6.process Capability

Process Capability Analysis
Dr. M. S. Memon
Department of Industrial Engineering & Management
Mehran University of Engineering and Technology
Jamshoro, Sindh, Pakistan
https://msmemon.wordpress.com/scmlab/
Process Capability
• We define process
capability analysis as a
formal study to estimate
process capability.
• The estimate of process
capability may be in the
form of a probability
distribution having a
specified shape, center
(mean), and spread
(standard deviation).
• Process capability analysis is a vital part of an overall quality-

improvement program. Among the major uses of data from a
process capability analysis are the following:
1. Predicting how well the process will hold the tolerances
2. Assisting product developers/designers in selecting or modifying a process
3. Assisting in establishing an interval between sampling for process monitoring
4. Specifying performance requirements for new equipment
5. Selecting between competing suppliers and other aspects of supply chain
management
6. Planning the sequence of production processes when there is an interactive effect of
processes on tolerances
7. Reducing the variability in a process
• Thus, process capability analysis is a technique that

has application in many segments of the product
cycle, including product and process design, supply
chain management, production or manufacturing
planning, and manufacturing.
• Three primary techniques are used in process
capability analysis: histograms or probability plots,
control charts, and designed experiments.
Process Capability
Define the Process
Is the Process Capable? Select CTQ

Purpose: Determine the
adequacy of the process with Collect Data
respect to customer needs.
Is No Investigate and Fix

process
assignable cause
Stable?
Yes
Is
Improve process No Process
capability Capable
?
Yes
Use SPC to monitor
current process
Process Capability
• It is customary to take the six-sigma spread in the

distribution of the product quality characteristic as a
measure of process capability.
• Previous Figure shows a process for which the quality
characteristic has a normal distribution with mean μ and
standard deviation σ.
• The upper and lower natural tolerance limits of the
process fall at μ + 3 σ and μ − 3 σ, respectively; that is,
Process Capability
Process Capability Analysis Using a Histogram
• The histogram can be helpful in estimating

process capability.
• At least 100 or more observations should be
available for the histogram to be moderately
stable so that a reasonably reliable estimate of
process capability may be obtained.
• The histogram, along with the sample average
𝑥ҧ and sample standard deviation s, provides
information about process capability.
Example 1
• The data are shown in following Table. What

is the capability of the process?
Example 1
Solution: Analysis of the 100

observations gives
Process Capability Ratios (Cp)
• It is frequently convenient to have a simple,

quantitative way to express process capability.
• One way to do so is through the process
capability ratio (PCR) Cp.
To illustrate the calculation of Cp, recall the semiconductor hard-bake process first
analyzed in Example 4 for variable control chart.
Following Equations assume that the process has both upper and lower specification
limits. For one-sided specifications, one-sided process-capability ratios are used.
Onesided PCRs are defined as follows.
Process Capability Ratio for an Off-Center Process
• The process capability ratio Cp does not

take into account where the process
mean is located relative to the
specifications. Cp simply measures the
spread of the specifications relative to the
six-sigma spread in the process.
• For example, the top two normal
distributions in adjacent Fig. both have Cp
= 2.0, but the process in panel (b) of the
figure clearly has lower capability than the
process in panel (a) because it is not
operating at the midpoint of the interval
between the specifications.
This situation may be more accurately reflected by defining a new process capability
ratio—PRC Cpk—that takes process centering into account. This quantity is
Note that Cpk is simply the one-sided PCR for the specification limit nearest to the
process average. For the process shown in above Fig., we would have
This situation may be more accurately reflected by defining a new process capability
ratio—PRC Cpk—that takes process centering into account. This quantity is
Note that Cpk is simply the one-sided PCR for the specification limit nearest to the
process average. For the process shown in above Fig., we would have
Thus, we usually say that Cp measures potential capability in the process, whereas
Cpk measures actual capability.
Process Capability
Homework
• Construct and interpret 𝑥ҧ and R charts using the piston ring

inside diameter measurements in following Table.
• Calculate the process capability from the following data if

specification limits are 74 ± 0.035mm
Homework
Process Performance Analysis
Short term capability vs Long Term Performance
• The assumption of normality it's critical to the usual
interpretation of the capability analysis.
For non normal data option is
• Transform non normal data (flatness, ovality, surface finish,
delivery time, cycle times) the normal by checking following
transformation square root, inverse, log
• use Box-Cox power transformation for positive response
variable with subgroups
• Johnson's transformation for any type of response variable (+
or -)
• we must also transform the specifications
Process Capability for Attribute Data
• Process capability for count data is assessed

differently from continuous data
• Summary of process capability using count data
– DPU, DPMO and Sigma level metrics are used
• Ability to meet customer requirement
• Process must be stable
– For e.g., last month 16,810 units were produced over
18 days
– 231 were defective
– did we meet customer requirements?
• when dealing with attribute data, defects per

unit (DPU) is used as statistic to measure the
capability
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑠
𝐷𝑃𝑈 =
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑
231
𝐷𝑃𝑈 = = 0.0137418
16810
• The DPU measure does not directly take the complexity of

the unit into account. A widely used way to do this is the
defect per million opportunities (DPMO) measure
𝐷𝑃𝑈
𝐷𝑃𝑂 = in 1 unit
𝑶𝒑𝒑𝒐𝒓𝒕𝒖𝒏𝒊𝒕𝒚
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑠

𝐷𝑃𝑀𝑂 = × 1,000,000
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 × 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑝𝑝𝑜𝑟𝑡𝑢𝑛𝑖𝑡𝑖𝑒𝑠
231
𝐷𝑃𝑀𝑂 = × 1,000,000 = 13741.8
16810
𝑺𝒊𝒈𝒎𝒂 𝒍𝒆𝒗𝒆𝒍 == 𝑁𝑂𝑅𝑀𝑆𝐼𝑁𝑉 1 − 𝐷𝑃𝑂 + 1.5

Sigma level and DPMO calculations

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Process Capability Analysis

• Process capability analysis is a vital part of an overall quality-

• Thus, process capability analysis is a technique that

Is the Process Capable? Select CTQ

Is No Investigate and Fix

• It is customary to take the six-sigma spread in the

• The histogram can be helpful in estimating

• The data are shown in following Table. What

Solution: Analysis of the 100

• It is frequently convenient to have a simple,

• The process capability ratio Cp does not

• Construct and interpret 𝑥ҧ and R charts using the piston ring

• Calculate the process capability from the following data if

• Process capability for count data is assessed

• when dealing with attribute data, defects per

• The DPU measure does not directly take the complexity of

𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑠

𝑺𝒊𝒈𝒎𝒂 𝒍𝒆𝒗𝒆𝒍 == 𝑁𝑂𝑅𝑀𝑆𝐼𝑁𝑉 1 − 𝐷𝑃𝑂 + 1.5

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