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Statistical Process Control: Prof. Haroon Chughtai

Statistical process control (SPC) is a method to monitor and control a process to ensure it operates optimally and produces conforming products. [1] Variation exists in all processes, and SPC uses statistical tools like control charts to determine when variation is normal versus requiring correction. [2] SPC activities include understanding the process, identifying sources of variation, and eliminating special causes of variation. [3] Control charts in particular help identify whether a process is stable or needs adjustment by monitoring whether data points fall within established control limits.

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68 views22 pages

Statistical Process Control: Prof. Haroon Chughtai

Statistical process control (SPC) is a method to monitor and control a process to ensure it operates optimally and produces conforming products. [1] Variation exists in all processes, and SPC uses statistical tools like control charts to determine when variation is normal versus requiring correction. [2] SPC activities include understanding the process, identifying sources of variation, and eliminating special causes of variation. [3] Control charts in particular help identify whether a process is stable or needs adjustment by monitoring whether data points fall within established control limits.

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STATISTICAL

PROCESS
CONTROL

Prof. Haroon Chughtai


STATISTICAL PROCESS CONTROL (SPC)

•Is the application of Statistical Methods to monitor and


control a process to ensure that it operates at its full
potential to produce conforming product.

OR

•Is an analytical decision making tool which allows you to see


when a process is working correctly and when it is not.

•Variation is present in any process, deciding when the


variation is natural and when it needs correction is the key
to quality control.
TRADITIONAL METHODS VS STATISTICAL PROCESS CONTROL

The quality of the finished article was traditionally achieved


through post-manufacturing inspection of the product;
accepting or rejecting each article (or samples from a
production lot) based on how well it met its
design specifications

SPC uses Statistical tools to observe the performance of the


production process in order to predict significant deviations
that may later result in rejected product.
TYPES OF VARIATION

Two kinds of variation occur in all manufacturing processes

1. Natural or Common Cause Variation


consists of the variation inherent in the process as
it is designed.
may include variations in temperature, properties of
raw materials, strength of an electrical current
etc.

2. Special Cause Variation or Assignable-cause Variation


With sufficient investigation, a specific cause, such
as abnormal raw material or incorrect set-up
parameters,
can be found for special cause variations.
‘In Control’ and ‘Out Of Control’

 Process is said to be ‘in control’ and stable

If common cause is the only type of variation that


exists in the process
It is also predictable within set limits i.e. the probability
of any future outcome falling within the limits can be stated
approximately.

 Process is said to be ‘out of control’ and unstable

Special cause variation exists within the process


Statistical process control -broadly broken
down into 3 sets of activities

1. Understanding the process

2. Understanding the causes of variation

3. Elimination of the sources of special


cause variation.
Understanding the process

• Process is typically mapped out and the process is


monitored using control charts.

Understanding the causes of variation

• Control charts are used to identify variation that may be due to


special causes, and to free the user from concern over
variation due to common causes.

• It is a continuous, ongoing activity.

• When a process is stable and does not trigger any of the


detection rules for a control chart, a process capability
analysis may also be performed to predict the ability of the
current process to produce conforming product in the future.
•When excessive variation is identified by the control chart detection
rules, or the process capability is found lacking, additional effort is
exerted to determine causes of that variance.

• The tools used include

• Ishikawa diagrams(cause and effect diagram)


•Designed experiments
•Pareto chart
(graphically rank data in descending order , he coined the
phrase vital few and use full many )
Example of vital few is “ a few customer account for the majority
Elimination of the sources of special cause variation

• Once the causes of variation have been quantified, effort is


spent in eliminating those causes that are both statistically
and practically significant.

• includes development of standard work, error-proofing and


training.

• Additional process changes may be required to reduce


variation or align the process with the desired target,
especially if there is a problem with process capability.
ADVANTAGES OF SPC

• Reduces waste

• Lead to a reduction in the time required to produce the


product
or service from end to end
due to a diminished likelihood that the final product
will have to be reworked, identify bottlenecks, wait times, and
other sources of delays within the process.

• A distinct advantage over other quality methods,


such as inspection - its emphasis on early detection and
prevention of problems

•Cost reduction

•Customer satisfaction
SPC CHARTS

•One method of identifying the type of variation present.

•Statistical Process Control (SPC) Charts are essentially:


Simple graphical tools that enable process performance
monitoring.
Designed to identify which type of variation exists within the
process.
Designed to highlight areas that may require further
investigation.
 Easy to construct and interpret.

•2 most popular SPC tools


 Run Chart
 Control Chart
•SPC charts can be applied to both dynamic processes and
static processes.

Dynamic Processes
oA process that is observed across time is known as a
dynamic process.
oAn SPC chart for a dynamic process - „time-series‟ or a
„longitudinal‟ SPC chart.

Static Processes
oA process that is observed at a particular point in time
is known as a static process.
oAn SPC chart for a static process is often referred to as
a
„cross sectional‟ SPC chart.
Control charts

Show the variation in a measurement during the time period that


the process is observed.

Monitor processes to show how the process is performing and


how the process and capabilities are affected by changes to
the process. This information is then used to make quality
improvements.

 A time ordered sequence of data, with a centre line calculated


by
the mean.

 Used to determine the capability of the process.

 Help to identify special or assignable causes for factors that


impede peak performance.
Control charts have four key features:

1) Data Points:
Either averages of subgroup measurements or individual
measurements plotted on the x/y axis and joined by a line.
Time is always on the x-axis.

2) The Average or Center Line


The average or mean of the data points and is drawn
across the middle section of the graph, usually as a heavy or
solid line.

3) The Upper Control Limit (UCL)


Drawn above the centerline and annotated as "UCL". This
is often called the “+ 3 sigma” line.

4) The Lower Control Limit (LCL)


Drawn below the centerline and annotated as "LCL". This
is called the “- 3 sigma” line.
Control limits define the zone where the observed data for a
stable and consistent process occurs virtually all of the time
(99.7%).

Any fluctuations within these limits come from common causes


inherent to the system, such as choice of equipment, scheduled
maintenance or the precision of the operation that results from
the design.

An outcome beyond the control limits results from a special


cause.

 The automatic control limits have been set at 3-sigma


limits.
•The area between each control limit and the centerline is
divided into thirds.

1) Zone A - "1-sigma zone“


2) Zone B - "2-sigma zone"
3) Zone C - " 3-sigma zone “
PROCESS CAPABILITY
ANALYSIS
 Examines
◦ whether the process is capable of producing products which
conforms to specifications
◦ range of natural variability in a process what we measure with
control charts

 Process capability studies distinguish between conformance to


control limits and conformance to specification limits (also called
tolerance limits)
◦ if the process mean is in control, then virtually all points will
remain within control limits
◦ staying within control limits does not necessarily mean that
specification limits are satisfied
◦ specification limits are usually dictated by customers
21
Process Capability analysis cont.

Design
Specificatio
ns

(a) Natural variation


exceeds design
specifications;
process is not
capable of meeting
specifications all the
time.
Process
Design
Specificatio
ns

(b) Design
specifications and
natural variation the
same; process is
capable of meeting
specifications most of
the time.
Process
22
Process Capability (cont.)

Design
Specificatio
ns

(c) Design
specifications
greater than natural
variation; process is
capable of always
conforming to
specifications.
Process
Design
Specificatio
ns

(d) Specifications
greater than natural
variation, but
process off center;
capable but some
output will not meet
upper
specification. Process
23

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