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IES 331 Quality Control

Chapter 7
Process and Measurement System Capability Analysis
Week 10
August 911, 2005

Dr. Karndee Prichanont

IES331 1/2005

Process Capability

Uniformity of the process

A uniformity of output

Process Capability
Analysis: Quantifying
variability relative to
product requirements or
specifications

Natural tolerance limits are defined


as follows:

Dr. Karndee Prichanont

IES331 1/2005

Process Capability Analysis

Process Capability Analysis:

In the form of probability distribution having

a specified shape,

center (mean), and

spread (standard deviation)

A percentage outside of specifications

However, specifications are not necessary to process


capability analysis

Dr. Karndee Prichanont

IES331 1/2005

Major Uses of Process Capability Analysis


1.

Predicting how well the process will hold the tolerances

2.

Assisting product developers/designers in selecting or


modifying a process

3.

Assisting in establishing an interval between sampling


process

4.

Specifying performance requirements for new equipment

5.

Selecting suppliers

6.

Planning the sequence of production processes

7.

Reducing the variability in a manufacturing process

Dr. Karndee Prichanont

IES331 1/2005

Reasons for Poor Process Capability

Process may have


good potential
capability
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Dr. Karndee Prichanont

IES331 1/2005

Process Capability Analysis using a


Histogram or a Probability Plot

If use Histogram, there should be at least 100 or


more observations

Data collection Steps


1.

Choose machines or machines. Try to isolate the headto-head variability in multiple machines

2.

Select the process operating conditions

3.

Select representative operator

4.

Monitor data collection process

Dr. Karndee Prichanont

IES331 1/2005

Exercise 7-11: page 377


The weights of nominal 1-kg
containers of a
concentrated chemical
ingredient are shown
here. Prepare a normal
probability plot of the
data and estimate process
capability

0.9475
0.9705
0.9770
0.9775
0.9860
0.9960
0.9965
0.9975
1.0050
1.0075
1.0100
1.0175
1.0180
1.0200
1.0250

Dr. Karndee Prichanont

IES331 1/2005

Exercise 7-11: page 377 (cont)


Normal Probability Plot for 7-11Weights
ML Estimates - 95% CI

99

ML Estimates

95

Mean

0.996767

StDev

0.0209315

90

Goodness of Fit

Percent

80

AD*

70
60
50
40
30

1.007

20
10
5
1
0.95

1.00

Data

1.05

Dr. Karndee Prichanont

IES331 1/2005

Process Capability Ratios

Process capability ratio (PCR Cp)


introduced in Chapter 5

Percentage of the specification band


used up by the process

Exercise 7-7: A Process is in statistical


control with CL(x-bar) = 39.7 and
R-bar = 2.5. The control chart uses
sample size of 2. Specification are
at 40+/-5. The quality characteristic
is normally distributed. Find Cp and
P
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Dr. Karndee Prichanont

IES331 1/2005

One-Sided PCR

Exercise 7-7: A Process is in statistical control with


CL(x-bar) = 39.7 and R-bar = 2.5. The control chart
uses sample size of 2. Specification are at 40+/-5. The
quality characteristic is normally distributed.
Find C

pu

and Cpl
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Dr. Karndee Prichanont

IES331 1/2005

Interpretation
of the PCR

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Dr. Karndee Prichanont

IES331 1/2005

Assumptions for Interpretation of


Numbers in Table 7-2
1.

The quality characteristic has a normal


distribution

2.

The process is in statistical control

3.

In the case of two-sided specifications, the


process mean is centered between the lower and
upper specification

Violation of these assumptions can lead to big


trouble in using the data in Table 7-2.
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Dr. Karndee Prichanont

IES331 1/2005

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Dr. Karndee Prichanont

IES331 1/2005

Cp does not take


process centering into
account
It is a measure of
potential capability, not
actual capability

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Dr. Karndee Prichanont

IES331 1/2005

A Measure of Actual Capability


Cpk = minimum (Cpu, Cpl)

Measure the one-sided PCR for the specification


limit nearest to the process average.

If Cp = Cpk, the process is centered at the


midpoint of the specifications,

If Cpk < Cp , the process is off-center

Cp measures potential capability,

Cpk measures actual capability


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Dr. Karndee Prichanont

IES331 1/2005

Normality and Process Capability Ratios

The assumption of normality is critical to the


usual interpretation of these ratios (such as
Table 7-2)

For non-normal data, options are


1.

Transform non-normal data to normal

2.

Extend the usual definitions of PCRs to handle nonnormal data

3.

Modify the definitions of PCRs for general families of


distributions

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Dr. Karndee Prichanont

IES331 1/2005

Confidence Interval and Tests of


Process Capability Ratios
Confidence intervals are an important way to
express the information in a PCR

Exercise 7-20: Suppose that a quality characteristic has a normal


distribution with specification limits at USL = 100 and LSL = 90. A
random sample of 30 parts results in average of 97 and standard
deviation of 1.6
Calculate a point estimate of Cpk
Find a 95% confidence interval on Cpk
How can we decrease the width of confidence interval on Cpk?

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Dr. Karndee Prichanont

IES331 1/2005

Process Capability Analysis Using


a Control Chart

Process must be in an in-control state to produce


a reliable estimates of process capability

When process is out of control, we must find and


eliminate the assignable causes to bring the
process into an in-control state

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Dr. Karndee Prichanont

IES331 1/2005

Gauge and Measurement System


Capability Studies

Determining the capability of the measurement system

Variability are from (1) the items being measured, and (2) the
measurement system

We need to:
1.

Determine how much of the total observed variability is due to the


gauge or instrument

2.

Isolate the components of variability in the instrument system

3.

Assess whether the instrument of gauge is capable

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Dr. Karndee Prichanont

IES331 1/2005

Example 7-7

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Dr. Karndee Prichanont

IES331 1/2005

Setting Specification Limits on Discrete


Components

For components that interact with other


components to form the final product

To prevent tolerance stack-up where there are


many interacting dimensions and to ensure that
final product meets specifications

In many cases, the dimension of an item is a


linear combination of the dimensions of the
component parts

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Dr. Karndee Prichanont

IES331 1/2005

Exercise 7-30

Three parts are assembled in series so that their


critical dimensions x1, x2, and x3 add. The
dimensions of each part are normally distributed
with the following parameters:

1 = 100; std dev1 = 4

2 = 75; std dev2 = 4

3 = 75; std dev3 = 2

What is the probability that an assembly chosen


at random will have a combined dimension in
excess of 262
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