PROCESS CAPABILITY FOR

UNILATERAL TOLERANCES
INCLUDING TRUE POSITION
Tools & Tips Webinar sponsored by the
AESQ Process Control Methods SMIG
8th February 2023

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CAPABILITY FOR UNILATERAL
Agenda – 60 minutes
Overview – P. Teti

Who is the PCM Subject Matter Interest Group – P. Teti

Why this webinar? Where can we find help?
Andrew Stout Pete Teti
PCM Community of Practice – Linked In MBB, + Fellow, Quality Engineering
Pratt & Whitney Canada Pratt and Whitney
Process Capability – A. Stout
Non-normal – A. Stout
Capability for Unilateral Tolerances – A. Stout
Capability for True Position – A. Stout
Q&A – PCM SMIG Team
Summary and Close – P. Teti

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WEBINAR OVERVIEW
We are recording today’s webinar and
will distribute the video link following the
close of the webinar. It will also be
posted on the AESQ website for free
viewing.

We will take questions during today’s

webinar using the Chat feature.

Please remain on Mute during the

presentation to prevent background
noise. We will also be muting all lines at
the start of the session.

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CAPABILITY FOR UNILATERAL
Why this webinar?

Communicate how to conduct a robust Process

Capability study that meets RM13006 guidelines
Show how to use statistical tools in conducting and
analyzing a Process Capability Analysis
Promote the available free documents and tools that
can be used by any AESQ supplier
Answer questions suppliers may have about process
capability methods

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PROCESS CONTROL METHODS PER RM13006
Purpose of this reference manual

RM13006 provides the user with an array of practical approaches to

process control used to ensure consistent product quality.

The purpose of this reference manual is to raise the overall capability of

the aerospace engine supply chain, standardize the process control
requirements across AESQ suppliers, and build on the requirements for
PFMEA and Control Plans (ref. RM13004).

RM13006 supports AS9145 - Requirements for Advanced Product

Quality Planning and Production Part Approval Process, and AS9103 -
Variation Management of Key Characteristics, supported by detailed
guidance and case studies.

This reference manual was developed by a dedicated team from AESQ

member companies with expert knowledge and experience in the areas
of process control, process improvement, quality systems, and supplier
engagement.

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PROCESS CONTROL METHODS SUPPORT
What is the Process Control Methods SMIG Group?
• The purpose of the PCM Subject Matter Interest
Group is to promote the effective deployment of the
process control methods across the AESQ Supply
Chain.
• The Group is made up of Subject Matter Experts
from the AESQ Member Companies.
• The Group is accountable for the AS13100 related
Requirements and associated Reference Manual
content, ensuring that it is up to date and reflects
current knowledge and best practice.
• It shall promote the effective deployment of the
Reference Manual using Communities of Practice
(CoP). The CoP is open to any subject matter expert
or individual experienced or trained in process https://aesq.sae-
control from the aero engine community. itc.com/interest-groups
• Activities may include webinars, best practice
sharing, development of shared training materials,
conferences and published papers.

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SUBJECT MATTER INTEREST GROUPS
Who is the Process Control Methods SMIG Team?
Andrew
Pete Teti Nicklas
PWA
Stout
PWC Gödebu
Paul Gorg Curators for RM13006
PCC
(Leader) GKN
(Co-Lead)

Experts to answer process

control related questions
Rudi Karen Steve
Douglas
Braunrieder
MTU
Scavotto
PWA
Hampton
PCC
Dush Provider of process
Honeywell
control related guidance

Grant Geoffrey Marnie Shailesh Ricardo

Braun Carpentier Ham Shinde Banuelas
PCC Safran GE RR RR

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PROCESS CONTROL METHODS CoP
Where to get help
AESQ Supplementary Materials webpage for a
copy of RM13000 and supporting templates
https://aesq.sae-itc.com/supplemental-material

Subject Matter Interest Group – meets monthly –

supports continuous improvement of RM13006 and
supporting templates & tools
AESQ Process Control Methods Community of
Practice (CoP) on Linked-In
Current membership is 200 – let’s get some more!!
https://www.linkedin.com/groups/12647920/
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PROCESS CAPABILITY IN RM13006
SECTIONS INVOLVING PROCESS CAPABILITIES IN RM13006
• 2.1.1 IMPORTANCE OF PRODUCT CAPABILITY
• 3.3 CHOICE OF CAPABILITY METRIC
• 5.3 PROCESS CAPABILITY FOR PROCESSES WITH INTENTIONAL SHIFTS
• 6.0 PROCESS CAPABILITY INDICES
• 6.1 FUNDAMENTALS OF VARIABLE DATA
• 6.2 PROCESS STABILITY IN PRACTICE
• 6.3 PROCESS CAPABILITY FOR ATTRIBUTE DATA
• 7.0 GUIDANCE FOR NON-NORMAL DATA
• 7.2 CAPABILITY ANALYSIS FOR NON-NORMAL DATA
• 9.1.2 PROCES CAPABILITY FOR MULTIPLE IDENTICAL FEATURES
• 11 DATA ANALYSIS ENABLERS
• 13 STATISTICAL FORMULAE FOR PROCESS CAPABILITY

+ New material for future update

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THE IMPORTANCE OF PROCESS CAPABILITY
Why does Process Capability matter?

• It gives a voice to your process from the viewpoint of the customer

• It gives you a number to evaluate your process

• It lets you know your potential (compare Ppk to Cpk to Cp)

• It lets you know where to spend your resources and be proactive

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KEY PRINCIPLES OF PROCESS CAPABILITY
Before looking at capability

• Can you trust your measurements? (MSA)

• Can you can trust your data? (visualize)

• Do you have enough data to capture full process

variation?

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KEY PRINCIPLES OF PROCESS CAPABILITY
• Is the data in time order?
• Is the process in statistical control?

I-MR I-MR
X Bar

Red alert! Need to investigate shift

before doing a capability analysis.
Looks good May be a trend at the start.
Investigate prior to starting capability
analysis.
To get an estimate of capability it may be acceptable to allow up to 2 “out of control” points, per 25.
Every effort should be made to identify the root cause and correct it.
The real world is not so pretty.

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KEY PRINCIPLES OF PROCESS CAPABILITY

Distributions can differ in:

LOCATION SPREAD SHAPE

This one is not normal!

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KEY PRINCIPLES OF PROCESS CAPABILITY

Normal Distribution
• The shape of a histogram can provide important
information about the presence of assignable
causes and variation
• The Normal distribution (bell-curve) frequently
occurs when the process is subjected only to
random variation (common causes)

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KEY PRINCIPLES OF PROCESS CAPABILITY
Bimodal Distribution
• The histogram exhibits two “humps” (NOT a normal distribution)
• Normal probability plot shows a poor fit to the confidence interval

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KEY PRINCIPLES OF PROCESS CAPABILITY
Skewed Distribution
• Not symmetrical, NOT a normal distribution
• One tail is longer than the other
• Skewing is said to be in the direction of the longer tail
• Could be due to unilateral tolerance

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KEY PRINCIPLES OF PROCESS CAPABILITY
Truncated Distributions
• A distribution in which one or both tails are missing (NOT a normal distribution)
• The histogram either begins or ends abruptly

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GUIDANCE FOR NON-NORMAL DATA
• Distribution fit
– Using Normal for Non-Normal data will provide incorrect and
misleading capability values

Cpk = 1.4 Cpk = 0.9, Ppk = .83

Really good? Is that correct?

Ppk = 0.53
Is that right?

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GUIDANCE FOR NON-NORMAL DATA
• Assessing Normality
• A large amount of data can
make goodness of fit too
p .228
sensitive
AD 0.481
• Visually review of histogram
• Probability plot shows a good
fit, especially in area of risk
(near spec limit)
• p-value > 0.05 for Normal
• Anderson Darling Number
(AD or A** or A square)
preferably < 0.75 p < 0.005
• Or other statistic AD 4.311
(RJ, K-S, S-W, AIC,…)

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GUIDANCE FOR NON-NORMAL DATA
RM13006 Section 7 – Guidance for Non-Normal Data

Causes of Non-Normal include

– Natural skew due to a boundary condition
– Data from two or more components of variation (e.g., true position of a hole from x
and y coordinates)
– A cyclic process behaviour
– A process with a natural tendency to drift
– Selective or biased measurements
– Process instability - lack of control
– Lack of resolution in measurement systems or rounding
– Reworking non-conformances prior to measurement
– Human factors (e.g., stopping at a maximum limit when machining down to a size)
– Two distributions being present within the data (i.e., bi-modal).

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GUIDANCE FOR NON-NORMAL DATA
Actions
• Check your process
• Check your data (at least 30)
• Find a non-normal distribution with better fit
– Weibull is often used
• Zero values will need McAdam shift (see RM13006 section 7.2.2)
• Capability
• Z-score method that uses proportions
• ISO method uses 0.135 or 99.865 percentiles
• Special cases
• Last resort: Transform with Box Cox or Johnson
For more
– See RM13006 section 7
– Attend our Webinar #8 - Dealing with Non-Normal Data

Note: Standard Deviation (SD or σ) is not applicable for non-normal

distributions.
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ONE SIDED TOLERANCES
RM13006 Section 6. Process Capability Indices

“NOTE: It will not be possible to calculate Cp or Pp indices for processes with unilateral (single
sided) tolerances as the tolerance width cannot be defined. However, Cpk and Ppk can be
calculated from the Cpl/Ppl or Cpu/Ppu (whichever can be calculated).”

Case 1 Case 2
0= Physical limit USL = Maximum value LSL = Min USL = none

Non-risk Risky Risky Non-risk

side side side side

X X
Shaft Runout Min wall

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ONE SIDED TOLERANCES
Unilateral – Case 1: A natural or physical limit on lower side
• Don’t analyze as 2 sided
• Example: Shaft runout would have a maximum spec, not to be exceeded.
But runout cannot be less than zero
• When calculating capability leave LSL blank or identify it as a boundary

0= Physical limit USL = Maximum value

Non-risk Risky
side side
PpU answers: Is the process likely to yield products with
characteristics beyond the maximum allowable?
USL − X
X P =
Shaft Runout 3𝜎

Ppk = PpU
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ONE SIDED TOLERANCES
Unilateral – Case 2: Lower spec only

Examples
• Min wall
• MTBF
• MTTF
• Horsepower
PpL answers: Is the process likely to yield products
LSL = Min USL = none with characteristics below the minimum allowable?
Risky Non-risk X − LSL
side side P =
3𝜎

Ppk = PpL
X
Min wall

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MAXIMUM MATERIAL CONDITION
Ø2.00 +/-.040
|Ø.060(M)|A|B
(M) MMC - Maximum Material Condition
• Condition where the most material exists Dimensions in inches
• Greatest mass on feature
• Min ID
• Max OD
• If (M) on drawing, as the feature deviates from its Maximum
Material Condition, that amount may be added to the Min ID is the MMC condition
positional tolerance 2.000 - .040 = 1.960”

If Actual ID is 2.010”
MMC Bonus = 2.010 – 1.960 = .050” dia
Or .025” radial

TP tolerance with bonus = .060 + .050 = .110” Dia

or .055” radial

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TRUE POSITION CAPABILITY
Special Case

How to analyse?
• TP Rad
• Adjusted TP
• Residual Tolerance
• Percent of Tolerance Y Axis
• Effective Size to Virtual
• Area Method

X Axis

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TRUE POSITION CAPABILITY
TP Rad Process Capability of TP_1
Calculations Based on Weibull Distribution Model

Using conventional radius/diameter P rocess D ata

LB USL
O v erall C apability

analysis method LB
Target
0
*
Pp
PPL
*
*
USL 3.65 PPU 1.00
S ample M ean 1.25414 P pk 1.00

Good Weibull fit only occurs only when S ample N

S hape
10000
1.99766
Exp. O v erall P erformance
P P M < LB *
S cale 1.4154
X & Y are on target. O bserv ed P erformance
P P M > U S L 1313.11
P P M Total 1313.11
P P M < LB 0
P P M > U S L 1000

Both X and Y axis are usually Normally

P P M Total 1000

distributed.

TP Rad is Non-Normally Distributed

0.0 0.6 1.2 1.8 2.4 3.0 3.6 4.2

TP Rad = 𝑥 +𝑦 TP Dia = 2 * TP Rad

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TRUE POSITION CAPABILITY
Using TP Rad method

Capability Case 1 = Capability Case 2

Not good as variability is different

Case 1 Case 2
Y Axis Y Axis

X Axis X Axis

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TRUE POSITION AREA METHOD
Not the only way, but a new way to start to understand.
Discussion, development and incorporation into RM13006 is
pending.

Advantages of Area Method

• Good way to visualize and represent the true situation.
Y Axis

• “Most methods combine the individual variable bonus

tolerance with the individual position deviation and then
compare the resulting surrogate variable to a constant
limit…found to be untrustworthy” isixsigma.com
• “…the natural variability must also be expressed in terms
of a circular region.” infinityqs.com
X Axis

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TRUE POSITION
AREA METHOD

R = Radial Tolerance
𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒

𝑃 = = r = Process Radius
(3smax(x,y) )
𝐴𝑟𝑒𝑎 = 𝜋𝑟 To be conservative the larger
Y Axis variability is used, either x or y.
𝜋𝑅
𝐴𝑟𝑒𝑎𝑃 =
𝜋𝑟
𝑅
𝐴𝑟𝑒𝑎𝑃𝑝 = ∑ (𝑥 − 𝑥̅ )
(3𝑠 ( , )) 𝑠=
𝑛−1
Used with Pp and Ppk
X Axis
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TRUE POSITION AREA METHOD
Actual TP
Y Axis average center

Actual TP
TP nominal center line 3s radial zone r
X Axis

TP tolerance radial zone R

𝑃 = =

𝐴𝑟𝑒𝑎 = 𝜋𝑟

𝜋𝑅 𝑅
𝐴𝑟𝑒𝑎𝑃 = 𝐴𝑟𝑒𝑎𝑃𝑝 =
𝜋𝑟 (3𝑠 ( , ))

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TRUE POSITION AREA METHOD
k = radius to process center 𝑘= 𝑋 +𝑌 Actual TP
Y Axis average center

Actual TP
TP nominal center line 3s radial zone r
X Axis

TP tolerance radial zone R

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TRUE POSITION AREA METHOD
k = radius to process center 𝑘= 𝑋 +𝑌 Actual TP
Y Axis average center

Actual TP
TP nominal center line 3s radial zone r
X Axis

TP tolerance radial zone R

Consumed Process 𝐴𝑟𝑒𝑎𝑃𝑝𝑘=

Variation diameter zone ( )
(for Ppk calc.)
𝑃𝑝𝑘 = min(𝑃 , 𝑃 )
𝐴𝑟𝑒𝑎𝑃𝑝𝑘=
𝑈𝑆𝐿 − 𝑋 (
𝑃 = ( , ))
3𝑠

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TRUE POSITION AREA METHOD
k = radius to process center 𝑘= 𝑋 +𝑌 Actual TP
Y Axis average center

Actual TP
TP nominal center line 3s radial zone r
X Axis
Actual TP variability +
feature MMC bonus variability
TP tolerance radial zone R
(Pooled 6s diameter zone )

Consumed Process
Variation diameter zone
(for Ppk calc.)

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TRUE POSITION AREA METHOD
k = radius to process center 𝑘= 𝑋 +𝑌 Actual TP
average center

Actual TP
TP nominal center line 3s radial zone r

Actual TP variability +
feature MMC bonus variability
TP tolerance radial zone R
(Pooled 6s diameter zone )

Consumed Process
TP tolerance + Variation diameter zone
Convert Bonus feature MMC bonus (for Ppk calc.)
𝐴𝑟𝑒𝑎𝑃𝑝𝑘=
to radial diameter zone ( )

(𝑅 + 0.5 ∗ 𝐵𝑜𝑛𝑢𝑠 ) (𝑅 + 0.5 ∗ 𝐵𝑜𝑛𝑢𝑠 )

𝐴𝑟𝑒𝑎𝑃𝑝 = 𝐴𝑟𝑒𝑎𝑃𝑝𝑘 =
(3 𝑠 ( , ) +𝑠 ) ( 𝑋 +𝑌 +3 𝑠 ( , ) +𝑠 )

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TRUE POSITION AREA METHOD
Area Pp without MMC Bonus Area Ppk without MMC bonus

𝑅
𝐴𝑟𝑒𝑎𝑃𝑝 = 𝐴𝑟𝑒𝑎𝑃𝑝𝑘=
(3𝑠 ( , ))
( ( , ))

Area Pp with MMC Bonus Area Ppk with MMC Bonus

(𝑅 + 0.5 ∗ 𝐵𝑜𝑛𝑢𝑠 ) (𝑅 + 0.5 ∗ 𝐵𝑜𝑛𝑢𝑠 )

𝐴𝑟𝑒𝑎𝑃𝑝 = 𝐴𝑟𝑒𝑎𝑃𝑝𝑘 =
(3 𝑠 ( , ) +𝑠 ) ( 𝑋 +𝑌 +3 𝑠 ( , ) +𝑠 )

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TRUE POSITION AREA METHOD
PreControl type chart to monitor
1. Diameter
2. X-axis
3. Y-axis
4. TP Dia
5. X-Y Plot

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TRUE POSITION AREA METHOD
Example without Bonus

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TRUE POSITION AREA METHOD
Example with Bonus

Special recognition goes to Paul McAdam,

retired P&WC Quality Fellow, who did
most of the development of these
methods.

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SUMMARY
Have quality data you can trust (MSA)
Have enough data to capture full process variability
Make sure your process is stable (Control Charts)
Choose the correct distribution
Choose the appropriate capability Indices to evaluate your process (Ppk preferred, Area Method for TP)
Track and improve!

AESQ – Aerospace Engine Supplier Quality Strategy Group

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confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
FUTURE WEBINARS
From the Process Control Methods SMIG Group

Look for these

future topics in
the “Upcoming
Events” page on
the AESQ
website:

https://aesq.sae-
itc.com/interest-
groups

AESQ – Aerospace Engine Supplier Quality Strategy Group

This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and 41
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
 Q & A SESSION

USE THE “CHAT” FUNCTION

TO ASK A QUESTION…

AESQ – Aerospace Engine Supplier Quality Strategy Group

This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
SUMMARY
All resources will be
available on the AESQ
website within a few
days.

An email will be sent to

all registrants with a link.

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AESQ – Aerospace Engine Supplier Quality Strategy Group
This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
THANK YOU FOR PARTICIPATING

AESQ – Aerospace Engine Supplier Quality Strategy Group

44
This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.