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Process Capability - Tool

The document discusses process capability and related concepts. It defines process capability as the inherent variability of a quality characteristic that a process is capable of maintaining under given conditions. Process capability is judged by comparing process performance to requirements and specifications. Key indices for measuring process capability are introduced, including Cp, Cpk, and one-sided versions of these for processes with only upper or lower specification limits. The importance of process centering for optimizing Cpk is also highlighted.

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Fouzan Soniwala
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217 views26 pages

Process Capability - Tool

The document discusses process capability and related concepts. It defines process capability as the inherent variability of a quality characteristic that a process is capable of maintaining under given conditions. Process capability is judged by comparing process performance to requirements and specifications. Key indices for measuring process capability are introduced, including Cp, Cpk, and one-sided versions of these for processes with only upper or lower specification limits. The importance of process centering for optimizing Cpk is also highlighted.

Uploaded by

Fouzan Soniwala
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPS, PDF, TXT or read online on Scribd
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FICCI

CE

Process capability

Process A combination of equipment, materials, people, methods and environment that act together to produce an output. The quality of the process is judged by the quality ( characteristic ) of the output.

FICCI

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Process capability

Process capability The inherent variability of a quality characteristic that the process is capable of maintaining, when in a state of statistical control under a given set of conditions. Assuming normal distribution of the quality characteristic Process Capability = +/- 3 SD = Total spread of 6 SD.

FICCI

CE

Process capability

Process capability is judged by comparing process performance with process requirements. Since meeting specification limits is one of the most basic requirements of a process capability study, it is extremely important to accurately verify and define the specification limits.

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Need for process capability

For meeting customer requirements/ specifications.


To compare actual performance of equipment with manufacturers claim. To compare the performance of two processes. To provide more realistic tolerances for component dimensions. Provide a basis for process control.

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Factors influencing process capability

1. Condition of machine/ equipment. 2. Type of operation and operational conditions. 3. Raw materials. 4. Skill of operators. 5. Measurement method / instruments. 6. Inspectors skill.

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Estimation of process capability

Visual from run chart. Frequency distribution and histogram. Control charts. Analysis of variances. Probability papers.

Note : Reduction of variability can be achieved through use of SPC tools and Design of Experiments.

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The empirical rule

We have seen in the earlier chapter that almost all (to be


accurate 99.73%) the process output from a normally distributed process lies between (process mean - 3 SD) and (process mean+ 3 SD).

The total spread of the process can thus be described as 6 SD

FICCI

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99.73% population between process mean +/- 3 SD

LSL

USL

5 - 3 SD

10

11 12 13 + 3 SD

14

15

16

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Process capability indices : The Cp index

A major reason for quantifying process capability is to compute the ability of a process to hold product tolerances. A measure of this relationship is process capability ratio or Cp. Process capability is also known as potential capability. The Cp index is given by:Cp = Tolerance 6 SD
Where Tolerance = USL - LSL SD = Standard Deviation

FICCI

CE

Process capability indices : The Cp index

Interpretations of Cp Cp > 1 : The process is quite capable Cp = 1 : The process is just capable Cp < 1 : The process is incapable The recommended value of Cp is 1.33 ( minimum) In order to achieve Six Sigma quality in the organization, we must reduce the variation in the process so as to achieve the value of Cp=2.

FICCI

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Calculating defective PPM at various levels of sigma.

Quality level 2 Sigma 3 Sigma 4 Sigma 5 Sigma 6 Sigma

Cp 0.67 1.00 1.33 1.67 2.00

z 2 3 4 5 6

Defective PPM 22750 1350 32 0.3 0.001

Refer normal distribution table for finding defective parts per million ( PPM ) for corresponding z values.

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Impact of process capability

For individual parts, the ideal design is Cp = 2; in other words, the design specification is twice as wide as the true capability of the process. This is where the phrase Six Sigma Quality originated. Since the process capability is +/- 3SD, a design specification twice as wide would be +/- 6 SD.

FICCI

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Impact of process capability

However, it is learnt from the industry experience across the world, that the processes rarely stay centered on their targeted nominals, shifts of 1.5 SD to either side of the mean are common, even in well controlled processes. Therefore in practice, an ultimate z-value of 4.5 is considered Six Sigma Quality. Consulting the z-table, we find that the probability of producing non conformities associated with a zvalue of 4.5 is 0.0000034. If this value is obtained, then only 3.4 out of every million parts manufactured will be defective.

FICCI

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Calculating defective PPM with permissible shift of 1.5 SD at various levels of sigma. ( practical situation )

Quality level 2 Sigma 3 Sigma 4 Sigma 5 Sigma 6 Sigma

Cp 0.17 0.50 0.83 1.17 1.50

z 0.5 1.5 2.5 3.5 4.5

Defective PPM 308538 66807 6210 233 3.4

Refer normal distribution table for finding defective PPM for corresponding z values.

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Drawbacks of Cp

Cp however is not a very reliable measure as it does not tell us all. Consider the following four processes producing the same output X with specification 20+/- 4. Each of these processes have the Standard deviation of 1.

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Process 1
X=20 SD=1
LSL

USL

Cp=1.33

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Process 2
X=22 SD=1

LSL

USL

Cp=1.33

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Process 3
X=15 SD=1
LSL

USL

Cp=1.33

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Process 4
X=25 SD=1
LSL USL

Cp=1.33

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Calculation of Cpk index

Cpk is a measure of process performance capability The process performance index Cpk is given by:Cpk = Min [ USL - x , x - LSL ] 3SD 3SD Example : Specification : 20 +/- 4, SD = 1 Cp = Tolerance/6SD = 8/6 = 1.33

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Calculation of Cpk index - Example


Example : Specification : 20 +/- 4, SD = 1 Cp = Tol/6 SD = 8/6 = 1.33 x = 20, Cpk = Cp = 1.33 x = 22, Cpk = 0.67

x = 15, Cpk = -0.33 x = 25, Cpk = -0.33

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Calculation of Cpk index

In the previous slide we observe that, although the Cp value = 1.33 in all the four cases, but because of the shift in the process setting level we are getting Cpk values as 0.67 in 2nd case and hence the non conformities. Similar observations are noticed in 3rd and 4th case where we get the Cpk as -0.33.

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The Cpk index

Thus Cpk = Cp means the process is centered. Cpk < 1 means non- conformances are being produced. Cpk < 0 indicates that the process has been set beyond either of the two specification limits.
Note : Cpk is always less than or equal to Cp.

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Cp and Cpk indices

Therefore, the first step is to bring Cpk=Cp by proper centering of the process. The second step should be to improve the Cp value by decreasing the variation.

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Process capability indexes for one sided tolerances

One-sided Tolerances - The Cp and Cpk indexes are used for characteristics with two-sided tolerances - that is, processes with both upper and lower specification limits. Since many characteristics have only one-sided specifications, it is also convenient to have one-sided capability indexes.

FICCI

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Process capability indexes for one sided tolerances


For processes that have only a Lower specification limit, LSL, the lower capability index Cpl is defined by:Cpl = x - LSL 3 SD

Correspondingly, when only an Upper specification exists, we define an upper capability index by:Cpu = USL - x 3 SD

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