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Statistical Process Control: Variable and Attribute Charts

This document discusses statistical process control and different types of control charts used for variable and attribute data. It explains that control charts can be used to monitor processes and identify special causes of variation. Variable charts like X-bar and R charts are used for measurable quality characteristics, while attribute charts like p, np, c, and u charts are used for non-measurable defects. The document evaluates different attribute chart options for monitoring defects in a garment manufacturing process and recommends creating separate c charts for each defect type based on defect counts rather than fractions. This approach would make it easier to identify root causes of quality issues.

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AKIN KAYODE
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51 views34 pages

Statistical Process Control: Variable and Attribute Charts

This document discusses statistical process control and different types of control charts used for variable and attribute data. It explains that control charts can be used to monitor processes and identify special causes of variation. Variable charts like X-bar and R charts are used for measurable quality characteristics, while attribute charts like p, np, c, and u charts are used for non-measurable defects. The document evaluates different attribute chart options for monitoring defects in a garment manufacturing process and recommends creating separate c charts for each defect type based on defect counts rather than fractions. This approach would make it easier to identify root causes of quality issues.

Uploaded by

AKIN KAYODE
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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STATISTICAL PROCESS

CONTROL

VARIABLE AND ATTRIBUTE CHARTS

Presented By :
Surya Bakshi
 Statistical Process Control is
 a technique used within the TQM framework
 Aims to reduce variation in processes
 control, manage, analyze and improve the
performance
 eliminates special causes of variation
 defective products,
 operator error,
 errors in measurements
CONCEPTS
 PROCESS
 Is a set of interrelated or interacting activities which
transform inputs into outputs.
 VARIATION
 No two products are exactly alike due to sources of
variability
 Sources of variation : speed of the operator, accuraccy,
procedure followed, variation over time.
Advantages of maintaining a state
of Statistical Control
 Variation( inherent) is restricted to common causes

 Since variability exhibits a regularity in pattern,


the process is repeatable

 Since process is repeatable, quality of future


production can be predicted.
SPC is a strategy of Defect prevention which aims
 To increase the knowledge about any process

 To steer a process to behave in the desired way

 To reduce variation in the product or in other ways

to improve performance of the process


 To reduce cost and increase profit by improving the

performance of the process


 Increase consistency of the process
 Periodic sampling of products from the process and
inspecting them for characteristic under
cosideration
 Computing a suitable index of quality for each
statistic
 Taking actions to detect and eliminate special
causes wherever control limits are exceeded
 Leaving the process alone when there’s no
evidence of “out of control”
 Control charts or graphical trend analysis are
used to understand changes in the process
mean and process standard deviation.

 Process variation
 adds needless cost to the product
 reason why a product does not comply with
specifications
 are a graphical device to aid in process control
 Control chart consists of:
 Points representing a quality characteristic in
samples under observation
 A Centre line, drawn at the process characteristic

mean, which is calculated from the data.


 Upper and Lower Control Limits that indicate the

threshold at which the process output is


considered statistically 'unlikely'.
 Control Chart technique can be used for both
Variable and Attributes.
 Measurement or Variables
 quality characteristics which can be measured
 Attribute
 quality characteristics that can be evaluated with a
discrete response
 not measurable on the quantitative scale
 Data obtained by classification or counting are called
 There are four types of attribute charts used for
 non measurable defect controlling and
 defectives controlling

 N and NP Charts for the control of number of


defectives or non- conforming
 C and U – Charts for the control of the defects or non-
conformities
• Used at places where
▫ various defects could occur in a single product that is being
manufactured

• Fixed sample size , 13 in this case as per 2.5 AQL


• The proportion of defectives are
▫ plotted and
▫ analyzed for improvement of the process
 The graph is made from the quality checks done in the front
section of Jackets Line 3 for three consecutive days

 The plotting shows that the process is shown to be


 within limits and
 very much stabilized
 the UCL is far beyond the fraction of defectives that have been
plotted.

 Hence if this chart is applied it will


 not solve the purpose
 identifying the process instability is difficult.
 Used at places where
 various defects could occur
 product wise checking

 variable sample size


 The UCL and LCL are calculated
 on hourly basis
 on the last hour’s data available
 The chart is
 very time taking to be prepared
 The Quality Checker has to be trained
 Follow up to let them know how to prepare it.
 The same problem of data always show within control
persists

 Hence, the chart cannot be used.

 The two chart applicable to check no. of defectives


is ruled out.
 The C Chart and the U chart are used to assess defects
occurring in the product individually.

 The U chart is used at places where


 The defects are checked to be present as per a specific unit,
 For example is carpet making
 The defect per square unit area is checked in this case.

 There is no such unit that can segregate the garment


defects hence U chart is also not applied in this case.
• The C chart loses its characteristic of showing

▫ the no. of defects present


▫ the fractional values are plotted

• The C Chart previously

▫ Was used for several defects


▫ It is difficult to asses as to which defect led to the inconsistency
▫ Hence should be used for a single defect.
 Preparation of separate chart for different defect
that has to be checked

 The no. of defects instead of fractions should be


plotted on hourly basis

 the UCL and LCL for the next day to be calculated


on the basis of the last day’s data

 THE NEW CHART proposed to be implemented.


 The new chart
 shows the situations out of control where the defect
needs to be checked
 makes it easier to identify the root cause of the defect
 when it happened
 where it happened
 who did it and
 proper steps can be taken to mend it, and
 record is maintained for the future reference

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