Statistical Process Control

What is a process?
Inputs PROCESS Outputs

A process can be described as a transformation of set of inputs into desired outputs.

Types of Measures
Measures where the metric is composed of a classification in one of two (or more) categories is called Attribute data.
_ Good/Bad Yes/No Measures where the metric consists of a number which indicates a precise value is called Variable data. Time Miles/Hr

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Population Vs. Sample (Certainty Vs. Uncertainty)

A sample is just a subset of all possible values sample population Since the sample does not contain all the possible values, there is some uncertainty about the population. Hence any statistics, such as mean and standard deviation, are just estimates of the true population parameters.
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WHY STATISTICS? THE ROLE OF STATISTICS

LSL

USL

Statistics is the art of collecting, classifying, presenting, interpreting and analyzing numerical data, as well as making conclusions about the system from which the data was obtained.
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Descriptive Statistics
Descriptive Statistics is the branch of statistics which most people are familiar. It characterizes and summarizes the most prominent features of a given set of data (means, medians, standard deviations, percentiles, graphs, tables and charts.

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Inferential Statistics

Inferential Statistics is the branch of statistics that deals with drawing conclusions about a population based on information obtained from a sample drawn from that population.

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WHAT IS THE MEAN?

The mean is simply the average value of the data.
ORDERED DATA SET
-5 -3 -1 -1 0 0

xi = - 2 = -.17 mean = x =
n 12
n=12

0 0 0 1 3

-6

-5

-4

-3

-2

-1

Mean
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= -2
8

WHAT IS THE MEDIAN?

If we rank order (descending or ascending) the data set ,we find the value half way (50%) through the data points and is called the median value.
ORDERED DATA SET -5 -3 -1 -1 0 0 0 0 0
50% of data points

Median

1
3 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
Median Value August 27, 2012

WHAT IS THE MODE?

If we rank order (descending or ascending) the data set We find that a single value occurs more often than any other. This is called the mode. .
ORDERED DATA SET -5

-3
-1 -1 0 0 0

Mode

Mode

0 0
1 3 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
10

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WHAT IS THE RANGE?

The range is a very common metric . To calculate the range simply subtract the minimum value in the sample from the maximum value.
ORDERED DATA SET -5 -3 -1

Range = x MAX - x MIN = 4 - ( -5) = 9

-1
0 0 0 0 0

Range

1
3 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4

Range Min
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Max
11

WHAT IS THE VARIANCE/STANDARD DEVIATION?

The variance (s2) is a very robust metric . The standard deviation(s) is the square root of the variance and is the most commonly used measure of dispersion.

X =

Xi

-2 12
2

= -.17

(X =

- X) 61.67 = = 5.6 n -1 12 - 1
i

-6 -5 -4 -3 -2 -1 0

DATA SET -5 -3 -1 -1 0 0 0 0 0 1 3 6 4

Xi - X
-1-(-.17)=-.83 -1-(-.17)=-.83 0-(-.17)=.17 0-(-.17)=.17 0-(-.17)=.17 0-(-.17)=.17 0-(-.17)=.17 1-(-.17)=1.17 3-(-.17)=3.17 4-(-.17)=4.17

(X

- X)

-5-(-.17)=-4.83 (-4.83)2=23.32 -3-(-.17)=-2.83 (-2.83)2=8.01 (-.83)2=.69 (-.83)2=.69 (.17)2=.03 (.17)2=.03 (.17)2=.03 (.17)2=.03 (.17)2=.03 (1.17)2=1.37 (3.17)2=10.05 (4.17)2=17.39 61.67 12

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Statistical Process Control (SPC)

Measures performance of a process Uses mathematics (i.e., statistics) Involves collecting, organizing, & interpreting data Objective: Regulate product quality Used to Control the process as products are produced Inspect samples of finished products

CONTROL CHART

Functions of a Process Control System are

To signal the presence of assignable causes of variation To give evidence if a process is operating in a state of statistical control

CONTROL CHART

Essential features of a control chart

Variable Values Upper Control Limit Central Line Lower Control Limit

Time

Control Chart Purposes

Show changes in data pattern e.g., trends Make corrections before process is out of control Show causes of changes in data Assignable causes Data outside control limits or trend in data Natural causes Random variations around average

Quality Characteristics

Variables

Attributes

1. Characteristics that 1. Characteristics for which you focus on defects you measure, e.g., 2. Classify products as either weight, length good or bad, or count # 2. May be in whole or in defects e.g., radio works or not fractional numbers 3. Continuous random 3. Categorical or discrete variables random variables

CONTROL CHART
Types of Control Charts for Attribute Data
Description Control Chart for proportion non conforming units Control Chart for no. of non conforming units in a sample Control Chart for no. of non conformities in a sample Control Chart for no. of non conformities per unit Type p Chart np Chart c Chart u Chart Sample Size May change Must be constant Must be constant May Change

Control Chart Types

Control Charts
Variables Charts Attributes Charts

Chart

Chart

`X

Chart

Chart

X Chart
Type of variables control chart Interval or ratio scaled numerical data Shows sample means over time Monitors process average and tells whether changes have occurred. These changes may due to 1. Tool wear 2. Increase in temperature 3. Different method used in the second shift 4. New stronger material
Example: Weigh samples of coffee & compute means of samples; Plot

R Chart
Type of variables control chart Interval or ratio scaled numerical data
Shows sample ranges over time Difference between smallest & largest values in inspection sample Monitors variability in process, it tells us the loss or gain in dispersion. This change may be due to: 1. Worn bearing 2. A loose tool 3. An erratic flow of lubricant to machine 4. Sloppiness of machine operator Example: Weigh samples of coffee & compute ranges of samples; Plot

Construction of X and R Charts

Step 1: Select the Characteristics for applying a control chart. Step 2: Select the appropriate type of control chart. Step 3: Collect the data. Step 4: Choose the rational sub-group i.e Sample Step 5: Calculate the average ( X) and range R for each sample. Step 6: Cal Average of averages of X and average of range(R)

Construction of X and R Charts

Steps 7:Cal the limits for X and R Charts. Steps 8: Plot Centre line (CL) UCL and LCL on the chart Steps 9: Plot individual X and R values on the chart. Steps 10: Check whether the process is in control (or) not. Steps 11: Revise the control limits if the points are outside.

X Chart Control Limits

UCL = x A R x 2 LCL = x - A R x 2
Sub group average X = x1 + x2 +x3 +x4 +x5 / 5 Sub group range R = Max Value Min value

From Tables

R Chart Control Limits

UCL R = D 4 R LCL R = D 3 R

From Tables

Problem8.1 from TQM by V.Jayakumar Page No 8.5

p Chart for Attributes

Type of attributes control chart Nominally scaled categorical data e.g., good-bad Shows % of nonconforming items Example: Count # defective chairs & divide by total chairs inspected; Plot Chair is either defective or not defective

p Chart
p = np / n where p = Fraction of Defective np = no of Defectives n = No of items inspected in sub group p= Avg Fraction Defective = np/ n = CL

p Chart Control Limits

p (1 - p ) UCLp = p z n p (1 - p ) LCLp = p - z n

z = 3 for 99.7% limits

Purpose of the p Chart

Identify and correct causes of bad quality The average proportion of defective articles submitted for inspection,over a period. To suggest where X and R charts to be used. Determine average Quality Level.

Problem

Problem 9.1 Page no 9.3 TQM by V.Jayakumar

np CHART
P and np are quiet same Whenever subgroup size is variable,p chart is used. If sub group size is constant, then np is used. FORMULA: Central Line CLnp = n p Upper Control Limit, UCLnp = n p +3 n p (1- p ) Lower Control Limit, LCLnp = n p -3 n p (1- p )
Where p = np/n =Average Fraction Defective n = Number of items inspected in subgroup.

Problem

Problem No 9.11 page No 9.11 in TQM by V.Jayakumar

c Chart
Type of attributes control chart Discrete quantitative data
Shows number of nonconformities (defects) in a unit Unit may be chair, steel sheet, car etc. Size of unit must be constant Example: Count no of defects (scratches, chips etc.) in each chair of a sample of 100 chairs; Plot

c Chart Control Limits

UCLc = c 3 c LCLc = c - 3 c
Use 3 for 99.7% limits