Professional Documents
Culture Documents
83
Techniques used in process capability analysis
Histograms or probability plots
Control Charts
Designed Experiments
Histogram
The histogram along with the sample mean and sample standard
deviation provides information about process capability.
Example 7.1. Data for 100 units shown in Table 7-1.
84
Sample mean: x 264.06
85
25
R i
8.1302
R i 1
0.32521
25 25
R 0.32521
0.1398
d2 2.326
For this example problem, assume that the specs are 1.5 0.50 , so
USL=2.0 and LSL =1.0. The estimate of C p is
86
USL LSL
C p
6
2.00 1.00 1
Cp 1.192
6(0.1398) 0.8388
1
For this example, P ( )100% 83.89%
1.192
The one-sided specifications are defined by:
USL
C pu
3
LSL
C pl
3
Example 7.2
87
These quantities, C p C pu and C pl have very critical assumptions:
88
Process Capability Ratio for an Off-Center Process
C p does not take into account where the process mean is located
relative to the specifications.
A process capability ratio that does take into account centering is Cpk
defined as
C pk min(C pu , C pl )
89
Cpk depends inversely on and becomes large as approaches
zero. (That is, a large value of Cpk does not necessarily reveal
anything about the location of the mean in the interval (LSL, USL)
An improved capability ratio to measure process centering is Cpm.
USL LSL
C pm
6
where is the square root of the expected squared deviation:
2 2 ( T )2
from the target T :
1
T (USL LSL )
2
Cpm can be rewritten as:
C p Tx
C pm with V
1V 2 S
90
Example. Two processes shown in Figure 8-11.
Cp 2 .0
C pm 0.63
1 2
1 ( 3) 2
91
Null hypothesis H 0 : Cp Cp0 (process is not capable)
Table 8-4 provides sample sizes and critical values for rejecting
H 0 : Cp Cp0
It means that we do not reject the process with probability while its
capability is not higher than Cp (Low)
Example 8-6. For a supplier to demonstrate that his process capability
exceeds 1.33.
H 0 : C p 1.33
H1 : C p 1.33
We can use the information in Table 8-4 to decide the value of C p , the
estimated process capability ratio. We first calculate that:
92
C p ( High ) 1.66
1.25
C p ( Low ) 1.33
From Table 8-4, we find that the sample size should be 70. Then we use
the second column to find that
C
1.10
C p ( Low )
The supplier must take a sample of n = 70 parts, and the sample process
capability ratio must exceed 1.46.
93
Process Capability Analysis Using a Control Chart
The process is in statistical control.
An in-control process may not be capable.
PCRs can be calculated using the process mean and process
standard deviation estimates.
Example. Table 7-5. The same data for Example 7.2. LSL=200
94
For the R chart, Center Line: R 77.3
UCL = D4 R ( 2.1145)( 77.3) 163 .49 , LCL = D3 R (0)( 77.3) 0
95
Gauge and Measurement System Capability
Total
2
p2 Gauge
2
Example 8.7
A gauge will be used in a SPC process. The gauge capability should be
assessed. 20 units of the products are obtained for this purpose. Since it
is to determine the capability of the measurement operation by the
operator using the given device, the operator measured each unit of the
product twice. The data of the measurement are shown in Table 8-6. The
control charts are shown in Figure 8-14 below.
96
The x chart, not served as a control chart in this case, shows that the
gauge can be used for a certain range of the measurement. The R chart
shows that the points are within control limits. The operator is good in
using this instrument to do the measurement. The standard deviation of
R 1 .0
Gauge 0.887
d 2 1.128
97
Estimating the Variance of the Components
From the data in Table 8-6, we can calculate that the standard deviation
of the 40 measurements is s=3.17. Then:
Total
2
s 2 (3.17) 2 10.05
Since we have:
Total
2
p2 Gauge
2
P2 Total
2
Gauge
2
10.05 0.79 9.26
and the estimate of the process standard deviation of the process can be
P/T Ratio
The P/T ratio, or the precisionto-tolerance ratio, is to compare the
estimate of gauge capability to the width of the specs: USL-LSL for the
part that is measured.
k Guage
P /T
USL LSL
In most cases, k=6 is used. For the previous example, if the part has
USL=60, LSL=5, then
6(0.887)
P /T 0.097
60 5
98
Then the gauge capability is acceptable as the P/T ratio is less than 0.1.
99