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Stastistical Process Control

Quality Management System

Five Core Tools:-

1.Advanced Product Quality Planing
2.Production Part Approval Process
3. Measurement System Analysis
4.Statistical Process Control
5.Failure Modes and Effects Analysis
TPM – The Prime Mover Towards Excellence Slide No – 1
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What is Statistical Process Control ?

-Statistical Process Control is method of Monitoring

and detecting changes in processes.
-SPC uses an advanced from of time series plots.
Five Core tools :-

-SPC provides an easy method of deciding if a process

has changed (in other words ,is the process "in-control")

TPM – The Prime Mover Towards Excellence Slide No – 2

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Types of Data

- Attribute Data :-Data by counting

- Snap Gauge
- Plain Plug Gauge
- Thread Plug Gauge
-Good /Bad ,ok / Not ok

TPM – The Prime Mover Towards Excellence Slide No – 3

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Control Chart Decision Tree

u chart

Y/N

Attribute
Data Defects Inspection Y
Determine Defects or c chart
Data Type defective units units Same

Defectives

Sample size Y/N

p chart
constant

Y
Y=yes,
np chart
N=no

TPM – The Prime Mover Towards Excellence Slide No – 4

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np chart:-the number of
defective from 24 continue
days in daily sample 200
items is given draw np
chart and show the points

TPM – The Prime Mover Towards Excellence Slide No – 5

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SHAFT KICK SPINDLE -MT-2145 ,PF621003

np chart Sample Size = 200 nos

Days Defects Days Defects
1 10 13 12
2 5 14 15
3 10 15 8
4 12 16 14
5 11 17 10
6 9 18 4
7 19 19 11
8 4 20 11
9 12 21 26
10 27 22 3
11 25 23 10
12 9 24 11
=288
TPM – The153
Prime Mover Towards Excellence Slide No – 6
135
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Here sample size is constant -

CL=NP

where N is lot size ,

d where d is total defect Quantity,

P= n
where n is total days *sample size,

288
P= =0.06
24*200

P = 0.06
CL=200*0.06 =12

UCL=NP+3 NP(1-P) , LCL =NP-3 NP(1-P)

UCL=22.075 LCL=-1.924
TPM – The Prime Mover Towards Excellence Slide No – 7
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TPM – The Prime Mover Towards Excellence Slide No – 8

 p-chart- Proportion Defective Chart QM
BEARING CONE-MT-298

p chart Sample Size =Same /No

Days Lot size Variable (n) Defective Proportion (d/n)
1 150 11 0.0733
2 200 9 0.0450
3 250 13 0.0520
4 100 11 0.1100
5 90 12 0.1333
6 160 11 0.0688
7 210 9 0.0429
8 230 7 0.0304
9 210 14 0.0667
10 160 10 0.0625
11 190 8 0.0421
12 240 12 0.0500
13 300 13 0.0433
14 350 14 0.0400
15 110 7 0.0636

2950 161
TPM – The Prime Mover Towards Excellence Slide No – 9
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p chart- sample size variable
Dailywise data gathering

p = Summation of total defective value =

d = 161 =0.0545
Summation of total sample size n 2950

q = (1- p) =(1-0.0545) =0.945

Now,
x = Summation of total sample size = 2950 =196.66
Maximum days 15
pq
UCL= p+3 x

UCL=0.1028
LCL= p-3 pq
x
LCL=0.005

TPM – The Prime Mover Towards Excellence Slide No – 10

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TPM – The Prime Mover Towards Excellence Slide No – 11

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c-chart - c-charts are used to look at variation

in counting type attributes data .They are
used to determine the variation in the number
of defects in a constant subgroup size.

TPM – The Prime Mover Towards Excellence Slide No – 12

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CL = C

32 = 4
C =
8
LCL = C - 3 C
UCL = C + 3 C ,

= 4-3*2
= 4+3*2

UCL = 10 = -2 = 0

TPM – The Prime Mover Towards Excellence Slide No – 13

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(Plots the number of non-conformities per inspection unit)

TPM – The Prime Mover Towards Excellence Slide No – 14

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u chart
(Plots the number of non-conformites per inspection unit)

A u-chart is an attributes control chart used with data collected in

subgroups of varying sizes .U-charts show how the process ,
measured by number of nonconformities per item ,changes over
time .Nonconformities are defects in sampled subgroups

TPM – The Prime Mover Towards Excellence Slide No – 15

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TPM – The Prime Mover Towards Excellence Slide No – 16

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CL= Total Defect

Total days

TPM – The Prime Mover Towards Excellence Slide No – 17