Statistical Process Control

This is a control system which uses

statistical techniques for knowing, all the time, changes in the process.
It is an effective method in preventing

defects and helps continuous quality improvement.

Statistical Process Control

Statistics are tools used to make

predictions on performance. There are a number of simple methods for analysing data and, if applied correctly, can lead to predictions with a high degree of accuracy.

Statistical Process Control

The process involves people, machines,

materials, methods, management and environment working together to produce an output, such as an end product.

Statistical Process Control

Controlling a process is guiding it and

comparing actual performance against a target. Then identifying when and what corrective action is necessary to achieve the target. Statistics aid in making decisions about a process based on sample data and the results predict the process as a whole.

Definition
S.P.C. is statistical analysis of the

predictability and capacity of a process to give a uniform product

The Aim of S.P.C

Detection:

This focuses on identification of problems after production, by 100% inspection or by customer complaints.
It is a history-based strategy.

The Aim of S.P.C.

Detection Drawbacks: Production is already made. Customer dissatisfaction. Inflated costs - rework; inspection. Repetitive problems. Neglected improvements

Prevention:

This focuses on in-process production and identification of problems through analysis of process capability.
It is a future-orientated strategy.

Prevention Benefits: Improved design and process capability. Improved manufacturing quality. Improved organisation. Continuous Improvement.

The S.P.C. has to be looked at as a stage

towards completely preventing defects. With stable processes, the cost of inspection and defects are significantly reduced.

The Benefits of S.P.C.

Assesses the design intent. Achieves a lower cost by providing an early

warning system. Monitors performance, preventing defects. Provides a common language for discussing process performance

Process Variations
Process Element Examples Variable
Machine.Speed, operating temperature, feed rate Tools..Shape, wear rate Fixtures..Dimensional accuracy MaterialsComposition, dimensions OperatorChoice of setup, fatigue

No industrial process or machine is able to

produce consecutive items which are identical in appearance, length, weight, thickness etc. The differences may be large or very small, but they are always there. The differences are known as variation. This is the reason why tolerances are used.

Stability
Common causes are the many sources of

variation that are always present. A process operates within normal variation when each element varies in a random manner, within expected limits, such that the variation cannot be blamed on one element. When a process is operating with common causes of variation it is said to be stable.

Process Control
The process can only be termed under

control if it gives predictable results.

Its variability is stable over a long period of

time.

Process Control Charts

Graphs and charts have to be chosen for

their simplicity, usefulness and visibility. They are simple and effective tools based on process stability monitoring. They give evidence of whether a process is operating in a state of control and signal the presence of any variation.

7 tools of Quality
Cause and Effect Diagram Check Sheet Control Chart Flow Chart Histogram Pareto Chart Scatter Diagram

Cause and Effect Diagram

Also known as Ishikawa diagram. Ishikawa proposed this concept. Looks like skeleton of a fish. Idea is to identify and state the problem. Then to find out all possible causes of that

problem. To draw this cause and effect diagram one has to think logically and carefully.

Cause and effect diagram

Also called fishbone diagrams (because of their

shape). Helps in identifying root causes of the quality failure.

Cause and Effect Diagram

Check Sheet
A form used to collect data in such a way

that it makes collection of data very easy Analysis of data from that format is also very easy.

Check Sheet

Control Chart
Simple graph or chart Time is depicted on X axis The quality characteristic measured is

depicted on Y axis. A control chart is a continuous graphic indication of the state of the process with respect to a quality characteristic being measured.

Control charts
Control chart: Add Upper Control Limit and Lower Control

Limit to the run chart.

Procedure to Establish the Control Charts

1. For each sample, an average is calculated
j=1

Xij
n where X is the j-th measurement in the i-th sample.
ij

X =
i

2. Calculate the range within the sample:

R =X
i

largest

-X

smallest

3. Calculate the GRAND AVERAGE:

X =

i=1

, where N is the number of subgroups.

4. Calculate the average of the sample RANGES:

R=
5. Control limits for R-chart

Ri

i=1

LCL = D3 R , UCL = D4 R
6. Control limits for X-bar chart

UCL = X + A2 R LCL = X A2 R
where A2 D3 , and D4 are functions of sample size.

Flow Chart
A schematic diagram of a process including

all the steps or operations in the sequence they occur. This will help in better understanding of the entire process.

Flow chart
Process map identifies the sequence of activities or the

flow in a process. Objectively provides a picture of the steps needed to accomplish a task. Helps all employees understand how they fit into the process and who are their suppliers and customers. Can also pinpoint places where quality-related measurements should be taken. Also called process mapping and analysis.

Histogram
Is a bar chart or bar graph It is a graphical depiction of a number of

occurrences of an event.

Pareto Chart
A Pareto chart is nothing but a histogram Where no. of occurrences of an event are

arranged in descending order. Named after Vilfredo Pareto (1848-1923). Used when one needs to separate important from trivial

Scatter Diagram
Simplest and most useful. A scatter diagram is a plot of one variable

vs. another variable. Useful in finding relation between two factors. Example : Yarn strength may depend upon Twist per inch. If slope is going up then +ve correlation. If slope going down then ve correlation. If there is no pattern then there is no correlation.

Thank you!!