CAPABILITY INDICES

Bambang Eko Cahyono

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 Fasilitator

Founder ECI Communities

Co-Founder PT. Eci Bisnis Manajemen
Ketua Yayasan Edukasi Citra Indonesia
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 APA ITU SPESIFIKASI

Target berat apel 200 Gram +/- 6 Gram

Minimal 194 Gram
Maximal 206 Gram

Target isi air 200 ml +5 ml/-10 ml

Minimal 190 ml
Maximal 205 ml

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 APA ITU SPESIFIKASI
Observasi 10 Apel

200
205
202
198 MEAN =
195
Target berat apel 200 Gram +/- 6 Gram 198 200,5
201
202
204
200

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 APA ITU SPESIFIKASI
Observasi 10 Apel

198
200
201
197 MEAN =
195
Target berat apel 200 Gram +/- 6 Gram 198 200,5
201
202
204
209

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 CUSTOMER BUTUH AKURAT DAN PRESISI

Mencapai Harapan, Konsisten setiap waktu

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 BAGAIMANA MENCAPAINYA

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 HUBUNGAN CAUSALITAS

OUTPUT-1 OUTPUT-2 OUTPUT-3

INPUT-1 9 9 5

INPUT-2 9 1 9

INPUT-3 1 9 5

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 CP = “Presisi” -----> “Kesetiaan”
Sejauh mana dia konsisten pada nilai prosesnya
CPk = “Pemusatan

Sejauh mana proses mendekati target nominalnya

Suatu data dengan target nilai nominal = 7, bandingkanlah!

Proses pertama = 4, 5, 6, 3, 7, 8, 9, 9
Proses kedua = 7, 6, 5, 7, 6, 5, 6, 6
Proses ketiga = 7, 7, 7, 6, 7, 7, 7, 7
Proses keempat = 5, 5, 5, 5, 5, 5, 4, 5
Proses keenam = 3, 3, 3, 3, 3, 3, 3, 3
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 How to calculate the process
capability indices
• Collect the data of a particular parameter from the n sigma
process. The process must be STABLE. There
must be at least 100 data (in 30 number of
sample).
• Draw the histogram for the data. Include the upper
and lower specification limits on the histogram.
• Calculate the indices using the followingformulas.
¦USL – LSL¦
Cp = ---------------------
6σ
• Where USL and LSL the respective upper and
lower specification limits and o is the standard
deviation or the data.

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 capability indices
¦USL – x¦
Cpu = ---------------------
3σ

¦x - LSL¦
Cpl = ---------------------
3σ

R
Sigma =
d2

CPk = Nilai terkecil antara Cpu & Cpl

atau Min (Cpu , Cpl)

Atau CPk = (Nearer spec – X) / 3 σ

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Process capable ialah jika sebagian besar hasil pengukuran (data) masih didalam
batas specifikasi. Bayangkan anda punya mobil sedan dan garasi anda lebarnya 5
m. Mudahkah anda memarkirkannya?
LOGIKA
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 LSL USL LSL USL LSL USL

X X X

LOGIKA
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 LSL USL LSL USL LSL USL

X X X

LOGIKA
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 Nilai Kapabilitas dan Estimasi Tingkat Kegagalan
(Defective level)
Assumsi
• Normal distribution
• Prosesnya stabil
• Terpusat diantara specification limit
• 2 sisi spec (jika 1 sisi spec limit maka defective level
nilainya dibagi 2)

Capability (Cp) Defective level

1.00 0.27
1.33 6.3ppm
1.50 7 ppm
1.67 0.6 ppm
2.00 2 ppb
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 LOGIKA

Tembakan 10 CP dan CPk

peluru
mengarah ke Akan rendah
bidang sasaran

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 LOGIKA

Tembakan 10
CP > CPk
peluru
mengarah ke
bidang sasaran

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 LOGIKA

Tembakan 10
CP tinggi
peluru
mengarah ke CPk juga tinggi
bidang sasaran

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 LOGIKA

Tembakan 10
CPk > Cp
peluru
mengarah ke
bidang sasaran

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 LOGIKA

Tembakan 10
peluru Bagaimana
mengarah ke dengan ini?
bidang sasaran

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 LOGIKA
Bagaimana dengan ini?

Tembakan 10
peluru
mengarah ke
bidang sasaran

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 LOGIKA
Bagaimana dengan ini?

Tembakan 10
peluru
mengarah ke
bidang sasaran

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 LOGIKA
Bagaimana dengan ini?

Tembakan 10
peluru
mengarah ke
bidang sasaran

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 Review
Control Chart & Capability Indices

USL

UCL

CL

LCL

LSL

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 MENGAPA KITA HARUS MELAKUKAN ANALISA
KAPABILITAS PROSES

• Defect prevention – A use of a benchmark of 1.33 ensures that

parts are produced within specification
• Continuous improvement – The capability indices are a measure
of the performance of a process. As such they can also be used to
monitor improving quality
• Communication between manufacturing and Engineering – It can
be used as a common language between the two groups
• Prioritization – Unacceptable capabilities are given attention
• Comparison between Cp and Cpk – A comparison of the two
indices shows the direction of corrective actions: location or
variability
• Evaluation of new machines – The standard is set at 1.67 for new
machines to ensure an acceptable capability at the user’s
• Process audits – This will focus attention on the problem areas

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 Cp Versus Cpk
Both inidices must be calculated and
compared
A low Cpk value indicates that the
process variation is too high
A low Cpk value indicates that the
process is not centered well between
the specifications.
The typical Benchmark is 1.33 or 1.67.
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JIKA TARGET CUSTOMER
TIDAK DI TENGAH
SPESIFIKASI?
 Cpm
• Cpm (Taguchi Index): indeks yang menggambarkan kemampuan
proses memenuhi spesifikasi. Dimana target prosesnya bukan
merupakan titik tengah spesifikasi limit.

Cpm = USL - LSL : rata-rata ;

T: target/nominal ;
6 ( – T )2 +  2
  standard deviasipopulasi

LSL T: Target USL LSL T: Target USL

OR

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 CONTOH PERHITUNGAN Cpm
Diketahui :
Specification limit : 28 + 3/-4 . Rata-rata X = 29.0, dan standard
deviasi S = 0.43
Berapa nilai Cpm?

Cpm = USL - LSL = 31 – 24 = 1.07

6 ( – T )2 +  2 6 (29 – 28 )2 + 0.43 2

LSL Target USL

24 25 26 27 28 29 30 31

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 MINITAB
TUTORIAL

Assesing Quality

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 MINITAB
The Story
You work for an automobile manufacturer in a department that
assembles engines. One of the parts, a camshaft, must be 600 mm +/-2
mm long to meet engineering specifications. There has been a chronic
problem with camshaft length being out of specification- a problem that
has caused poor-fitting assemblies down the production line and high
scrap and rework rates.
Your supervisor wants to run X and R charts to monitor this
characteristic. For a month, data are collected on the length of five
camshafts per shift (1 sample of size 5 per shift). You have been asked
to lead a problem-solving team and recommend a solution.
What you will learn
In this session you will learn how to:
· Produce X and R charts
· Produce histograms with normal curves
· Perform a process capability analysis

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 MINITAB
STEP 1

You will get data from a Minitab saved worksheet named

CAMSHAFT.MTW that is located in the Data subdirectory or folder.
1 Choose File > Open Worksheet.
2Move to the Data subdirectory and select the worksheet
CAMSHAFT.MTW. Click OK.
3If it is not visible, open the Data window by pressing [Ctrl]+[D].
The Data window shows you the columns of data in detail.
This worksheet contains the results of the sampling plan from the last
month. For now, you are concerned with the first column, Length,
which contains 100 observations (20 samples of 5 camshafts each).
Recall that the camshaft lengths are measured in millimeters.

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 MINITAB
STEP 2

First, you want to produce a control chart to look at the range of camshaftlengths
within the sample subgroups. You hope that the plotted points fall inside the
control limits in a random manner.
1 Choose Stat >Control Charts >Variable Charts for Subgroups > R.
2 Choose All observations for a chart are in one column, then enter Length.
3 In Subgroup sizes, type 5. Verify dialog box .
4 Click OK.

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 MINITAB
STEP 2

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 MINITAB
STEP 3

You will create an X chart to see if there is a problem with camshaft lengths being
outside acceptable limits. In addition, you will instruct Minitab to use eight common tests
that point out special causes for variation.
1 Choose Stat > Control Charts > Variable Charts for Subgroups > Xbar.
2 Choose All observations for a chart are in one column, then enter Length.
3 In Subgroup sizes, then type 5. Verify dialog box .
4 Click Xbar Options, then click the Tests tab.
5 Choose Perform all tests for special causes. Verify dialog box .
6 Click OK in each dialog box.
Test Results for Xbar Chart of Length

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 8
TEST 6. 4 out of 5 points more than 1 standard deviation from center line (on
one side of CL).
Test Failed at points: 12, 13

* WARNING * If graph is updated with new data, the results above may no
* longer be correct.

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 STEP 3

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 STEP 3
MINITAB
The X chart shows
that the process is
out of control.
Specifically, one
point has failed test
1, and two points
have failed test 6.
To find out what
these tests mean,
look in the Session
window.

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 STEP 4
MINITAB

Choose Window > Session.

By looking at the Session window output, you see that the process produced one point more than 3 standard
deviations from the center line, and four of five points more than 1 standard deviation from the center line (on
one side of the center line).
Now that you have confirmed that a problem does exist, it is time to look for causes and solutions.
Unfortunately, the sampling plan did not allow for detailed inspection of precisely where and when the
problems occurred because only one sample was taken per shift. A better plan would have been to take
multiple samples per shift for the troubleshooting phase, and to switch to this monitoring plan after special
causes were found and eliminated. Nonetheless, you are determined to get what you can out of the data
that you have.

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 STEP 5
MINITAB
The histogram with normal curve is useful for examining a variable's
distribution. You decide to examine the variable Length.
1 Choose Graph > Histogram.
2 Choose With Fit, then click OK.
3 In Graph variables, enter Length. Verify dialog box .
4 Click OK.

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 STEP 5
MINITAB
Examine the histogram. In
general, we expect a variable
such as Length to follow the
normal distribution. In this
case, the histogram would be
approximately bell-shaped.
The histogram you just
created is certainly not bell-
shaped. In fact, it would
appear from the spikes at 598,
599, and 601 that we may be
dealing with more than one
separate and distinct
distributions.
An examination of the inventory records indicates that there are two suppliers for the
camshafts. Now you are starting to understand the odd histogram. You decide to obtain
measurements from both suppliers and run X and R charts separately on each set of data
with a subgroup size of 5 for each. The data for each supplier are stored in the columns
Supp1 and Supp2 of your worksheet.

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 STEP 6
MINITAB

Your worksheet contains variables named Supp1 and Supp2 with data for
Suppliers 1 and 2. You could repeat the same procedures to produce control
charts for Supplier 1 as you did to produce the charts for Length. However, the X
and R chart will display both charts together.
Evaluate Supplier 1
1 Choose Stat > Control Charts > Variable Charts for Subgroups > Xbar-R.
2 Choose All observations for a chart are in one column, then enter Supp1.
3 In Subgroup sizes, type 5. Verify dialog box . Click OK.

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 STEP 6
MINITAB

According to the X and R chart, both the means and ranges for Supplier 1 appear to be in
control, although you notice that the mean is 599.548 mm, not 600. The average range for
Supplier 1 is 1.341 mm.
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 STEP 6
MINITAB
Evaluate Supplier 2
You can produce the same control charts for Supplier 2, using the variable named Supp2,
as you did for Supplier 1.
1 Press [Ctrl]+[E].
This keyboard shortcut, for Edit > Edit Last Dialog, brings up the Xbar-R Chart dialog
box again.
2 Under All observations for a chart are in one column, delete Supp1 and enter
Supp2. Click OK.
You do not need to enter a subgroup size because it was still set to 5 from the last time
you used this dialog box. Minitab "remembers" the dialog box settings from the last time a
dialog box was used in a session.

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 STEP 6
MINITAB

Supplier 2's X and R

chart reveals problems.
From the chart, you can
see that two points are
above the upper control
limit.

The R chart does not indicate that the process is out of control. However, you notice that
the center line is at 3.890, which is almost three times larger than Supplier 1's R of
1.341.
As team leader, you recommend that longer production runs be accepted from Supplier
1 until Supplier 2 can demonstrate that camshaft production is in control. You will work
with Supplier 2 to reduce process variability to an acceptable level. Because of the
statistical evidence that supports your position, your recommendation is implemented.

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 STEP 7
MINITAB

PREPARING FOR A PROCESS CAPABILITIES ANALISYS

Using only Supplier 1 reduced variability. While the number of poor-quality
assemblies has dropped significantly, problems have not completely
disappeared. You decide to run a capability study to see whether Supplier 1
alone is capable of meeting your engineering specifications of 600 mm +/-2
mm.

The process must be in control before you can proceed with the capability
analysis. The X and R Chart shows that, due to using only parts from
Supplier 1, the process is now in control. You also expect the camshaft
lengths to be normally distributed. Now you want to view a histogram to
check normality.
First you want to look at the distribution of camshaft lengths for Supplier 1:
1 Choose Graph > Histogram.
2 Choose With Fit, then click OK.
2 In Graph variables, enter Supp1. Click OK.

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 STEP 7
MINITAB

Minitab produces a histogram with normal curve again, based on your earlier selections.
You are satisfied by the bell shape of the distribution, and you do not see multiple modes or
peaks as you did earlier. You are ready to proceed.
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 STEP 8
MINITAB

PERFORM A PROCESS CAPABILITIES ANALISYS

Now you are ready to run a process capability analysis to see if
Supplier 1 is capable of meeting your engineering specifications of 600
mm +/-2 mm.
1 Choose Stat > Quality Tools > Capability Analysis > Normal.
2 Choose Single column and enter Supp1.
3 In Subgroup size, type 5.
Next, enter the specification limits.
4 In Lower spec, type 598.
5 In Upper spec, type 602. Verify dialog box .
6 Click Options.
7 In Target (adds Cpm to table), type 600. Verify dialog box .
8 Click OK in each dialog box.

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 STEP 8
MINITAB

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 STEP 8
MINITAB

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 STEP 8
MINITAB
From the graph you can
see that the process mean
falls short of the target and
the process distribution
mean lies to the left of the
target. Also, the left tail of
the distribution falls
outside the lower
specification limit.
Therefore, some
camshafts will not meet
the lower specification of
598 mm.

The Capability Analysis command also produces a table of statistics. The Cpk index indicates
whether the process will produce units within the tolerance limits. A Cpk index of 1 means that a
process is exactly capable of meeting specifications, while less than 1 means that the process is
not meeting specification limits. Ideally, you would like to see a Cpk much larger than 1, because
the larger the index, the more capable the process. The Cpk index for Supplier 1 is only 0.90,
indicating that they need to improve by reducing variability and by centering the process around
the target.
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 Because Supplier 1 is currently your best supplier of camshafts, you will work
with them to improve their process and, therefore, your own.
Minitab offers analysis of variance (ANOVA), regression, design of experiments (DOE), and many other statistical tools that you
will use to continuously improve your processes.

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 Lets Post Test
quiz

Terimakasih
Bambang Eko Cahyono