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08 Process Capability

The document provides information on quality control processes and analyzing processes that are in and out of statistical control. Key points include: - A process is in statistical control when sample points remain within control limits on a control chart, indicating a high degree of uniformity with the existing process. - Advantages of an in-control process include more uniform products, fewer needed samples, easier process capability determination, and higher prediction assurance. - An out-of-control process occurs when a sample point falls outside the control limits, signifying an assignable cause of variation. Various patterns of out-of-control points are analyzed. - Process capability is determined by comparing the natural process variation (6σ)

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Mugni Srinovia
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41 views36 pages

08 Process Capability

The document provides information on quality control processes and analyzing processes that are in and out of statistical control. Key points include: - A process is in statistical control when sample points remain within control limits on a control chart, indicating a high degree of uniformity with the existing process. - Advantages of an in-control process include more uniform products, fewer needed samples, easier process capability determination, and higher prediction assurance. - An out-of-control process occurs when a sample point falls outside the control limits, signifying an assignable cause of variation. Various patterns of out-of-control points are analyzed. - Process capability is determined by comparing the natural process variation (6σ)

Uploaded by

Mugni Srinovia
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Quality Control

Lesson 8

State
of
Control
Process in Control
a state where Points plotted in the control

chart remain within control limits


No Higher degree of uniformity can be
attained with the existing process, BUT
Only Change in the basic process through
quality improvements ideas

Natural pattern of
variation

UCL

Central line
34%
13%
2.5%
LCL

Advantage if process is in
control
1. More uniform product (less variation)
2. Fewer samples are needed to judge quality

reduce inspection cost


3. Process capability/spread of process is easily
attained from 6 decide:
Product spec.
b. Amount of scrap/rework
c. Tight/loose spec.
a.

Advantage if process is in
control
4. Prediction with highest degree of assurance
5. Permits the consumer to use the producers

data
6. Satisfying performance of operator

Process out-of-control
Condition when a point (subgroup value) falls

outside its control limits


an assignable cause of variation is present

Process out-of-control
UCL

X0
LCL
UCL

X0

A
B
C
C
B
A

A
B
C

LCL

B
A

UCL

X0
LCL

A
B
C
C
B
A

Analysis of Out-of-control
Condition
1. Change or jump in level
X-bar chart
Intentional/unintentional changes in the process
setting
New or inexperienced operator
Different raw material
Minor failure of a machine part

R chart

Inexperienced operator
Sudden increase in gear play
Greater variation in incoming material

Analysis of Out-of-control
Condition
2. Trend or steady change in level

X-bar chart

Tool or die wear


Gradual deterioration of equipment
Gradual change in temp/humidity
Viscosity breakdown in a chemical process
Build-up of chips in a work-holding device

R chart

An improvement in worker skill (downward trend)


A decrease in worker skill due to fatigue, boredom,
inattention, etc (upward trend)
A gradual improvement in the homogeneity of
incoming material

Analysis of Out-of-control
Condition
3. Recurring cycles
X-bar chart

The seasonal effect of incoming material

The recurring effects of temp.& humidity (cold


morning start-up)

Any daily or weekly, chemical, mechanical or


psychological event
R chart (not so common)

Operator fatigue or rejuvenation resulting from


breaks
Lubricant cycles

Analysis of Out-of-control
Condition
4. Two population (also called mixture)
X-bar chart

Large differences in mat.quality


Two or more machines on the same chart
Large differences in test method or equipment

R chart

Different workers using the same chart


Materials from different suppliers

Analysis of Out-of-control
Condition
5. Mistakes
Measuring equipment out of calibration
Errors in calculations
Errors in using test equipment
Taking samples from different populations

Nonrandom Patterns

Quality Control
Lesson 9

Process capability &


Tolerance
1. 6 < USL-LSL
2. 6 = USL-LSL
3. 6 > USL-LSL

Case 1 :6 < USL-LSL


UCL

USL-LSL
6

X0
LCL

a. Desirable

b. Undesirable but
no waste

Case 2 : 6 = USL-LSL
Out of
control

UCL

USL-LSL

X0

6
LCL
a. Satisfactory

b. Out of Control &


waste

Case 3 : 6 > USL-LSL


USL

6
USL-LSL

X0
LSL

a. In control &
waste

b. Out of control
and waste

Solution
Discuss with engineer the possibility to

increase the tolerance


Perform 100% inspection to eliminate
nonconforming products
Change process dispersion (e.g. reduce std
dev. Of raw mat.,more exp. Operator,
retraining, etc.)
Shift the process average (condition in
case 3.b)

Process Capability
Procedure
Calculate sample standard deviation for each

subgroup (s)
Calculate average sample std dev

s s/ g

Calculate the estimate of the population std

dev

s / c4

Process capability will equal 6o

Process Capability
Procedure
Calculate range for each subgroup (R)
Calculate average range

R R/ g

Calculate the estimate of the population std

dev
Process capability will equal 6o

R / d 2

Capability Index
Process capability & tolerance are combined

to form capability index

USL LSL
Cp
6 0

Cp = capability index
USL-LSL = tolerance
6o = process capability

Analysis
If Cp > 1.00 : case 1 desirable
If Cp = 1.00 : case 2
If Cp < 1.00 : case 3 undesirable

Process Performance
Capability index does not measure process

performance in terms of the nominal or target


value use Cpk

C pk

Z (Min)

Z(min) yang terkecil dari

Z(USL)=(USL-Xbar)/ atau
Z(LSL)= (Xbar-LSL) /

Hubungan Cp dan Cpk


1. Cp value does not change as the process
2.
3.
4.
5.
6.
7.
8.

center change
Cp = Cpk when the process is centered
Cpk is always equal to or less than Cp
Cpk=1.00 product conform to spec
Cpk < 1.00 product not conform to spec
Cp < 1.00 process is not capable
Cpk = 0 avg equal to one of spec limit
Cpk negative avg is outside spec

Control
Chart
Suatu control chart untuk Xbar dan R dibuat
terhadap data berat produk pewarna dalam
satu batch proses. Setelah 25 subgroup
dengan ukuran subgroup 4, didapatkan
Xbar=50.08 kg, R=11.82 kg. Asumsikan
proses dalam kondisi terkendali, hitung nilai
tengah untuk Xbar dan R chart serta batas
kendali untuk produksi berikutnya!

Jawab
Diketahui
n=25 ; g= 4
X = 52.08 kg; R= 11.82

Jawab

Ditanya:
CL Xbar, CL R,
UCLx & LCLx ; UCLR & LCLR

52.08

2.0832
n
25
R 11.82

0.4728
n
25

UCLX X A2 R

UCLR D4 R

= 2.0832 + (0.729)
(0.4728)
=2.427

=(2.282) ( 0.4728)
= 1.079

LCL X X A2 R

LCLR D3 R

= 2.0832 - (0.729) (0.4728)


=1.473

=(0 ) ( 0.4728)
=0

Scrap & Rework


Diameter suatu produk yang diinginkan adalah
12.50mm, dengan toleransi 0.05mm. Jika nilai
tengah proses adalah 12.50 mm () dan dispersinya
0.02 mm (),
a.Berapa persen produk yang harus discrap dan
berapa persen rework?
b.Berapa nilai tengah proses jika scrap dihilangkan?
Berapa persen rework sekarang?

Jawab

LSL

USL

Area 1
scra
p

USL = + 0.05 = 12.55mm


LSL = 0.05 = 12.45mm

rework

X i 12.45 12.50
Z

2.50

0.02
Dari Tabel nilai Z
Z=-2.50 area 1 = 0.0062 atau 0.62% scrap

Area 3

Area 2

Area 1
rework
Scrap= 0

Jumlah scrap = 0 area1=0; dari Tabel nilai

Z, yang terdekat dg nilai area 1=0 adalah


0.00017; yaitu dengan nilai Z=-3.50
Xi
Maka:
Z

12.45
3.59
0.02
= 12.52 mm

Persentase rework didapat dari luas area3


Xi
Z

12.55 12.52
Z
1.50
0.02
Dari Tabel nilai Z: luas area 3 = 0.9332
Area 2 = area total area 3

= 1.0000 0.9332 = 0.0668 6.68%


Jumlah rework 6.68% yang kurang dari total
scrap dan rework (1.24%)

Process capability
Suatu proses baru dimulai dan jumlah std dev

sampel utk 20 subgroup berukuran 4 adalah


84. tentukan process capability ?
s 84
Jawab

4 .2
g

20
s
4.2
0
4.56
c4 0.9213

6 = (6) (4.56) = 27.4

Process Capability
Diameter suatu produk yang diinginkan

adalah 12.50 mm, dengan toleransi 0.05


mm. Setelah inspeksi pada 25 subgroup
dengan ukuran subgroup 5, diperoleh nilai
tengah proses adalah 12.50 mm dan
dispersinya 0.02 mm, dan rerata range 0.1
mm
a.Hitung process capability
b.Simpulkan kondisi proses

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