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1 Introduction To Statistical Quality Control, 7th Edition by Douglas C. Montgomery

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65 views17 pages

1 Introduction To Statistical Quality Control, 7th Edition by Douglas C. Montgomery

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farazomar.canada
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© © All Rights Reserved
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Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery.

1
Copyright (c) 2012 John Wiley & Sons, Inc.
5.2 Chance and Assignable Causes of Variation
• A process is operating with only chance causes of variation present is said to
be in statistical control.
• A process that is operating in the presence of assignable causes is said to be
out of control.

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 2


Copyright (c) 2012 John Wiley & Sons, Inc.
5.3 Statistical Basis of the Control Chart

• A control chart contains


– A center line
– An upper control limit
– A lower control limit
• A point that plots within the
control limits indicates the
process is in control
– No action is necessary
• A point that plots outside the
control limits is evidence that the
process is out of control
– Investigation and corrective
action are required to find and
eliminate assignable cause(s)
• There is a close connection
between control charts and
hypothesis testing

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 3


Copyright (c) 2012 John Wiley & Sons, Inc.
Photolithography Example

• Important quality characteristic in hard bake is resist flow width


• Process is monitored by average flow width
– Sample of 5 wafers
– Process mean is 1.5 microns
– Process standard deviation is 0.15 microns
• Note that all plotted points fall inside the control limits
– Process is considered to be in statistical control

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 4


Copyright (c) 2012 John Wiley & Sons, Inc.
Determination of the Control Limits

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 5


Copyright (c) 2012 John Wiley & Sons, Inc.
Shewhart Control Chart Model

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 6


Copyright (c) 2012 John Wiley & Sons, Inc.
How the Shewhart Control Chart Works

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 7


Copyright (c) 2012 John Wiley & Sons, Inc.
Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 8
Copyright (c) 2012 John Wiley & Sons, Inc.
More Basic Principles
• Control charts may be used to estimate process
parameters, which are used to determine capability
• Two general types of control charts
– Variables (Chapter 6)
• Continuous scale of measurement
• Quality characteristic described by central tendency and a measure
of variability
– Attributes (Chapter 7)
• Conforming/nonconforming
• Counts
• Control chart design encompasses selection of
sample size, control limits, and sampling frequency

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 9


Copyright (c) 2012 John Wiley & Sons, Inc.
Types of Process Variability
• Stationary and uncorrelated  data vary around a fixed mean in a stable
or predictable manner
• Stationary and autocorrelated  successive observations are dependent
with tendency to move in long runs on either side of mean
• Nonstationary  process drifts without any sense of a stable or fixed mean

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 10


Copyright (c) 2012 John Wiley & Sons, Inc.
Reasons for Popularity
of Control Charts
1. Control charts are a proven technique for improving
productivity.
2. Control charts are effective in defect prevention.
3. Control charts prevent unnecessary process
adjustment.
4. Control charts provide diagnostic information.
5. Control charts provide information about process
capability.

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 11


Copyright (c) 2012 John Wiley & Sons, Inc.
• 3-Sigma Control Limits
– Probability of type I error is 0.0027
• Probability Limits
– Type I error probability is chosen directly
– For example, 0.001 gives 3.09-sigma control limits
• Warning Limits
– Typically selected as 2-sigma limits

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 12


Copyright (c) 2012 John Wiley & Sons, Inc.
5.3.5 Patterns on Control Charts

• Pattern is very nonrandom in appearance


• 19 of 25 points plot below the center line, while only 6 plot
above
• Following 4th point, 5 points in a row increase in
magnitude, a run up
• There is also an unusually long run down beginning with
18th point
Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 13
Copyright (c) 2012 John Wiley & Sons, Inc.
The Cyclic Pattern

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 14


Copyright (c) 2012 John Wiley & Sons, Inc.
Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 15
Copyright (c) 2012 John Wiley & Sons, Inc.
5.3.6 Discussion of the Sensitizing Rules

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 16


Copyright (c) 2012 John Wiley & Sons, Inc.
4.3.7 Phase I and Phase II of Control Chart Application

• Phase I is a retrospective analysis of process


data to construct trial control limits
– Charts are effective at detecting large, sustained
shifts in process parameters, outliers, measurement
errors, data entry errors, etc.
– Facilitates identification and removal of assignable
causes
• In phase II, the control chart is used to monitor
the process
– Process is assumed to be reasonably stable
– Emphasis is on process monitoring, not on bringing
an unruly process into control

Chapter 5 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 17


Copyright (c) 2012 John Wiley & Sons, Inc.

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