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The Quality Improvement Model

Is Process Capable?
Purpose: Determine the adequacy of the process with respect to customer /management needs.

Define Process

Is Process Capable ?

Select Measures Collect & Interpret Data

Is Process Stable ? Yes Improve Process Capability No Is Process Capable ? Yes Use SPC to Maintain Current Process

No

Investigate & Fix Special Causes

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Capable Process
A stable process that meets customer requirements.
Histogram Control Chart
UCL

Is Process Capable ?

CL

LCL
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32

Run Order

Lower Spec

Target

Upper Spec

Capability assessments for unstable processes, may not be indicative of how the process is actually performing.
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Assessing Process Capability

Is Process Capable ?

Counting Measures

The average percent defectives. The average number of defects.

Instrument Measures

Comparing both the center of the process and the process variation

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Capability Assessment for Counting Measures


Order Entry Process
Week # Errors 1 15 2 22 3 18 4 10 5 13 6 9 7 27 8 12 9 24 10 22 11 8 12 8 13 26 14 16 15 20 16 10 17 16 18 9 19 15 20 20 Total 320 Control Chart
UCL=28.0

Is Process Capable ?

35 30

Number of Errors

25 20 15 10 5 0 5 10 15 20 LCL=4.0 Avg=16.0

Week

Is this process adequate as is?


Should it be improved?
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Measures of Process Capability


USL - LSL Cp = Specification Range = 6sc True Process Range Cp < 1.0 Process is not capable of meeting specs Cp = 1.0 Process is marginally capable Cp > 1.0 Process is capable of meeting specs Problem: We are assuming the process has a target that is in the center of the specification range, and that the process is in fact centered on that target. Distance from process average Cpk = to closest specification limit = min (USL - x , x - LSL) 1 True Process Range 3sc 2
Note: a negative result is possible if the process average is outside specifications

Is Process Capable ?

Cpk < 1.0 Process is not capable of meeting specs Cpk = 1.0 Process is marginally capable Cpk > 1.0 Process is capable of meeting specs Benefits: Optimal values are attained by running exactly between specs. Can (must) be used for 1-sided specifications

Warning: Capability assessments for unstable processes, may not be indicative of how the process is actually performing. 8-5

Process Capability
LSL
USL

Is Process Capable ?

How much material is out of spec? In the short term? In the long term?
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Process Capability Ratios

Is Process Capable ?

LSL

USL

Voice of The Process


Voice of The Customer

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Process Capability - The Strategy


Centering The Process Is On Target Spread Reduce The Variation

Is Process Capable ?

Defects

Defects

LSL

USL
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Process Capability Ratios


2 Key Metrics for Measuring Capability
USL LSL Cp 6sc

Is Process Capable ?

X - LSL USL- X Cpk Min( , ) 3s c 3s c

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Process Capability Ratios - Concept

Is Process Capable ?

USL LSL Cp 6sc

Cp

Total Tolerance
Process Spread

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CP & CPK Measure Short-term I Chart for C1 Capability 39


3.0SL=37.36

Is Process Capable ?

Individual Value

34 X=30.60 29

Is The Process In Control ?

Is It Producing Defects ?

24 0 5 10 15 20 25 30 35

-3.0SL=23.84

Observation Number

A Short-term Capability study covers a relatively short period of time (days, weeks) generally consisting of 30 to 50 data points. The actual number depends on the subject under study.
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Long Term Performance for C3 I Chart


50 3.0SL=47.12

Is Process Capable ?

Individual Value

40 X=33.80 30

Is The Process In Control ?

Short term Capability

Is It Producing Defects ?

20 0 50 100

-3.0SL=20.49

Observation Number

A long-term capability study covers a relatively long period of time (weeks, months) generally consisting of 100-200 data points. Again, the actual amount depends on the subject under study.
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A Further Look at Capability


Compare the estimates of the process deviations from the short-term and long-term data Descriptive Statistics

Is Process Capable ?

Variable short term long term

N 30 180

Mean 30.6 33.8

StdDev 2.23 4.44

What is the difference between the short-term and the long-term data?
What implication does this have in doing capability studies?
8-13

Measures of Process Performance


Pp = Specification Range = USL - LSL 6ss True Process Range P p < 1.0 Process Performance is not meeting specs P p = 1.0 Process Performance is marginally meeting specs P p > 1.0 Process Performance is meeting specs Problem: We are assuming the process has a target that is in the center of the specification range, and that the process is in fact centered on that target.

Is Process Capable ?

Distance from process average to closest specification limit min (USL - x , x - LSL) P pk = = 1 3ss True Process Range 2
Note: a negative result is possible if the process average is outside specifications

Ppk < 1.0 Process Performance is not meeting specs Ppk = 1.0 Process Performance is marginally meeting specs Ppk > 1.0 Process Performance is meeting specs Benefits: Optimal values are attained by running exactly between specs. Can (must) be used for 1-sided specifications

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Performance vs. Capability


Days Sales Outstanding for 55 Days CO2 Levels for 55 Time Points
14

Is Process Capable ?

13

CO2-Shrt

DSO

12

11

10 Index 10 20 30 40 50

These data show that the process, if well controlled can perform much better than it currently is
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Capability vs. Performance


Days Sales Outstanding for 55 Days CO2 Levels for 55 Time Points
14

Is Process Capable ?

13

CO2-Shrt

DSO

12

11

10 Index 10 20 30 40 50

Capability: Only random or short term variability (Cp & Cpk)

Process Performance: Total Variation including shifts and drifts

(Pp & Ppk)


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Process Performance Ratios

Is Process Capable ?

USL LSL 6ss

X - LSL USL- X P pk Min( , ) 3ss 3ss

The P-family of indices are computationally the same as the C-family of capability indices, but use the observed long-term standard deviation.
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WARNING!!!
Statistical Assumptions Made In Capability Studies
1. Data Comes From a Stable Process

Is Process Capable ?

If not, work towards getting the process in control Dont despair, you can still make some assumptions about your process in the mean time

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