Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery.

1
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 2
Copyright (c) 2009 John Wiley & Sons, Inc.
 Learning Objectives

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 3

Copyright (c) 2009 John Wiley & Sons, Inc.
 Process Capability

Natural tolerance limits are defined

as follows:

Chapter 8 4
Uses of process capability data:

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 5

Copyright (c) 2009 John Wiley & Sons, Inc.
 Reasons for Poor Process Capability

Process may have

good potential
capability

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 6

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 7
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 8
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 9
Copyright (c) 2009 John Wiley & Sons, Inc.
 Probability Plotting

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 10

Copyright (c) 2009 John Wiley & Sons, Inc.
 • The distribution may not be normal; other types
of probability plots can be useful in determining
th appropriate
the i t distribution.
di t ib ti
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 11
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 12
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 13
Copyright (c) 2009 John Wiley & Sons, Inc.
 For the hard bake process:

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 14

Copyright (c) 2009 John Wiley & Sons, Inc.
 One-Sided
One Sided PCR

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 15

Copyright (c) 2009 John Wiley & Sons, Inc.
 Interpretation of the PCR

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 16

Copyright (c) 2009 John Wiley & Sons, Inc.
Assumptions for Interpretation of Numbers in
T bl 8.2
Table 82

• Violation of these assumptions can lead to big trouble in

using the data in Table 8.2.

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 17

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 18
Copyright (c) 2009 John Wiley & Sons, Inc.
 • Cp does not take
process centering
into account
• It is a measure
of potential
capability, not
actual capability

Chapter 8 19
 A Measure of Actual Capability

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 20

Copyright (c) 2009 John Wiley & Sons, Inc.
 Normalityy and Process Capability
p y Ratios

• The assumption
p of normalityy is critical to the usual
interpretation of these ratios (such as Table 8.2)
• For non-normal data, options are
1. Transform non-normal data to normal
2. Extend the usual definitions of PCRs to handle
non-normall data
d t
3. Modify the definitions of PCRs for general
families of distributions

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 21

Copyright (c) 2009 John Wiley & Sons, Inc.
 Other Types of Process Capability Ratios

• First generation
• Second generation
• Third generation
• Lots of research has been done to develop ratios that
overcome some of the problems with the basic ones
• Not much evidence that these ratios are used to any
ssignificant
g c eextent e in practice
p c ce

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 22

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 23
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 24
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 25
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 26
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 27
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 28
Copyright (c) 2009 John Wiley & Sons, Inc.
Process Capability
Analysis using Control
Charts

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 29

Copyright (c) 2009 John Wiley & Sons, Inc.
 Since LSL = 200

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 30

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 31
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 32
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 33
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 34
Copyright (c) 2009 John Wiley & Sons, Inc.
 8.7 Gauge and Measurement Systems
Capability Studies
• Determine how much of the observed variability is
due to the gauge or measurement system
• Isolate the components of variability in the
measurement system
• Assess whether the gauge is capable (suitable for the
intended application)

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 35

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 36
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 37
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 38
 The P/T (precision-to-tolerance) ratio:

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 39

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 40
Copyright (c) 2009 John Wiley & Sons, Inc.
 Estimating the Variance Components

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 41

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 42
Copyright (c) 2009 John Wiley & Sons, Inc.
 The gauge is not capable by this criterion
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 43
Copyright (c) 2009 John Wiley & Sons, Inc.
 Discrimination Ratio

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 44

Copyright (c) 2009 John Wiley & Sons, Inc.
 Accuracy and Precision

We have
focused only
on precision

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 45

Copyright (c) 2009 John Wiley & Sons, Inc.
 Gauge R&R Studies

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 46

Copyright (c) 2009 John Wiley & Sons, Inc.
 Gauge R&R Studies Are Usually Conducted
with a Factorial Experiment

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 47

Copyright (c) 2009 John Wiley & Sons, Inc.
 This is a two-factor factorial experiment
ANOVA methods are used to analyze the data and to
estimate the variance components

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 48

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 49
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 50
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 51
Copyright (c) 2009 John Wiley & Sons, Inc.
 • Negative estimates of a variance component
would lead to filling a reduced model, such as,
f example:
for l

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 52

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 53
Copyright (c) 2009 John Wiley & Sons, Inc.
 For this Example

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 54

Copyright (c) 2009 John Wiley & Sons, Inc.
 Other Topics in Gauge R&R Studies

• Section 8.7.3 pprovides a description

p of methods to
obtain confidence intervals on the variance
components and measures of gauge R&R

• Section 8.7.4 presents a new measure of gauge

capability the probabilities of misclassification of
capability,
parts
– Rejecting
j g good
g units (producer’s
(p risk))
– Passing bad units (consumer’s risk)
– Methods for calculating these two probabilities are given

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 55

Copyright (c) 2009 John Wiley & Sons, Inc.
 8.7.5 Attribute Gauge Capability
• Sometimes the output of a gauge isn’t numerical – it’s just
pass/fail
• Nominal or ordinal data is also common
• Occurs frequently in service businesses
• Common situation – do operating personnel consistently make
the same decisions regarding the units they are inspecting or
analyzing
• Example
E l – a bank
b k uses manuall underwriting
d iti off mortgage
t loans
l
• The underwriter uses information to classify the applicant into
one of four categories; decline or category 1, 2, 3 – categories
2 & 3 are low-risk and 1 is high risk
• Compare underwriters performance relative to a “consensus”
evaluation determined byy a ppanel of “experts”
p

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 56

Copyright (c) 2009 John Wiley & Sons, Inc.
 Thirty applicants,
three underwriters
Each underwriter
evaluates each
application twice
The applications are
“blinded” by
removingg names,,
SSNs, addresses,
and other identifying
information

Chapter 8 57
 Attribute Gauge Capability
• Determine the proportion of time that the underwriter
agrees with him/herself – this measures repeatability
• Determine the proportion of time that the underwriter
agrees
g with the correct classification – this measures
bias
• Minitab pperforms the analysis
y – usingg the attribute
agreement analysis routine

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 58

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 59
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 60
Copyright (c) 2009 John Wiley & Sons, Inc.
 8.8 Setting Specifications on Discrete
Components
• Components interact with other components
• Complex assemblies
• Tolerance stack-up problems
• Linear combinations
• Nonlinear combinations

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 61

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 62
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 63
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 64
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 65
Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 66
Copyright (c) 2009 John Wiley & Sons, Inc.
 8.9 Estimating the Natural Tolerance
Limits
i i off a Process

For a normal distribution with unknown mean and variance:

• Difference between tolerance limits and confidence limits

• Nonparametric tolerance limits can also be calculated

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 67

Copyright (c) 2009 John Wiley & Sons, Inc.
Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 68
Copyright (c) 2009 John Wiley & Sons, Inc.
 Learning Objectives

Chapter 8 Introduction to Statistical Quality Control, 6th Edition by Douglas C. Montgomery. 69

Copyright (c) 2009 John Wiley & Sons, Inc.