Process Capability, Statistical Process Control and Process Control Charts

A. Process Capability
a. Process Capability compares the process output with the customer’s
specification
i. Purpose: is to compare process specification with process output and
determine statistically if the process can meet the customer’s
specification
b. When it comes to process improvement efforts, the process capability
index/process capability ratio is a statistical measurement of the process
capability

Figure A.1. Process Capability Index

B. Statistical Process Control

a. Statistical Process Control is an industry-standard methodology for measuring
and controlling quality during the manufacturing process.
b. The quality data, in the form of product, is obtained real-time during the
manufacturing.
i. That data is then graphed with pre-determined Control Limits and
Specification Limits.
1. Control Limits- are determined by the capability of the
process
2. Specification Limits- are determined by the client’s needs

Figure B.1. Control Chart

 C. Process Control Chart
a. The control chart is a graph used to study how a process changes over time.
i. Where in data are plotted chronologically.
b. It is constructed with a middle line for the average, an upper line for the
UPPER CONTROL LIMIT and a lower line for the LOWER CONTROL
LIMIT
i. All data are historical and is determined from the data collected over
time.
c. Uses of Process Control Chart
i. It is used to be able to control processes by finding and correcting
problems as they occur.
ii. To be able to see the status of the production. Whether it is stable or not.
iii. To know whether changes should be implemented to be able to both
avoid problems and/or improve quality.
d. Basic Procedures (IMPORTANT)
i. Choose the appropriate control chart for the data collected
ii. Determine WHEN is the right time to collect data
iii. Collect data, construct a chart from the given data and analyse the data.
iv. Document investigation
1. What was learned?
2. The causes of problems which occurred?
3. How was the problems corrected?
D. Attribute Control Chart
a. Are control charts specifically designed for Attributes data.
b. It monitors the process location and variation over time in a single chart
c. Attribute Charts
i. NP-Chart- monitors the number of times a specific condition occurs
ii. P-chart- monitors the percentage of samples which has a condition
iii. C-chart- similar with NP-Chart, however, it checks if the samples can
have more than one instance that a condition occurs
iv. U-chart- Similar to P-Chart, however, it checks if the samples can have
more than one instance
/* TIPS IN MEMORIZATION
NP-C Charts
-are both for monitoring the number of times a condition occurs
-relative to a constant sample size
-difference: NP-Charts check whether each sample can either have a condition, or not have this
condition while C-charts, is used when a sample can have more than one instance of a condition
P-U Charts
- Both monitors the percent of samples having a condition
- Relative to fixed or varying sample sizes
- Difference: P- Charts, check whether a sample can either have this condition or not
while C-Charts, is when samples can have more the one instance of a condition */

E. Variable Control Charts

a. Variable control charts plot continuous measurement process data such as
length and width.
i. Variable Charts are used to detect unexpected variations in the
production
b. Variables control charts for subgroups include:
i. XBAR: Plots the process mean over time. Use to track the process level
and detect the presence of special causes affecting the mean.

1.
ii. R Chart: Plots the process range over time. Use to track process
variation and detect unexpected variation.

1.
iii. S Chart: Plots the process standard deviation over time. Use to track
the process variation and detect unexpected variation.
 1.
iv. Zone Chart: Plots the cumulative scores based on "zones" at 1, 2, and
3 standard deviations from the centre line. Use to detect unexpected
variation.

1.

c. Variable control charts for individual data

i. Variable control charts that show individual data represents an
individual measurement.
ii. Individual Charts are used when:
1. Measurements are expensive
2. Production is low
3. The products have long cycle time
iii. There are 2 types of individual charts
1. I Chart: Plots individual observations over time. Use to track the
process level and detect the presence of special causes
 a.
2. Moving Range Chart Plots the moving range over time. Use to track
the process variation and detect the presence of special causes.

a.
F. Appropriate Data Collection
a. According to Connell, an important part of the evaluation process is to
understand the client’s opinions and perspectives.
b. So what are the options in data collection? Here are they:
i. Interviews
1. Interviews both face-to-face and on the telephone are a great way
to collect data from population who have no access to paper or
web surveys. This type of survey are also good in collecting
open-ended type of answers
ii. Focus Groups
1. Focus groups are planned discussions with a small group of
people led by a trained facilitator to learn about ideas and
perceptions on a certain topic.
iii. Observations
1. Observations of individual groups are often done to document
behaviours and reactions such as facial expressions, gestures,
tones and voices. This type of data collection is helpful in
obtaining information from people who have barriers in
communicating ideas and perception.
iv. Surveys, Student Records, Collections of Material...
c. How do you choose a method of data collection?
i. There are many factors that one should consider when choosing a
method such as:
1. Target Population
a. The target population contains members of a group that
a researcher is interested in studying. The results of the
study are generalized to this population, because they all
have significant traits in common.
2. Timeframe of data collection
a. A period of time where in data collection is done(from
what time to what time)
3. Budget
a. Estimation of income and expenditure for a set period of
time
d. Advantages and Disadvantages of the Methods
i. Interviews
1. Advantages
a. The interviewer can ask additional information
b. The interviewer can provide much detailed data
2. Disadvantages
a. Time-Consuming
b. Can minimize sample size
c. Subjectivity of answers
d. Difficult to Analyze
ii. Focus Groups
1. Advantages
a. It enables the researcher to interview more people at once
b. Answers can affect other interviewees
2. Disadvantages
a. Inhibition of some individuals of information due to
other answers
b. Difficulty in organizing due to conflicting schedules
iii. Observations
1. Advantages
a. Objective Interpretation
b. Low burden for people in providing data
2. Disadvantages
a. Time-consuming
b. Some items are not observable and sometimes have no
relevance to the study
c. Can be expensive