Lecture 6 Process Capability, Specification Limits and Tolerances
Lecture 6 Process Capability, Specification Limits and Tolerances
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PROCESS CAPABILITY
Process capability refers to the uniformity of the
process
The variability of critical-to-quality characteristics
in the process is a measure of the uniformity of output
Two types of variability:
Natural or inherent variability (instantaneous)
Variability over time
UNTL = + 3
LNTL = - 3
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PROCESS CAPABILITY
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PROCESS CAPABILITY
Major uses of data from a process capability
analysis
Some reasons for poor process capability; (a) Poor process centering
(b) Excess process variability
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PROCESS CAPABILITY
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USING A HISTOGRAM OR A
PROBABILITY PLOT
Using a Histogram
USL LSL
Cp
6σ
where LSL and USL are the lower and upper
specification limits, respectively
The estimate 𝐶^of
𝑝 is given by
ˆ USL LSL
Cp
6ˆ
Where the estimate can be calculated using
the sample standard deviation, s, or
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USE AND INTERPRETATION OF
CP
One-Sided Specifications
USL
C pu
3
LSL
C pl
3
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USE AND INTERPRETATION OF CP
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USE AND INTERPRETATION OF
CP
Recommended Minimum Values of the process Capability
Ratio
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PROCESS CAPABILITY RATIO AN
OFF-CENTER PROCESS
does not take into account where the process mean is
located relative to the specifications, it is a measure of
potential capability not actual capability
A process capability ratio that does take into
account centering is
defined as
= min()
Relationship of and
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A MEASURE OF ACTUAL
CAPABILITY
simplyis the one-sided PCR for the specification
limits nearest to the process average
If the process is centered at the midpoint of the
specifications
If < the process is off center
should not be used alone as a measure of process
centering
depends inversely on and becomes large as
approaches zero. (That is, a large value of does not
necessarily reveal anything about the location of the
mean in the interval (LSL, USL)
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MORE ABOUT PROCESS
CENTERING
An improved capability ratio to
measure process centering is
USL LSL
C pm
6
where is the square root of
expected squared deviation from
target: 2
E 2 2 2
x T ( T )
Where T =½(USL+LSL)
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MORE ABOUT PROCESS
CENTERING
can be rewritten another way:
USL LSL
C pm
6 2 ( T) 2
Cp
1 2
where T
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EXAMPLE
Using the following data:
5.32 5.14 5.97 5.9 5.16
6.2 4.46 5.04 4.17 5.47
5.64 4.71 3.74 5.24 5.02
6.11 5.48 4.99 5.41 4.75
4.45 5.31 5.49 5.26 5.04
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SOLUTIONS
Sample Mean = 5.18
Sample s.d. = 0.59
0.814
C pk 0.67
C pkm 0.64
2 2
T 5.18 5
1 1
0.59
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CONFIDENCE INTERVALS AND TESTS
ON PROCESS CAPABILITY RATIOS
2
1 / 2 , n 1 2
/ 2 , n 1
Ĉ p C p Ĉ p
n 1 n 1
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CONFIDENCE INTERVALS AND TESTS ON
PROCESS CAPABILITY RATIOS
1 1 1 1
Ĉ pk 1 Z / 2 C pk Ĉ pk 1 Z / 2
9nĈ pk 2(n 1) 9nĈ pk 2(n 1)
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PROCESS CAPABILITY ANALYSIS
USING A CONTROL CHART
If a process exhibits statistical control, then the
process capability analysis can be conducted
A process can exhibit statistical control, but may
not be capable
PCRs can be calculated using the process mean
and process standard deviation estimates
When dealing with attributes data, defect per unit
(DPU) statistic is used as a measure of capability
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PROCESS CAPABILITY ANALYSIS
DESIGNED EXPERIMENTS
Systematic approach to varying the variables
believed to be influential on the process, (Factors that
are necessary for the development of a product)
Designed experiments can determine the sources of
variability in the process
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SETTING SPECIFICATIONS ON
DISCRETE COMPONENTS
Components interact with other components
Complex assemblies
Tolerance stack-up problems
Linear combinations
Nonlinear combinations
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SETTING SPECIFICATIONS ON
DISCRETE COMPONENTS
Linear
Combination
when an item is a linear combination of the dimension
of component parts then the dimension of the final
assembly is
y
Note that
3y<3(A+B+C) 2
𝜎 𝑦 =𝜎 2𝐴 +𝜎 2𝐵 +𝜎 2𝐶
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EXAMPLE
An assembled product is composed of
three components, the length in cm of the
components have the following means and
standard deviations.
Component Mean Sigma
A 5 .02
B 3.5 .01
C 4 .03
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SOLUTION
Component Tolerance Limits:
=Mean +/- 3 Sigma:
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SETTING SPECIFICATIONS ON
DISCRETE COMPONENTS
Vv
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ESTIMATING THE NATURAL
TOLERANCE LIMITS OF A PROCESS
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TOLERANCE ANALYSIS
In practice the mean and standard deviation of the
population are not known, but must be estimated
and , can be obtained by
Estimates of
and s from the sample data
The tolerance limits are then determined
by
X Ks
Where the factor K is a function of the confidence level
desired, the percentage of the population included within
the limits, and the sample size.
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EXAMPLE
A random sample of n=25 observations gives:
X 40.75
S 1.37
What tolerance limits contain 99% of all values with
95% confidence?
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EXAMPLE
From a table of tolerance factors , we find K = 2.972
Tolerance Limits:
X Ks 40.75 (2.972)1.37
(36.67, 44.82)
Interpretation : 99% of all values are contained within
the calculated tolerance limits with 95% confidence.
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MEASUREMENT
SYSTEM
ANALYSIS
A review of statistical procedures for use in test
method development and validation
GAGE AND MEASUREMENT
SYSTEM CAPABILITY STUDIES
Two portions of total variability:
product variability which is that variability that is inherent
to the product itself
gage variability or measurement variability which is the
variability due to measurement error
gage
2 2 2
Total product
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MEASUREMENT SYSTEM
ERROR
Measurement System Error can be classified into two
categories: Accuracy and Precision
Accuracy describes the difference between the
measurement and the part’s actual value
Precision describes the variation observed when the same
sample is measured repeatedly with the same device
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PRECISION VS. ACCURACY
The accuracy of a measurement system is usually
broken down into three components:
Bias
Linearity
Stability
The precision, or measurement variation can be broken
down into two categories:
Repeatability
Reproducibility
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ACCURACY
Bias is the difference between the
observed average of measurements and
the reference value
Linearity is the difference in bias values
through the expected operating range of
the gage
Stability (or drift) is the total variation
in the measurement system on the
same samples when measuring a single
characteristic over an extended period
of time
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PRECISION
Repeatability
is the variation in measurements obtained within a
single laboratory with one measurement instrument
when used several times by an appraiser while
measuring the identical characteristic on the same
sample.
Reproducibility
deals with the variation in the average of the
measurements made between different labs,
appraisers, days, etc. when measuring the identical
characteristic on the same sample.
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ANALYSIS OF MEASUREMENT
SYSTEMS
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CONTROL CHARTS AND TABULAR
METHODS
and R Charts
The variability seen on the chart can be interpreted
as that due to the ability of the gage to distinguish
between units of the product
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CONTROL CHARTS AND TABULAR
METHODS
Precision to Tolerance (P/T) Ratio
An estimate of the standard deviation for
measurement error is
R
ˆ gage
d2
The P/T ratio is
6ˆ gage
P/T
USL LSL
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CONTROL CHARTS AND
TABULAR METHODS
Total variability can be estimated using the sample
variance. An estimate of product variability can be
found using
2
Total 2
product 2
gage
S product gage
2
ˆ 2
ˆ 2
ˆ 2product S2 ˆ gage
2
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CONTROL CHARTS AND
TABULAR METHODS
Percentage of Product Characteristic Variability
A statistic for process variability that
does not depend on the specifications
limits is the percentage of product
characteristic variability:
ˆ gage
100
ˆ product
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CONTROL CHARTS AND TABULAR
METHODS
Gauge R&R Studies
Gauge repeatability and reproducibility
(R&R) studies involve breaking the total
gauge variability into two portions:
repeatability which is the basic inherent precision of
the gauge
reproducibility is the variability due to different
operators using the gauge
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CONTROL CHARTS AND
TABULAR METHODS
Gage R&R Studies
Gage variability can be broken down as
𝟐
𝝈 𝒎𝒆𝒂𝒔𝒖𝒓𝒆𝒎𝒆𝒏𝒕 ¿𝒆𝒓𝒓𝒐𝒓 =𝝈 𝟐𝒈𝒂𝒈𝒆 =𝝈 𝟐𝒓𝒆𝒑𝒓𝒐𝒅𝒖𝒄𝒊𝒃𝒊𝒍𝒊𝒕𝒚 + 𝝈 𝟐𝒓𝒆𝒑𝒆𝒂𝒕𝒂𝒃𝒊𝒍𝒊𝒕𝒚
More than one operator (or different
conditions) would be needed to conduct
the gage R&R study
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CONTROL CHARTS AND TABULAR
METHODS
Statistics for Gauge R&R Studies (The Tabular
Method)
Say there are p operators in the study
The standard deviation due to repeatability can
be found as R
ˆ Re peatability
d2
R1 R 2 R p
R
p
where
and d2 is based on the # of observations per part per operator
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CONTROL CHARTS AND TABULAR
METHODS
Statistics for Gauge R&R Studies (the Tabular
Method)
The standard deviation for reproducibility is given as
𝑅 ¯¯𝑥
𝜎^ 𝑟𝑒𝑝𝑟𝑜𝑑𝑢𝑐𝑖𝑏𝑖𝑙𝑖𝑡𝑦 =
𝑑2
R x x max x min
x max max( x1 , x 2 , x p )
x min min( x1 , x 2 , x p )
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MEASUREMENT
DISCRIMINATION
is the capability of the
Measurement discrimination
measurement systems to reliably measure small
changes of the measured characteristic (also
known as resolution).
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ATTRIBUTE INSPECTION
CAPABILITY
Two kinds of mistakes can be made in attributes
inspections:
Conforming items mistakenly classified as nonconforming
Nonconforming items mistakenly classified as conforming
The rates with which these errors are made are referred
to as the performance characteristics
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