Chapter 3

Statistical Process Control

3-1
 Lecture Outline
• Basics of Statistical Process Control
• Control Charts
• Control Charts for Attributes
• Control Charts for Variables
• Control Chart Patterns
• SPC with Excel and OM Tools
• Process Capability

S.R.DUTTA 3-2
 Statistical Process Control (SPC)
• Statistical Process Control
• monitoring production process
to detect and prevent poor UCL
quality
• Sample
• subset of items produced to
use for inspection LCL
• Control Charts
• process is within statistical
control limits

S.R.DUTTA 3-3
 Process Variability
• Random • Non-Random
• inherent in a process • special causes
• depends on equipment • identifiable and
and machinery, correctable
engineering, operator, • include equipment out of
and system of adjustment, defective
measurement materials, changes in
• natural occurrences parts or materials, broken
machinery or equipment,
operator fatigue or poor
work methods, or errors
due to lack of training

S.R.DUTTA. 3-4
 SPC in Quality Management
• SPC uses
• Is the process in control?
• Identify problems in order to make
improvements
• Contribute to the TQM goal of continuous
improvement

S.R.DUTTA. 3-5
 Quality Measures:
Attributes and Variables
• Attribute
• A characteristic which is evaluated with a
discrete response
• good/bad; yes/no; correct/incorrect
• Variable measure
• A characteristic that is continuous and can be
measured
• Weight, length, voltage, volume

S.R.DUTTA 3-6
 SPC Applied to Services
• Nature of defects is different in services
• Service defect is a failure to meet customer
requirements
• Monitor time and customer satisfaction

S.R.DUTTA 3-7
 SPC Applied to Services

• Hospitals
• timeliness & quickness of care, staff responses to requests,
accuracy of lab tests, cleanliness, courtesy, accuracy of
paperwork, speed of admittance & checkouts
• Grocery stores
• waiting time to check out, frequency of out-of-stock items, quality
of food items, cleanliness, customer complaints, checkout
register errors
• Airlines
• flight delays, lost luggage & luggage handling, waiting time at
ticket counters & check-in, agent & flight attendant courtesy,
accurate flight information, cabin cleanliness & maintenance

S.R.DUTTA 3-8
 SPC Applied to Services

• Fast-food restaurants
• waiting time for service, customer complaints, cleanliness, food
quality, order accuracy, employee courtesy
• Catalogue-order companies
• order accuracy, operator knowledge & courtesy, packaging,
delivery time, phone order waiting time
• Insurance companies
• billing accuracy, timeliness of claims processing, agent
availability & response time

S.R.DUTTA. 3-9
 Where to Use Control Charts
• Process
• Has a tendency to go out of control
• Is particularly harmful and costly if it goes out of control
• Examples
• At beginning of process because of waste to begin
production process with bad supplies
• Before a costly or irreversible point, after which product is
difficult to rework or correct
• Before and after assembly or painting operations that
might cover defects
• Before the outgoing final product or service is delivered

S.R.DUTTA 3-10
 Control Charts
• A graph that monitors process quality
• Control limits
• upper and lower bands of a control chart
• Attributes chart
• p-chart
• c-chart
• Variables chart
• mean (x bar – chart)
• range (R-chart)

S.R.DUTTA 3-11
 Process Control Chart
Out of control
Upper
control
limit

Process
average

Lower
control
limit

1 2 3 4 5 6 7 8 9 10
Sample number

S.R.DUTTA. 3-12
 Normal Distribution
• Probabilities for Z= 2.00 and Z = 3.00

95%
99.74%
-3 -2 -1 =0 1 2 3

S.R.DUTTA. 3-13
 A Process Is in Control If …

1. … no sample points outside limits

2. … most points near process average
3. … about equal number of points above
and below centerline
4. … points appear randomly distributed

S.R.DUTTA 3-14
 Control Charts for Attributes
• p-chart
• uses portion defective in a sample

• c-chart
• uses number of defects (non-conformities) in a
sample

S.R.DUTTA 3-15
 p-Chart

UCL = p + zp
LCL = p - zp
z = number of standard deviations from process
average
p = sample proportion defective; estimates
process mean
p = standard deviation of sample proportion
p(1 - p)
p =
n

S.R.DUTTA 3-16
 Construction of p-Chart

NUMBER OF PROPORTION
SAMPLE # DEFECTIVES DEFECTIVE
1 6 .06
2 0 .00
3 4 .04
: : :
: : :
20 18 .18
200

20 samples of 100 pairs of jeans

S.R.DUTTA. 3-17
 Construction of p-Chart

total defectives
p= = 200 / 20(100) = 0.10
total sample observations

p(1 - p) 0.10(1 - 0.10)

UCL = p + z = 0.10 + 3
n 100
UCL = 0.190

p(1 - p) 0.10(1 - 0.10)

LCL = p - z = 0.10 - 3
n 100
LCL = 0.010

S.R.DUTTA. 3-18
 Construction of p-Chart
0.20

0.18 UCL = 0.190

0.16

0.14
Proportion defective

0.12
p = 0.10
0.10

0.08

0.06

0.04

0.02 LCL = 0.010

2 4 6 8 10 12 14 16 18 20
Sample number

S.R.DUTTA 3-19
 p-Chart in Excel
Click on “Insert” then “Charts”

to construct control chart

I4 + 3*SQRT(I4*(1-I4)/100)

I4 - 3*SQRT(I4*(1-I4)/100)

Column values copied

from I5 and I6
S.R.DUTTA. 3-20
 c-Chart
UCL = c + zc
c = c
LCL = c - zc

where
c = number of defects per sample

S.R.DUTTA. 3-21
 c-Chart
Number of defects in 15 sample rooms
NUMBER
SAMPLE OF
DEFECTS
190
1 12 c= = 12.67
15
2 8
UCL = c + zc
3 16
= 12.67 + 3 12.67
: : = 23.35
: : LCL = c - zc
15 15
= 12.67 - 3 12.67
190 = 1.99

S.R.DUTTA 3-22
c-Chart
24
UCL = 23.35
21

18

Number of defects
c = 12.67

15

12

3 LCL = 1.99

2 4 6 8 10 12 14 16
Sample number

S.R.DUTTA 3-23
 Control Charts for Variables
 Range chart ( R-Chart )
 Plot sample range (variability)
 Mean chart ( x -Chart )
 Plot sample averages

S.R.DUTTA. 3-24
 x-bar Chart:  Known

UCL = x=+ z x-

=
LCL = x - z x-
Where
= x- 1 + x- 2 + ... + x- k
X=
k
s = process standard deviation
s x = standard deviation of sample means =/ n
k = number of samples (subgroups)
n = sample size (number of observations)

S.R.DUTTA 3-25
x-bar Chart Example:  Known
Observations(Slip-Ring Diameter, cm) n

Sample k 1 2 3 4 5 x-

We know σ = .08

S.R.DUTTA. 3-26
 x-bar Chart Example:  Known

= _____
50.09
X= = 5.01
10
=
UCL = x + z -x LCL = x=- z x-
= 5.01 + 3(.08 / 10) = 5.01 - 3(.08 / 10)
= 5.09 = 4.93

S.R.DUTTA. 3-27
x-bar Chart Example:  Unknown

_ _
= =
UCL = x + A2R LCL = x - A2R

where
=
x = average of the sample means
_
R = average range value

S.R.DUTTA 3-28
Control Sample
Size Factor for X-chart Factors for R-chart
n A2 D3 D4
Chart 2
3
1.880
1.023
0.000
0.000
3.267
2.575

Factors 4
5
0.729
0.577
0.000
0.000
2.282
2.114
6 0.483 0.000 2.004
7 0.419 0.076 1.924
8 0.373 0.136 1.864
9 0.337 0.184 1.816
10 0.308 0.223 1.777
11 0.285 0.256 1.744
12 0.266 0.283 1.717
13 0.249 0.307 1.693
14 0.235 0.328 1.672
15 0.223 0.347 1.653
16 0.212 0.363 1.637
17 0.203 0.378 1.622
18 0.194 0.391 1.609
19 0.187 0.404 1.596
20 0.180 0.415 1.585
21 0.173 0.425 1.575
22 0.167 0.435 1.565
23 0.162 0.443 1.557
24 0.157 0.452 1.548
25 0.153 0.459 1.541

S.R.DUTTA 3-29
 x-bar Chart Example:  Unknown
OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
Totals 50.09 1.15

S.R.DUTTA 3-30
x-bar Chart Example:  Unknown
_ ∑R 1.15
____ ____
R= k = 10 = 0.115

= åx
___ 50.09
_____
x= = = 5.01 cm
k 10
_
=
UCL = x + A2R = 5.01 + (0.58)(0.115) = 5.08
_
=
LCL = x - A2R = 5.01 - (0.58)(0.115) = 4.94

S.R.DUTTA 3-31
 x- bar 5.10 –
Chart 5.08 –
Example 5.06 –
UCL = 5.08

5.04 –

5.02 – =
Mean x = 5.01

5.00 –

4.98 –

4.96 –
LCL = 4.94
4.94 –

4.92 –
| | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number

S.R.DUTTA 3-32
 R- Chart

UCL = D4R LCL = D3R

åR
R=
k
Where
R = range of each sample
k = number of samples (sub groups)

S.R.DUTTA 3-33
 R-Chart Example
OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k 1 2 3 4 5 x R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
Totals 50.09 1.15

S.R.DUTTA 3-34
 R-Chart Example
_
UCL = D4R = 2.11(0.115) = 0.243
_
LCL = D3R = 0(0.115) = 0

Retrieve chart factors D3 and D4

S.R.DUTTA 3-35
 R-Chart Example

0.28 –
0.24 – UCL = 0.243
0.20 –
Range

0.16 – R = 0.115
0.12 –
0.08 –
0.04 – LCL = 0
| | | | | | | | | |
0–
1 2 3 4 5 6 7 8 9 10
Sample number

S.R.DUTTA 3-36
X-bar and R charts – Excel & OM Tools

S.R.DUTTA 3-37
 Using x- bar and R-Charts Together

• Process average and process variability must be

in control
• Samples can have very narrow ranges, but
sample averages might be beyond control limits
• Or, sample averages may be in control, but
ranges might be out of control
• An R-chart might show a distinct downward
trend, suggesting some nonrandom cause is
reducing variation

S.R.DUTTA 3-38
 Control Chart Patterns
• Run
• sequence of sample values that display same
characteristic
• Pattern test
• determines if observations within limits of a control
chart display a nonrandom pattern

S.R.DUTTA 3-39
 Control Chart Patterns
• To identify a pattern look for:
• 8 consecutive points on one side of the center line
• 8 consecutive points up or down
• 14 points alternating up or down
• 2 out of 3 consecutive points in zone A (on one side of
center line)
• 4 out of 5 consecutive points in zone A or B (on one
side of center line)

S.R.DUTTA 3-40
 Control Chart Patterns

UCL UCL

LCL LCL

Sample observations Sample observations

consistently below the consistently above the
center line center line

S.R.DUTTA 3-41
 Control Chart Patterns

UCL UCL

LCL LCL

Sample observations Sample observations

consistently increasing consistently decreasing

S.R.DUTTA 3-42
 Zones for Pattern Tests
UCL =
3 sigma = x + A2R
Zone A
=
2 sigma = x + 2 (A2R)
3
Zone B
=
1 sigma = x + 1 (A2R)
3

Process Zone C =
x
average
Zone C
=
1 sigma = x - 1 (A2R)
3
Zone B
=
2 sigma = x - 2 (A2R)
3
Zone A
=
LCL 3 sigma = x - A2R
| | | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12 13
Sample number

S.R.DUTTA 3-43
 Performing a Pattern Test

SAMPLE x ABOVE/BELOW UP/DOWN ZONE

1 4.98 B — B
2 5.00 B U C
3 4.95 B D A
4 4.96 B D A
5 4.99 B U C
6 5.01 — U C
7 5.02 A U C
8 5.05 A U B
9 5.08 A U A
10 5.03 A D B

S.R.DUTTA 3-44
 Sample Size Determination

• Attribute charts require larger sample sizes

• 50 to 100 parts in a sample

• Variable charts require smaller samples

• 2 to 10 parts in a sample

S.R.DUTTA 3-45
 Process Capability

• Compare natural variability to design variability

• Natural variability
• What we measure with control charts
• Process mean = 8.80 oz, Std dev. = 0.12 oz
• Tolerances
• Design specifications reflecting product
requirements
• Net weight = 9.0 oz  0.5 oz
• Tolerances are  0.5 oz

S.R.DUTTA 3-46
 Process Capability
Design
Specifications

(a) Natural variation

exceeds design
specifications; process is
not capable of meeting
specifications all the
time.
Process
Design
Specifications

(b) Design specifications

and natural variation the
same; process is capable
of meeting specifications
most of the time.

Process

S.R.DUTTA 3-47
 Process Capability
Design
Specifications

(c) Design specifications

greater than natural
variation; process is
capable of always
conforming to
specifications.
Process
Design
Specifications

(d) Specifications greater

than natural variation, but
process off center; capable
but some output will not
meet upper specification.

Process

S.R.DUTTA 3-48
 Process Capability Ratio

tolerance range
Cp =
process range

upper spec limit - lower spec limit

=
6

S.R.DUTTA 3-49
 Computing Cp

Net weight specification = 9.0 oz  0.5 oz

Process mean = 8.80 oz
Process standard deviation = 0.12 oz

upper specification limit -

lower specification limit
Cp =
6

9.5 - 8.5
= = 1.39
6(0.12)

S.R.DUTTA 3-50
 Process Capability Index

=
x - lower specification limit
,
Cpk = minimum 3
=
upper specification limit - x
3

S.R.DUTTA 3-51
 Computing Cpk

Net weight specification = 9.0 oz  0.5 oz

Process mean = 8.80 oz
Process standard deviation = 0.12 oz
=
x - lower specification limit
,
Cpk = minimum 3
=
upper specification limit - x
3

8.80 - 8.50 9.50 - 8.80

= minimum , = 0.83
3(0.12) 3(0.12)

S.R.DUTTA 3-52
Process Capability With Excel

=(D6-D7)/(6*D8)

See formula bar

S.R.DUTTA 3-53
Process Capability With OM Tools

S.R.DUTTA. 3-54
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S.R.DUTTA 3-55