Statistical Process Control

Sunday, February 7, 2016

Statistical Process Control

Control Charts (Numerical Evaluation of Metrics)

X & R Charts
I & MR Charts
P Charts

Measurement System Evaluation

Bias
Gage Bias & Linearity Studies
Gage Stability (Run) Studies
Gage R & R Studies
Repeatability
Reproducibility

Process Capability Studies

Capability Studies
Cpk
Non-Normal Distribution Capability Studies

Control Charts (Numerical Evaluation of Metrics)

Purpose of Control Charts

Determine Current Performance

Are we Stable and Consistent Over Time?
Stability
We are the same as we were Five minutes ago
Part dimensions
Process evaluations

Consistent Over Time

We are the same as we were yesterday, last week, last month, last year
Part dimensions
Process evaluations

Prevent Unnecessary Adjustments

Types of Control Charts

Average and Range ( X & R)

Average and Standard Deviation ( X & s)
Individual and Moving Range (I & MR)
Proportion Defective (P)

Average and Range ( X and R) Control Charts

 X and R Charts
Xbar-R Chart of Flow Rate

Sample Mean

24

UCL=23.702

22
__
X=19.701

20
18
16

LCL=15.700
1

11
Sample

13

15

17

19

Sample Range

16

UCL=14.67

12
_
R=6.94

8
4
0

LCL=0
1

11
Sample

13

15

17

19

Walter Shewhart
Bell Laboratories
1891-1967

Control Charts are often referred to as Shewhart Control Charts

after their Inventor, Walter Shewhart
7

 X and R Control Charts

Range (R Chart)
Short-term variation
In this example, well use day to day within a week
In manufacturing, this is often variation at a given point in time

Average ( X Chart)
Long-term variation
In this example, well use week to week
In manufacturing this could be hour to hour, shift to shift or day to day

Interpreting X and R Charts

1.
2.
3.

Three ways to determine that we are out of control

We have a point outside of the control limits.
We have a shift. As we will see, this is nine or more points on
the same side of the center line.
We have a trend. As we will see, this is six or more points
going in the same direction compared to the point that just
preceded them.

Control Chart Examples

Range In Control
R Chart of Flow Rate
16
UCL=14.67

14

Sample Range

12
10
8

_
R=6.94

6
4
2
0

LCL=0
1

11

11
Sample

13

15

17

19

Average In Control
Xbar Chart of Flow Rate
24

UCL=23.702

23

Sample Mean

22
21
__
X=19.701

20
19
18
17
16

LCL=15.700

15
1

12

11
Sample

13

15

17

19

Range Point Out of Control

Xbar-R Chart of Flow Rate

Sample Mean

25.0

UCL=24.26

22.5
__
X=19.76

20.0
17.5

LCL=15.27

15.0
1

11
Sample

13

15

17

19

20
Sample Range

UCL=16.48

15
10

_
R=7.79

5
0

LCL=0
1

13

11
Sample

13

15

17

19

 X Point Out of Control

Xbar-R Chart of Flow Rate

Sample Mean

24

UCL=23.40

21

__
X=19.40

18
LCL=15.40

15
1

12
1

11
Sample

13

15

17

19

Sample Range

16

UCL=14.67

12
_
R=6.94

8
4
0

LCL=0
1

14

11
Sample

13

15

17

19

Range Shift
Xbar-R Chart of Flow Rate
24

Sample Mean

UCL=23.012
22
__
X=19.551

20
18

LCL=16.090

16
1

11
Sample

13

15

17

19

UCL=12.69

Sample Range

12
9

_
R=6.00

6
2

LCL=0
1

15

11
Sample

13

15

17

19

Average Shift
Xbar-R Chart of Flow Rate
UCL=22.352

Sample Mean

22
20

_
_
X=18.351

18

16

LCL=14.350

14
1

11
Sample

13

15

17

19

Sample Range

16

UCL=14.67

12
_
R=6.94

8
4
0

LCL=0
1

16

11
Sample

13

15

17

19

Range Trend
Xbar-R Chart of Flow Rate

Sample Mean

24

UCL=23.717

22
_
_
X=19.721

20
18
16

LCL=15.725
1

11
Sample

13

15

17

19

16

Sample Range

UCL=14.65
12
3
3

_
R=6.93

4
0

LCL=0
1

17

11
Sample

13

15

17

19

 X Trend
Xbar-R Chart of Flow Rate

Sample Mean

24

UCL=23.702

22
__
X=19.701

20
3

18

16

LCL=15.700
1

11
Sample

13

15

17

19

Sample Range

16

UCL=14.67

12
_
R=6.94

8
4
0

LCL=0
1

18

11
Sample

13

15

17

19

Individual and Moving Range Charts (I & MR)

(I & MR) Charts

In some jobs, we usually deal with a sample size of one (1)

Weekly PPM #s or Monthly IPTV #s may be all one can get
When Sample Size = 1, we can use I & MR Charts
I stands for Individual
Plot each individual value on the I chart

MR stands for Moving Range

Range of last week & this week

20

Out of Control Point

Out of Control Point

I-MR Chart of Weekly IPTV

I ndividual Value

40

UCL=35.14
30
_
X=21.10

20

10
LCL=7.06
1

11
Observation

13

15

17

19

Moving Range

20
UCL=17.24
15
10
5

__
MR=5.28

LCL=0
1

22

11
Observation

13

15

17

19

P Charts

In Control P-Chart
P Chart of Defective
0.0275
UCL=0.02643

Proportion

0.0250

0.0225
_
P=0.02043

0.0200

0.0175

0.0150

LCL=0.01443
1

10

13

24

16
Sample

19

22

25

28

Out of Control Observations

P Chart of Defective
1

0.030

UCL=0.02643

Proportion

0.025
_
P=0.02043

0.020

0.015

LCL=0.01443

0.010
1

10

13

25

16
Sample

19

22

25

28

Shift
P Chart of Defective
0.0275
UCL=0.02643

Proportion

0.0250

0.0225
_
P=0.02043

0.0200
2
2

0.0175

0.0150

LCL=0.01443
1

10

13

26

16
Sample

19

22

25

28

Trend
P Chart of Defective
0.0275
UCL=0.02643

Proportion

0.0250

0.0225

_
P=0.02043

0.0200

0.0175

0.0150

LCL=0.01443
1

10

13

27

16
Sample

19

22

25

28

Measurement System Evaluation

Measurement System
I often say that when you can measure what you are
speaking about, and express it in numbers, you know
something about it; but when you cannot measure it,
when you cannot express it in numbers, your
knowledge is of a meagre and unsatisfactory kind;

William Thompson
(Lord Kelvin)
1824-1907

29

Measurement System Evaluation

Major Components of Measurement System Evaluation

Accuracy
Not Accurate
Accurate
Not Precise
Not Precise
Precision

Not Accurate
Precise

30

Accurate
Precise

Methods Used to Evaluate Accuracy and

Precision

Accuracy
Gage Bias Study
Bias Stability Study
Bias Linearity Study

Precision
Gage Repeatability and Reproducibility (R & R) Study

31

Gage Bias Study

Bias: Inaccurate Estimation of the Measurement

Parameters

Bias and Linearity Study

Minitab Graphic Output
Part Number 3333333 Bias and Linearity Analysis Study
Gage name:
Date of study:

Reported by:
Tolerance:
Misc:

Knob Gage
10-15-2000

Steve Smith
2.00 - 10.00
Gage Number 11245

Predictor
Constant
Slope

Regression
95% CI

1.0

Data
Avg Bias

S
Linearity

0.23954
1.05333

Reference
Average
2
4
6
8
10

P
0.000
0.000

R-Sq
71.4%
% Linearity
13.2

Gage Bias
Bias % Bias
-0.053333
0.7
0.491667
6.1
0.125000
1.6
0.025000
0.3
-0.291667
3.6
-0.616667
7.7

P
0.040
0.000
0.293
0.688
0.000
0.000

-0.5

Percent of Process Variation

-1.0
2

6
Reference Value

10

Percent

Bias

0.5

0.0

Gage Linearity
Coef SE Coef
0.73667 0.07252
-0.13167 0.01093

10
5
0

33

Linearity

Bias

Gage Dialog Box

Minitab Gage Run Chart Graphical Output
XYS Controller Gage Run Chart
Gage name:
Date of study:

Reported by:
Tolerance:
Misc:

Knob Gage
10-15-2000

Steve Smith
2.00 - 10.00

50

Torque

40
30
20
10

Mean

Day
Panel variable: Part

34

Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Gage R & R Study

Calculating R & R

Repeatability
Variation in measurements obtained when the same appraiser measures the
same part on the same measuring instrument.

Reproducibility
Variation in measurements obtained when different appraisers measures the
same part on the same measuring instrument or when different measuring
instruments are used.
R
e
p
e
a
t
a
b
i
l
i
t
y

Repeatability and Reproducibility Combine Quadratically

Repeatability2 + Reproducibility2 = (R&R)2
Repeatability & Reproducibility

Reproducibility

36

Gage R & R (TV vs. Tolerance)

Total Variation (TV) vs. Tolerance

Total Variation (TV)

Measure against TV to determine if Measuring system is adequate for Statistical
Process Control

Tolerance
Measure against Tolerance to determine if Measuring system is adequate for
capability studies and to make ship/scrap decisions

37

Gage R & R
Gage R & R Study Graphical Output
Voltage Drain Gage R & R
Gage name:
Date of study:

Reported by:
Tolerance:
Misc:

Voltage Drain Tester

April 22. 2001

Chuck Roast
0 to 0.750

Components of Variation

Vds by Part

Percent

100

% Contribution
% Study Var
% Tolerance

50

0.600
0.575
0.550

Gage R&R

Repeat

Reprod

Part-to-Part

Sample Range

10

Vds by Operator

3
0.600

0.02
0.01

UCL=0.00858
_
R=0.00333
LCL=0

0.00

0.575
0.550

2
Operator

Xbar Chart by Operator

1

Operator * Part I nteraction

0.60
_
_
UCL=0.58911
X=0.5857
LCL=0.58229

0.58

Average

Sample Mean

6
Part

R Chart by Operator
1

Operator

0.60

1
2
3

0.58
0.56

0.56

38

5
6
Part

10

Process Capability Studies

Purpose of Process Capability Studies

Determine our ability to meet our

customers requirements.

40

Prerequisites for A Process Capability

Study
1.
2.

Establish an Effective Measurement System

Determine The Process is in Statistical Control

41

Types of Capability Studies

Higher is Better
Resistance Used to Measure Cleanliness
Strength

Lower is Better
Warp
Strain

Nominal is Best
Oven Temperature
Air Flow Rate

42

Normal Capability Sixpack (Nominal is

Best)
Process Capability Sixpack of Thickness
Xbar Chart

Capability Histogram

Sample Mean

0.0550

UCL=0.054401

0.0525

LSL

USL

Specifications
LSL 0.0425
USL 0.0575

__
X=0.05139

0.0500
LCL=0.048379
1

11

13

15

17

19

0.045 0.048 0.051 0.054 0.057

Sample Range

R Chart
UCL=0.01104

0.010

_
R=0.00522

0.005

0.000

LCL=0
1

11

13

15

17

19

0.045

Last 20 Subgroups

Values

Normal Prob Plot

AD: 1.315, P: < 0.005

0.050

0.055
0.050
0.045

Within

Overall

Specs
10
Sample

0.060

Capability Plot
Within
StDev 0.00224419
Cp
1.11
Cpk
0.91

0.055

15

20

43

O verall
StDev 0.00240512
Pp
1.04
Ppk
0.85
Cpm *

Normal Capability Study, Nominal is Best

Process Capability of Thickness
LSL

USL
Within
Overall

Process Data
LSL
0.0425
Target
*
USL
0.0575
Sample Mean
0.05139
Sample N
100
StDev(Within) 0.00224419
StDev(Overall) 0.00240512

Potential (Within) Capability

Cp
1.11
CPL 1.32
CPU 0.91
Cpk 0.91
Overall Capability
Pp
PPL
PPU
Ppk
Cpm

0.045 0.048 0.051 0.054 0.057

Observed Performance
PPM < LSL
0.00
PPM > USL 10000.00
PPM Total
10000.00

Exp. Within Performance

PPM < LSL
37.26
PPM > USL 3238.63
PPM Total
3275.90

44

Exp. Overall Performance

PPM < LSL
109.39
PPM > USL 5536.05
PPM Total
5645.44

1.04
1.23
0.85
0.85
*

Normal Capability Sixpack, Lower is

Better
Process Capability Sixpack of Warp
Sample Mean

Xbar Chart

Capability Histogram
Specifications
USL 10

__
X=3.311

USL

UCL=5.225

LCL=1.397
1

11

13

15

17

19

21

23

25

0.0

1.5

3.0

R Chart
Sample Range

7.5

9.0

_
R=3.318

2.5
0.0

LCL=0
1

11

13

15

17

19

21

23

25

Last 25 Subgroups
Within
StDev 1.42645
Cp
*
Cpk
1.56

0
5

10

15

20

Sample

45

10

Capability Plot

8
Values

6.0

Normal Prob Plot

AD: 0.726, P: 0.057

UCL=7.016
5.0

4.5

25

Within
O verall
Specs

O verall
StDev 1.54454
Pp
*
Ppk
1.44
Cpm *

Normal Capability Study, Lower is Better

Process Capability of Warp
USL
Within
Overall

Process Data
LSL
*
Target
*
USL
10
Sample Mean
3.3112
Sample N
125
StDev(Within) 1.42645
StDev(O verall) 1.54454

Potential (Within) Capability

Cp
*
CPL
*
CPU 1.56
Cpk 1.56
O verall Capability
Pp
PPL
PPU
Ppk
Cpm

0.0
O bserved Performance
PPM < LSL
*
PPM > USL 0.00
PPM Total
0.00

1.5

3.0

Exp. Within Performance

PPM < LSL
*
PPM > USL 1.37
PPM Total
1.37

46

4.5

6.0

7.5

Exp. O verall Performance

PPM < LSL
*
PPM > USL 7.43
PPM Total
7.43

9.0

*
*
1.44
1.44
*

Normal Capability Sixpack, Higher is

Better
Process Capability Sixpack of Resistance
Sample Mean

Xbar Chart

Capability Histogram

5.6

UCL=5.646

4.8

__
X=4.612

LSL

Specifications
LSL 3.8

4.0
LCL=3.579
1

11

13

15

17

19

21

R Chart
Sample Range

Normal Prob Plot

AD: 0.831, P: 0.031

UCL=3.788
_
R=1.791

LCL=0
1

11

13

15

17

19

21

Last 21 Subgroups

Within
StDev 0.770124
Cp
*
Cpk
0.35

6
4
5

10
Sample

15

47

Capability Plot

8
Values

20

Within
O verall
Specs

Overall
StDev 0.867853
Pp
*
Ppk
0.31
Cpm *

Normal Capability Study, Higher is Better

Process Capability of Resistance
LSL
Within
Overall

Process Data
LSL
3.8
Target
*
USL
*
Sample Mean
4.61238
Sample N
105
StDev(Within)
0.770124
StDev(O verall) 0.867853

Potential (Within) Capability

Cp
*
CPL 0.35
CPU
*
Cpk 0.35
O verall Capability
Pp
PPL
PPU
Ppk
Cpm

3
O bserved Performance
PPM < LSL 171428.57
PPM > USL
*
PPM Total
171428.57

Exp. Within Performance

PPM < LSL 145742.36
PPM > USL
*
PPM Total
145742.36

48

Exp. O verall Performance

PPM < LSL 174615.70
PPM > USL
*
PPM Total
174615.70

*
0.31
*
0.31
*

Shift & Drift

This is a process with Cp = Cpk = 1.00; Our defect rate is

0.27% or 2700 PPM

P(x<6)=0.135%
P(6<x<18)=99.73%
50

P(x>18)=0.135%

This is a process with Cp = Cpk = 1.33; Our defect rate is

0.0063% or 63 PPM

P(x<6)=0.0032%
P(6<x<18)=99.9937%
51

P(x>18)=0.0032%

This is a process with Cp = Cpk = 1.67; Our defect rate is

0.000057% or 0.57 PPM

P(x<6)=0.000029%
P(6<x<18)=99.999943%
52

P(x>18)=0.000029%

This is a process with Cp = Cpk = 2.00; Our defect rate is

0.00000 20% or 0.002 PPM (2PPB)

P(x<6)=0.00000010%
P(6<x<18)=99.999999%
53

P(x>18)=0.00000010%

Shift & Drift Region:

+ 1.5

93.32% Good

6.68%
54

6.68%

Shift & Drift Region:

+ 1.5

99.38% Good

0.62%
55

0.62%

Shift & Drift Region:

+ 1.5

99.98% Good
0.02%

0.02%
56

Shift & Drift Region:

+ 1.5

99.99966% Good
0.00034%
57

0.00034%

Translating Capability Indices to PPM

58

Non-Normal Capability Studies

Histogram
Histogram of Tensile Strength
Normal
Mean
StDev
N

40

Frequency

30

20

10

10

15
20
25
Tensile Strength

60

30

35

12.67
4.650
150

Process Capability of Tensile Strength

LSL
Within
Overall

Process Data
LSL
5.5
Target
*
USL
*
Sample Mean
12.669
Sample N
150
StDev(Within) 4.5569
StDev(Overall) 4.65756

Potential (Within) Capability

Cp
*
CPL 0.52
CPU
*
Cpk 0.52
O verall Capability
Pp
PPL
PPU
Ppk
Cpm

5
O bserved Performance
PPM < LSL 0.00
PPM > USL
*
PPM Total
0.00

10

Exp. Within Performance

PPM < LSL 57833.59
PPM > USL
*
PPM Total
57833.59

61

15

20

25

30

Exp. Overall Performance

PPM < LSL 61875.03
PPM > USL
*
PPM Total
61875.03

35

*
0.51
*
0.51
*

3-Parameter Lognormal Capability

Analysis
Process Capability of Tensile Strength
Calculations Based on Lognormal Distribution Model
LSL
Process Data
LSL
5.5
Target
*
USL
*
Sample Mean 12.669
Sample N
150
Location
1.88118
Scale
0.558513
Threshold
5.00057

Overall Capability
Pp
*
PPL
1.54
PPU
*
Ppk
1.54
Exp. O verall Performance
PPM < LSL 2.00
PPM > USL
*
PPM Total
2.00

Observed Performance
PPM < LSL 0.00
PPM > USL
*
PPM Total 0.00

10

15

62

20

25

30

35

For More Information

NIST Engineering Statistics Handbook

http://www.itl.nist.gov/div898/handbook/

63