A lecture on SPC (Statistical Process Control)

SunMax Auto Engineering Pvt Limited

Brief about SPC

The concepts of Statistical Process Control (SPC) were initially developed by Dr. Walter Shewhart of Bell Laboratories in the 1920's, and were expanded upon by Dr. W. Edwards Deming Dr. Shewhart identified two sources of process variation: Chance variation that is inherent in process, and stable over time, and Assignable, or Uncontrolled variation, which is unstable over time - the result of specific events outside the system Dr. Shewhart devised control charts used to plot data over time and identify both Common/Inherent Cause variation and Assignable/Special Cause variation.

Aim of SPC ?
1. Stability:- Is the output Predictable and Consistent ? 2. Capability:- Does the Process meet customer specifications?

Causes of variations
1. 2. 3. 4. Man (unskilled new operator) Machine (Defect in machine) Material (Raw Material fault) Method (change in method)

1. Is the Process capable? 2. Is the Machine capable?

Process of doing SPC

Collect Data
1. Calculate Capability Index Cp

YES
1. Plot Control Chart- Range

1. Plot Control Chart- Averages

1. Calculate Capability Index Cpk

2. Normal Frequency Distribution Curve

5-why Analysis Fish Bone Diagram Shop Floor Level

Process/Machine Change Management Level

Is the Process Stable?

We will draw Variable chart for Range and Averages:

Is the Process Stable?

We will draw Variable chart for Range and Averages:

Rules of Variable Chart- Ranges

If all the Ranges are inside UCL & LCL, then the ranges are in statistical control If 1 or 2 ranges are outside control limit, then ignore those readings and recalculate average mean and average range, after this, if the ranges still fall out side control limit, then process is not stable If 3 or more ranges are outside control limit, then process is unstable, find out and remove the assignable causes which are upsetting the ranges.

Is the Process CAPABLE?

Once we observe that our Ranges and Averages are within the Control Limits (Process is STABLE), we should now move on to check if our Process is Capable as well (satisfies customer dimensional requirements).

This done by using CAPABILITY INDEX Cp & Cpk and Normal Distribution Curve.

34.13% of data lie between and 1 above the mean (). 34.13% between and 1 below the mean. Approximately two-thirds (68.28 %) within 1 of the mean. 13.59% of the data lie between one and two standard deviations Finally, almost all of the data (99.74%) are within 3of the mean.

Capability Indexes- Cp & Cpk

The ability of a process to meet specifications (customer expectations) is defined as Process Capability, which is measured by indexes that compare the:How Far from (variability) and the MEAN ( ) of the process to the upper and lower specifications. Cpk

Cp

Which Side of the Mean (L or R)

(Cp)
The Index Cp compares the natural sixsigma spread of the process to the tolerance.
Tolerance (Customer Specification)= USL-LSL Process Spread = 6 times Standard Deviation= 6

Cp= USL-LSL/6

(Cp)

(Cp)

(Cp)

(Cpk)
The measurement that assesses process centering in addition to spread, or variability, is Cpk. Think of Cpk as a Cp calculation that is handicapped by considering only the half of the distribution that is closest to the specification

(Cpk)

(Cpk)

Stability Vs Capability

Stability Vs Capability

Stability Vs Capability

Stability Vs Capability

Points to Keep in Mind

Thank You