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Statistical Process Control

This document discusses statistical process control and different types of control charts used for variable and attribute data. It describes variable and attribute charts, including X-bar and R charts for variables and P, NP, C, and U charts for attributes. Control charts help monitor processes, detect unusual variations, and ensure processes remain in statistical control. The document recommends preparing separate control charts for different defects to more easily identify root causes and determine when and where defects occurred.

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Surya Bakshi
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© Attribution Non-Commercial (BY-NC)
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Download as PPT, PDF, TXT or read online on Scribd
412 views

Statistical Process Control

This document discusses statistical process control and different types of control charts used for variable and attribute data. It describes variable and attribute charts, including X-bar and R charts for variables and P, NP, C, and U charts for attributes. Control charts help monitor processes, detect unusual variations, and ensure processes remain in statistical control. The document recommends preparing separate control charts for different defects to more easily identify root causes and determine when and where defects occurred.

Uploaded by

Surya Bakshi
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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STATISTICAL PROCESS

CONTROL

VARIABLE AND ATTRIBUTE CHARTS

Presented By :
Surya Bakshi
 Statistical Process Control is
a technique used within the TQM framework
Aims to reduce variation in processes
control, manage, analyze and improve the
performance
eliminates special causes of variation
 defective products,
 operator error,
 errors in measurements
CONCEPTS
 PROCESS
 Is a set of interrelated or interacting
activities which transform inputs into
outputs.
 VARIATION
 No two products are exactly alike due to
sources of variability
 Sources of variation : speed of the
operator, accuraccy, procedure followed,
variation over time.
Advantages of maintaining
a state of Statistical Control
 Variation( inherent) is restricted to
common causes

 Since variability exhibits a regularity in


pattern, the process is repeatable

 Since process is repeatable, quality of


future production can be predicted.
SPC is a strategy of Defect prevention which aims
 To increase the knowledge about any process

 To steer a process to behave in the desired way

 To reduce variation in the product or in other ways to

improve performance of the process


 To reduce cost and increase profit by improving the

performance of the process


 Increase consistency of the process
 Periodic sampling of products from the
process and inspecting them for
characteristic under cosideration
 Computing a suitable index of quality for
each statistic
 Taking actions to detect and eliminate
special causes wherever control limits are
exceeded
 Leaving the process alone when there’s no
evidence of “out of control”
 Control charts or graphical trend
analysis are used to understand
changes in the process mean and
process standard deviation.

 Process variation
 adds needless cost to the product
 reason why a product does not comply
with specifications
 are a graphical device to aid in process control
 Control chart consists of:
 Points representing a quality characteristic in samples under
observation
 A Centre line, drawn at the process characteristic mean,

which is calculated from the data.


 Upper and Lower Control Limits that indicate the threshold at

which the process output is considered statistically 'unlikely'.


 Control Chart technique can be used for
both Variable and Attributes.
 Measurement or Variables
 quality characteristics which can be measured
 Attribute
 quality characteristics that can be evaluated
with a discrete response
 not measurable on the quantitative scale

 Data obtained by classification or counting


are called
 There are four types of attribute charts used for
 non measurable defect controlling and
 defectives controlling

 N and NP Charts for the control of number of


defectives or non- conforming
 C and U – Charts for the control of the defects or
non- conformities
• Used at places where
▫ various defects could occur in a single product that is being
manufactured

• Fixed sample size , 13 in this case as per 2.5 AQL


• The proportion of defectives are
▫ plotted and
▫ analyzed for improvement of the process
 The graph is made from the quality checks done in the
front section of Jackets Line 3 for three consecutive days

 The plotting shows that the process is shown to be


 within limits and
 very much stabilized
 the UCL is far beyond the fraction of defectives that have
been plotted.

 Hence if this chart is applied it will


 not solve the purpose
 identifying the process instability is difficult.
 Used at places where
 various defects could occur
 product wise checking

 variable sample size


 The UCL and LCL are calculated
 on hourly basis
 on the last hour’s data available
 The chart is
 very time taking to be prepared
 The Quality Checker has to be trained
 Follow up to let them know how to prepare it.
 The same problem of data always show within
control persists

 Hence, the chart cannot be used.

 The two chart applicable to check no. of


defectives is ruled out.
 The C Chart and the U chart are used to assess defects
occurring in the product individually.

 The U chart is used at places where


 The defects are checked to be present as per a specific unit,
 For example is carpet making
 The defect per square unit area is checked in this case.

 There is no such unit that can segregate the garment defects


hence U chart is also not applied in this case.
• The C chart loses its characteristic of showing

▫ the no. of defects present


▫ the fractional values are plotted

• The C Chart previously

▫ Was used for several defects


▫ It is difficult to asses as to which defect led to the
inconsistency
▫ Hence should be used for a single defect.
 Preparation of separate chart for different defect that has to be
checked

 The no. of defects instead of fractions should be plotted on


hourly basis

 the UCL and LCL for the next day to be calculated on the basis of
the last day’s data

 THE NEW CHART proposed to be implemented.


 The new chart
 shows the situations out of control where
the defect needs to be checked
 makes it easier to identify the root cause of
the defect
 when it happened

 where it happened

 who did it and

 proper steps can be taken to mend it, and

 record is maintained for the future


reference

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