Methods and Philosophy of Statistical Process Control
Methods and Philosophy of Statistical Process Control
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Learning Objectives
1.Understand chance and assignable causes of variability in a
process
2.Explain the statistical basis of the Shewhart control chart,
including choice of sample size, control limits, and sampling
interval
3.Explain the rational subgroup concept
4.Explain phase I and phase II use of control charts
5.Explain how average run length is used as a performance
measure for a control chart
6.Explain how sensitizing rules and pattern recognition are
used in conjunction with control charts
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Basic SPC Tools
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Chance and Assignable Causes of Variation
• A process is operating with only chance causes of variation 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.
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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
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Photolithography Example
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Shewhart Control Chart Model
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Process improvement activity
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Out-Of-Control-Action Plan (OCAP)
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More Basic Principles
• Two general types of control charts
– Variables
• Continuous scale of measurement
• Quality characteristic described by central tendency and
a measure of variability
– Attributes
• Conforming/nonconforming
• Counts
• Control chart design encompasses selection of sample size,
control limits, and sampling frequency
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Types of Process Variability
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Reasons for Popularity of Control Charts
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Sample Size and Sampling Frequency
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Rational Subgroups
• The rational subgroup concept means that subgroups or
samples should be selected so that if assignable causes are
present, chance for differences between subgroups will be
maximized, while chance for difference due to assignable causes
within a subgroup will be minimized.
• Two general approaches (Snapshot and Random Sample) for
constructing rational subgroups:
1. Sample consists of units produced at the same time − consecutive units
– Primary purpose is to detect process shifts
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Rational Subgroups
2. Each sample consists of units that are representative of all units produced
since last sample
– Often used to make decisions about acceptance of product
– Effective at detecting shifts to out-of-control state and back into in-control
state between samples
– Care must be taken because we can often make any process appear to
be in statistical control just by stretching out the interval between
observations in the sample.
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Patterns on Control Charts
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The Cyclic Pattern
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Decision rules for detecting non-random
patterns on control charts
1. One point plots outside the three-sigma
control limits,
2. Two out of three consecutive points plot
beyond the two-sigma warning limits,
3. Four out of five consecutive points plot at
a distance of one-sigma or beyond from the
center line, or
4. Eight consecutive points plot on one side
of the center line.
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Sensitizing Rules
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Phase I and Phase II of Control Chart Application
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