Variation Control

FICCI CE

Variation Control

Variation is a basic phenomenon of nature. This effects all entities

including products and processes. Variation is found in all stages of product
life cycle including design & development, manufacturing, service and
supplier processes. Controlling process variation is a key to achieving
WORLD CLASS quality.
FICCI CE

Understanding & controlling variation

Variation is responsible for the difference between one unit of product and
another. It can also be defined as the difference between specifications
and customer requirements. Variation is present in all processes. When it
is present in one or more characteristics of a product or process, it causes
poor quality and customer dissatisfaction.
FICCI CE

Understanding & controlling variation

Products and processes are expected to vary because no two things are
exactly alike. Differences result from material characteristics, methods,
people, machine and environmental factors as depicted on the next
slide.
 Sources of variation

Material Methods Environment

•Assemblies •Procedures •Noise level
•Components •Policies •Humidity
•Suppliers •Accounting •Temperature
•Consumables •Lighting

Variation

People Machine Measurement

•Training •Technology •Counting
•Experience •Variability •Instruments
•Skill •Tooling •Gauging
•Attitude •Fixtures •Tests
 Causes of variation

Causes

Chance / Inherent Causes Special / Assignable Causes

They have the influence on They influence the output
the output all the time. only once in a while.
FICCI CE

Chance / inherent causes of variation

Chance or inherent causes are sources of variation which are always

present because of small day-to-day variables. These causes are
inherently part of the process (or system) and affect everyone working in
the process. They are typically due to a large number of small random
sources of variation. Chance causes also contribute to the output
variability because they themselves vary.
FICCI CE

Chance / inherent causes of variation

Each chance/inherent cause typically contributes a small portion to the total

variation in process outputs. Inherent causes usually have a nonsystematic,
random appearance. Process or system variability is defined in terms
inherent causes because they are regular contributors. The variables
involved in inherent causes may change slightly from day to day, but this is
natural. They will always be present, and the best way to stay ahead of this
situation is to plan for it.
FICCI CE

Special / assignable causes

These are causes that do not occur naturally and are unusual. These types
of causes are not inherent part of the process (or system) all the time or do
not affect everyone but arise because of specific circumstances. Special
causes are sporadic contributors and are due to some specific
circumstances. Process or system variability is defined without them. Special
causes can be identified and efforts can be made to minimize their influence
on the process.