
are interdependent. – determined by the
process
 C. Charts CANNOT determine process meets
spec.
Process Capability &
Tolerance
 When spec. established without knowing
whether process capable of meeting it or
not serious situations can result
 Process capable or not – actually looking
at process spread, which is called process
capability (6)
 Let’s define specification limit as tolerance
(T) : T = USL -LSL
 3 types of situation can result
the value of 6 < USL-LSL
the value of 6 = USL - LSL
the value of 6 > USL - LSL
Case I and Case II situations
Case 3 situation
Process Capability
 Procedure (s – method)
1. Take subgroup size 4 for 20 subgroups
2. Calculate sample s.d., s, for each subgroup
3. Calculate avg. sample s.d. s = s/g
4. Calculate est. population s.d. ˆ o  s c 4
5. Calculate Process Capability = 6̂
 R - method
1. Same as 1. above
2. Calculate R for each subgroup
3. Calculate avg. Range, = R/g
4. Calculate R
5. σ̂ o  R
Calculate Calculate 6 d2
̂o
Process Capability (6) And
Tolerance
 Cp - Capability Index
T = U-L
Cp = 1  Case II 6 = T Formulas
Cp > 1  Case I 6 < T Cp = (T)/6
Cp < 1  Case III 6 > T
Usually Cp = 1.33 (de facto Z(min)
Cpk =
std.) 3
 Measure of process
USL  x
performance Z (USL) =
σ
 Shortfall of Cp - measure
Z (LSL) = x  LSL
not in terms of nominal or
target value >>> must use 
Cpk
Example
Determine Cp and Cpk for a Solution
Cp= T/6= 0.2/6(0.03)=1.11
process with average 6.45,
Cpk = Z(min)/3
 = 0.030, having USL =
Z(U) = (USL -x)/  =
6.50 , LSL = 6.30 -- T = 0.2 6.50-6.45)/0.03 = 1.67
L T U Z(L) = (x –LSL)/  = 6.45-
6.30)/0.03 = 5.00
Cpk = 1.67/3 = 0.56
Process NOT capable since
6.30 6.45 6.50 not centered. Cp > 1 doesn’t
x = mean capable. Have to
check Cpk
Comments On Cp, Cpk
 Cp does not change when process center
(avg.) changes
 Cp = Cpk when process is centred
 Cpk  Cp always this situation
 Cpk = 1.00 de facto standard
 Cpk < 1.00  process producing rejects
 Cp < 1.00  process not capable
 Cpk = 0  process center is at one of spec.
limit (U or L)
 Cpk < 0  i.e. – ve value, avg outside of limits
Exercise
1. Find Cp, Cpk 3. Find Cp, Cpk
x = 129.7 (Length of U = 56
radiator hose)
 = 2.35 L = 44
Spec. 130.0  3.0 =2
What is the % defective? When = 50
2. Find Cp, Cpk
When = 56
Spec.U = 58 mm
L = 42 mm
 = 2 mm
When = 50
When = 54