Statistical process control notes
Statistical process control notes
Process Control
Improved Increased
Quality Profits
Reduced Costs via
• Increased productivity
• Lower rework and scrap costs
• Lower warranty costs
Internal Failure
Prevention
Appraisal
Quality Improvement
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Weight
Figure S6.1
© 2014 Pearson Education, Inc. S6 - 18
Samples
To measure the process, we take samples and
analyze the sample statistics following these
steps
The solid line
(b) After enough samples represents the
are taken from a stable distribution
process, they form a
pattern called a
distribution
Frequency
Weight
Figure S6.1
© 2014 Pearson Education, Inc. S6 - 19
Samples
To measure the process, we take samples and
analyze the sample statistics following these
steps
(c) There are many types of distributions, including the normal (bell-
shaped) distribution, but distributions do differ in terms of central
tendency (mean), standard deviation or variance, and shape
Figure S6.1
Frequency
e
Tim
Weight
Figure S6.1
e
Tim
Weight
Figure S6.1
Size
(weight, length, speed, etc.) Figure S6.2
© 2014 Pearson Education, Inc. S6 - 24
Random variable
The first formula says that if we could take every possible sample from the
population and compute the corresponding sample mean, then those numbers
would center at the number we wish to estimate, the population mean μ.
The second formula says that averages computed from samples vary less than
individual measurements on the population do, and quantifies the relationship.
© 2014 Pearson Education, Inc. S6 - 27
Population and Sampling Distributions
A sampling distribution is the theoretical distribution of a sample statistic that
would be obtained from a large number of random samples of equal size from a
population. Consequently, the sampling distribution serves as a statistical “bridge”
between a known sample and the unknown population.
Population Distribution of
distributions sample means
Uniform
| | | | | | |
Average mean
of 12 samples
Average mean
of 12 samples
17 = UCL
Variation due to
16 = Mean natural causes
15 = LCL
Variation due
| | | | | | | | | | | |
to assignable
1 2 3 4 5 6 7 8 9 10 11 12 Out of causes
Sample number control
UCL = 12.144
Mean = 12
From Table
S6.1
LCL = 11.856
where
UCL = 11.2
Mean = 5.3
LCL = 0
UCL
(x-chart detects
x-chart shift in central
tendency)
LCL
UCL
(R-chart does not
R-chart detect change in
mean)
LCL
Figure S6.5
© 2014 Pearson Education, Inc. S6 - 41
Mean and Range Charts
(b)
These
sampling (Sampling mean
distributions is constant, but
result in the dispersion is
charts below increasing)
UCL
(x-chart indicates
x-chart no change in
central tendency)
LCL
UCL
(R-chart detects
R-chart increase in
dispersion)
LCL
Figure S6.5
© 2014 Pearson Education, Inc. S6 - 42
Example
e r c e nt
p
.11 –
.10 – UCLp = 0.10
.09 –
Fraction defective
.08 –
.07 –
.06 –
.05 –
.04 – p = 0.04
.03 –
.02 –
.01 – LCLp = 0.00
.00 – | | | | | | | | | |
2 4 6 8 10 12 14 16 18 20
Sample number
.08 –
.07 –
.06 –
.05 –
.04 – p = 0.04
.03 –
.02 –
.01 – LCLp = 0.00
.00 – | | | | | | | | | |
2 4 6 8 10 12 14 16 18 20
Sample number
UCLc = 13.35
14 –
Number defective
12 –
10 –
8 –
6 – c= 6
4 –
2 – LCLc = 0
0 – | | | | | | | | |
1 2 3 4 5 6 7 8 9
be a
Cannot mber Day
e nu
negativ
© 2014 Pearson Education, Inc. S6 - 60
Managerial Issues and
Control Charts
Three major management decisions:
► Select points in the processes that
need SPC
► Determine the appropriate charting
technique
► Set clear policies and procedures
Target
Figure S6.7
Target
Figure S6.7
Target
Figure S6.7
Target
Figure S6.7
Target
Figure S6.7
Target
Figure S6.7
(.251) - .250
Cpk = minimum of ,
(3).0005
Cpk = zero
Cpk = 1
Cpk > 1
Lower Upper
specification specification
limit limit
© 2014 Pearson Education, Inc. S6 - 80
Acceptance Sampling
► Form of quality testing used for incoming
materials or finished goods
► Take samples at random from a lot
(shipment) of items
► Inspect each of the items in the sample
► Decide whether to reject the whole lot
based on the inspection results
► Only screens lots; does not drive quality
improvement efforts
100 –
75 – Return whole
shipment
50 –
Cut-Off
25 –
| | | | | | | | | | |
0 –
0 10 20 30 40 50 60 70 80 90 100
% Defective in Lot
Probability of
Acceptance
= 0.10 | | | | | | | | | Percent
0 1 2 3 4 5 6 7 8 defective
Consumer’s AQL LTPD
risk for LTPD Good Indifference
Bad lots
lots zone
n = 50, c = 1
n = 100, c = 2
(Pd)(Pa)(N – n)
AOQ =
N
where
Pd = true percent defective of the lot
Pa = probability of accepting the lot
N = number of items in the lot
n = number of items in the sample