Chapter 8 Statistical Quality Control, 7th Edition by Douglas C. Montgomery.

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 Process Capability

Natural tolerance limits are defined as follows:

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 Uses of process capability data:

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Reasons for Poor Process Capability

Process may have

good potential
capability
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 Probability Plotting

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 • The distribution may not be normal; other types of
probability plots can be useful in determining the
appropriate distribution.

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 For the hard bake process:

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 One-Sided PCR

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 Interpretation of the PCR

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 Assumptions for Interpretation of
Numbers in Table 8.2

• Violation of these assumptions can lead to big trouble in using the

data in Table 8.2.

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 • Cp does not take
process centering
into account
• It is a measure
of potential
capability, not
actual capability

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 A Measure of Actual Capability

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 Normality and Process Capability
Ratios
• The assumption of normality is critical to the
usual interpretation of these ratios (such as
Table 8.2)
• For non-normal data, options are
1. Transform non-normal data to normal
2. Extend the usual definitions of PCRs to handle
non-normal data
3. Modify the definitions of PCRs for general
families of distributions

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 Other Types of Process Capability Ratios

• First generation
• Second generation
• Third generation
• Lots of research has been done to develop
ratios that overcome some of the problems
with the basic ones
• Not much evidence that these ratios are used to
any significant extent in practice
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Process Capability
Analysis using Control
Charts

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 Since LSL = 200

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 7.8 Gauge and Measurement Systems
Capability Studies
• Determine how much of the observed
variability is due to the gauge or measurement
system
• Isolate the components of variability in the
measurement system
• Assess whether the gauge is capable (suitable
for the intended application)

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 The P/T ratio:

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 Estimating the Variance Components

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 The gauge is not capable by this criterion

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 Discrimination Ratio

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 Accuracy and Precision

We have
focused only on
precision

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 Gauge R&R Studies

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 Gauge R&R Studies Are Usually Conducted
with a Factorial Experiment

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 This is a two-factor factorial experiment
ANOVA methods are used to analyze the data and yo estimate the
variance components

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 • Negative estimates of a variance component
would lead to filling a reduced model, such as,
for example:

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 For this Example

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 Other Topics in Gauge R&R
Studies
• Section 8.7.3 provides a description of methods to
obtain confidence intervals on the variance
components and measures of gauge R&R

• Section 8.7.4 presents a new measure of gauge

capability, the probabilities of misclassification of
parts
– Rejecting good units (producer’s risk)
– Passing bad units (consumer’s risk)
– Methods for calculating these two probabilities are given

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 8.7.5 Attribute Gauge Capability
• Sometimes the output of a gauge isn’t numerical – it’s just
pass/fail
• Nominal or ordinal data is also common
• Occurs frequently in service businesses
• Common situation – do operating personnel consistently make
the same decisions regarding the units they are inspecting or
analyzing
• Example – a bank uses manual underwriting of mortgage loans
• The underwriter uses information to classify the applicant into
one of four categories; decline or category 1, 2, 3 – categories
2 & 3 are low-risk and 1 is high risk
• Compare underwriters performance relative to a “consensus”
evaluation determined by a panel of “experts”

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 Thirty applicants,
three underwriters
Each underwriter
evaluates each
application twice
The applications are
“blinded” by
removing names,
SSNs, addresses,
and other identifying
information

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 Attribute Gauge Capability
• Determine the proportion of time that the
underwriter agrees with him/herself – this
measures repeatability
• Determine the proportion of time that the
underwriter agrees with the correct
classification – this measures bias
• Minitab performs the analysis – using the
attribute agreement analysis routine

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 8.8 Setting Specifications on Discrete Components

• Components interact with other components

• Complex assemblies
• Tolerance stack-up problems
• Linear combinations
• Nonlinear combinations

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 8.9 Estimating the Natural Tolerance
Limits of a Process

For a normal distribution with unknown mean and variance:

• Difference between tolerance limits and confidence limits

• Nonparametric tolerance limits can also be calculated

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