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Process Capability To Prevent Failures: K.P.S.Verma

The document discusses process capability and related terms. Process capability is a measure of a machine/process's ability to manufacture items within customer specifications. Key terms include lower/upper specification limits, control limits, mean, standard deviation, Cp, Cpk. An optimal process capability is 1.33-1.5, allowing for reduced inspection. Both Cp and maintaining the mean close to the specification range midpoint are important for process control.

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euserodriguez
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33 views

Process Capability To Prevent Failures: K.P.S.Verma

The document discusses process capability and related terms. Process capability is a measure of a machine/process's ability to manufacture items within customer specifications. Key terms include lower/upper specification limits, control limits, mean, standard deviation, Cp, Cpk. An optimal process capability is 1.33-1.5, allowing for reduced inspection. Both Cp and maintaining the mean close to the specification range midpoint are important for process control.

Uploaded by

euserodriguez
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Process Capability To Prevent

Failures

K.P.S.Verma
Statistics: Friend of Ignorant

• All of us use statistics in day to day life.


• Grand Mother gave remedies based on
statistics.
• Intuition or hunch is statistics of
subconscious mind
Statistics: Honesty in use is
MUST

• Use data to arrive at inferences


• Do not justify your pet ideas by USING or
rather MISUSING data.
Knowledge vs Problem Solving
Potential
Knowledge Prob.Sol.Pot Remarks

5% 80% laymen
( Basic of Basics)
15% 95% Basics(7 tools+PC)
15-100% >95% Expert
Seven Tools Of SQC

• Trend chart or Graph


• Stratification
• Frequency Curve
• Histograms
• Pareto Diagram
• Control Charts
• Cause Effect diagram(Fishbone Diagram)
Process Capability

Process capability of a machine/process/system is


index of capability of Machine/Process/System
to do the assigned job. It is a measure of its
capability in quantitative terms to manufacture
item to customer's satisfaction.
Process Capability

When to undertake process capability studies


1. Periodically as a measure of quality control
2. Mandatory when new product started
3. Mandatory when process altered
4. Mandatory when specs changed
5. When vendor rating is to be done
6. Shortlisting the vendors
Process Capability-terms used
• LSL-Lower Specified Limit
• USL-Upper Specified Limit
• LCL-Lower Control Limit
• UCL-Upper Control Limit
• Mean-Average of Data
Process Capability-terms used

• Central tendency
• Standard Deviation
Process Capability
• Mathematically Process Capability is
defined as

USL-LSL USL-LSL
CP = ---------- = -----------
UCL-LCL 6σ
Upper and Lower Process
Capability
Mean-LSL USL-LSL
CPL = ---------- = -----------
Mean-LCL 3σ

USL-Mean USL-Mean
CPU =---------- = ----------
USL-Mean 3σ
Critical Process Capability

Smaller of two values, that is, of lower and


upper Capability is termed as critical
process capability and is denoted by CPK
Process Capability
Process capability Defectives

1.00 0.27%
1.33 64 ppm
1.66 5 ppm
2.00 <0.1 ppm
Process Capability

Some home truths about process capability


 
1.   If Cp is high, >1.5, you can reduce inspection
2.   If Cp is too high, >2, you probably have purchased
too costly a m/c. Your product cost will go up
3.   Cp of 1.33 to 1.50 is optimum for most industrial
applications
 
Process Capability
Some home truths about process capability
 
1.   If Cp is high, >1.5, you can reduce inspection
2.   If Cp is too high, >2, you probably have purchased
too costly a m/c. Your product cost will go up
3.   Cp of 1.33 to 1.50 is optimum for most industrial
applications
 
Note: When you accept a m/c after overhaul or tool
change check central tendency.
CP and CPK
• If CP > 1.0, it is considered barely satisfactory but
regular rejections likely as CPK will almost
always be lower than 1.
 
• If CP is >1.33 but CPK very low (<1.0), the
machine is capable but process not under control.
This happens when central tendency of data is far
away from middle of specified range.
CP and CPK…contd
• In practical terms it means that initial setting of
tools, zigs & fixtures is not correct. With trial &
error, central tendency should be brought very
close to mean value of USL & LSL.

• A low CP is more difficult problem. You may


have to overhaul machine or buy new one. Or
change specification if it does not hurt customer.
Though CPK is called critical process capability
index, it is CP which is more critical problem to
handle. If CP is OK but CPK is low, you have to do
trial error or make adjustments to bring CPk
preferably more than 1.33

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