IsIs

The Define
Process
Process
Capable
Capable
??

Quality Process

Improvement Select
Measures

Model
Collect &
Interpret
Data

Is Process Capable? Is Investigate

No & Fix
Process
Stable Special
? Causes
Purpose: Determine the
adequacy of the Yes

process with respect No IsIs

Improve
Process
Process
to customer Process
Capable
Capable
Capability
/management needs. ??

Yes
Use SPC to
Maintain
Current
Process

8-1
 IsIs
Process
Process
Capable Process Capable
Capable
??

A stable process that meets customer requirements.

Histogram
Control Chart

UCL

CL

LCL
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Run Order Lower Spec Upper Spec
Target

Capability assessments for unstable processes, may not

be indicative of how the process is actually performing.
8-2
 IsIs
Process
Process
Capable
Capable
??

Assessing Process Capability

 Counting Measures
 The average percent defectives.
 The average number of defects.

 Instrument Measures
 Comparing both the center of the process and the
process variation

8-3
Capability Assessment for Counting Measures IsIs
Process
Process
Capable
Capable
“Order Entry Process” ??

Week# Errors
1 15
2 22 Control Chart
35
3 18
4 10 30
UCL=28.0
5 13 Number 25
6 9 of Errors
20
7 27 Avg=16.0
15
8 12
9 24 10
10 22 5 LCL=4.0
11 8
0
12 8 5 10 15 20
13 26 Week
14 16
15 20
16 10 Is this process adequate as is?
17 16
18 9 Should it be improved?
19 15
20 20
Total 320
8-4
Capability Assessment for Instrument IsIs
Process
Process
Capable
Capable
Measures ??

Histogram
Control Chart

UCL

CL

LCL
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Run Order Lower Spec Upper Spec
Target

Is this process adequate as is?

Should it be improved?
8-5
Measures of Process Capability IsIs
Process
Process
Capable
Capable
USL - LSL
Cp = Specification Range =
??
True Process Range 6c

Cp < 1.0  Process is not capable of meeting specs

Cp = 1.0  Process is marginally capable
Cp > 1.0  Process is capable of meeting specs
Problem: We are assuming the process has a target that is
in the center of the specification range, and that
the process is in fact centered on that target.

Distance from process average

Cpk = to closest specification limit = min (USL - x , x - LSL)
1 True Process Range 3c
2
Note: a negative result is possible if the process average is outside specifications

Cpk < 1.0  Process is not capable of meeting specs

Cpk = 1.0  Process is marginally capable
Cpk > 1.0  Process is capable of meeting specs
Benefits: • Optimal values are attained by running exactly
between specs.
• Can (must) be used for 1-sided specifications
Warning: Capability assessments for unstable processes,
may not be indicative of how the process is actually 8-6
 IsIs
Process
Process
Capable
Capable

Process Capability ??

LSL USL
USL
LSL

How much material is out of spec?

 In the short term?
 In the long term?

8-7
 IsIs
Process
Process
Process Capability Ratios Capable
Capable
??

LSL
LSL USL
USL

Voice of The Process

Voice of The Customer

8-8
 IsIs
Process
Process
Capable
Capable

Process Capability - The Strategy ??

Centering –The Process Is On Target

Spread – Reduce The Variation

Defects Defects

LSL USL

8-9
Process Capability Ratios IsIs
Process
Process
Capable
Capable
??

2 Key Metrics for Measuring Capability

USL  LSL
Cp 
6c

X- LSL USL- X
Cpk  Min( , )
3c 3c

8-10
 IsIs
Process
Process

Process Capability Ratios - Concept Capable

Capable
??

USL  LSL
Cp 
6c

Total Tolerance
Cp 
Process Spread

8-11
Process Capability – Example 1 IsIs
Process
Process
Capable
Capable
LSL USL ??

27 Inches 33 Inches

u = 30 Inches
 c= 1

USL  LSL
Cp  Sigma Level = 3C p
6c

Cp = __________ Sigma Level = __________

8-12
Process Capability – Example 2 IsIs
Process
Process
Capable
Capable
LSL USL ??

29 Inches 31 Inches

u = 30 Inches
c= 1

USL  LSL
Cp  Sigma Level = 3C p
6c

Cp = __________ Sigma Level = __________

8-13
Process Capability – Example 3 IsIs
Process
Process
Capable
Capable
LSL USL ??

28 Inches 32 Inches

u = 30 Inches
 c = .333

USL  LSL Sigma Level = 3C p

Cp 
6c

Cp = __________ Sigma Level = __________

8-14
Process Capability – Example 4 IsIs
Process
Process
Capable
Capable
??
LSL USL
28 Inches 32 Inches

u = 33 Inches
 c = .333

USL  LSL Sigma Level = 3C p

Cp 
6c

Cp = __________ Sigma Level = __________

8-15
Process Capability Ratios IsIs
Process
Process
Capable
Capable
??

X- LSL USL- X
Cpk  Min( , )
3c 3c

X- LSL USL- X
CpL  CpU 
3c 3c

A metric to take into account process shift

8-16
Process Capability – Example 5 IsIs
Process
Process
Capable
Capable
??
LSL USL
28 Inches 32 Inches

u = 33 Inches
 c = .333

CpL = ___________ CpU = ___________

Cpk = ____________

Recall Cp=2.0 8-17

 IsIs

CP & CPK Measure Short-term

I Chart for C1 Capability
Process
Process
Capable
Capable
??
39
3.0SL=37.36

Individual Value 34
Is The Process
In Control ?
X=30.60
29
Is It Producing
Defects ?

24 -3.0SL=23.84

0 5 10 15 20 25 30 35
Observation Number

A Short-term Capability study covers a relatively

short period of time (days, weeks) generally
consisting of 30 to 50 data points. The actual
number depends on the subject under study.

8-18
Long Term Performance
I Chart for C3 IsIs
Process
Process
Capable
Capable
??
50
3.0SL=47.12

Individual Value 40
Short term
Is The Process Capability
In Control ? X=33.80
30
Is It Producing
Defects ?

20 -3.0SL=20.49

0 50 100
Observation Number

A long-term capability study covers a relatively long

period of time (weeks, months) generally consisting of
100-200 data points. Again, the actual amount depends
on the subject under study.

8-19
A Further Look at Capability IsIs
Process
Process
Capable
Capable
??

Compare the estimates of the process deviations

from the short-term and long-term data

Descriptive Statistics

Variable N Mean StdDev

short term 30 30.6 2.23
long term 180 33.8 4.44

What
Whatis
isthe
thedifference
differencebetween
betweenthe
theshort-term
short-termand
andthe
the
long-term
long-termdata?
data?
What
Whatimplication
implicationdoes
doesthis
thishave
havein
indoing
doingcapability
capability
studies?
studies?

8-20
The Dynamic Process IsIs
Process
Process
Capable
Capable
??

LSL USL

Short-Term
Capability

Long-Term
Capability

Over
Overtime,
time,aaprocess
processtends
tendsto
toshift
shiftby
byapproximately 1.5
approximately1.5
8-21
Measures of Process Performance IsIs
Process
Process
Specification Range = USL - LSL Capable
Capable
Pp = ??
True Process Range 6s

P p < 1.0  Process Performance is not meeting specs

P p = 1.0  Process Performance is marginally meeting specs
P p > 1.0  Process Performance is meeting specs

Problem: We are assuming the process has a target that is

in the center of the specification range, and that
the process is in fact centered on that target.

Distance from process average

to closest specification limit min (USL - x , x - LSL)
P pk = 1 =
True Process Range 3s
2

Note: a negative result is possible if the process average is outside specifications

Ppk < 1.0  Process Performance is not meeting specs

Ppk = 1.0  Process Performance is marginally meeting specs
Ppk > 1.0  Process Performance is meeting specs

Benefits: • Optimal values are attained by running exactly

between specs.
• Can (must) be used for 1-sided specifications 8-22
Performance vs. Capability IsIs
Process
Process
Capable
Capable
??

CO2Sales
Days Levels for 55 Timefor
Outstanding Points
55 Days

14

13
CO2-Shrt
DSO

12

11

10
Index 10 20 30 40 50

These data show that the process, if well controlled can

perform much better than it currently is

8-23
 IsIs

Capability vs. Performance Process

Process
Capable
Capable
??

CO2Sales
Days Levels for 55 Timefor
Outstanding Points
55 Days

14

13
CO2-Shrt
DSO

12

11

10
Index 10 20 30 40 50

Capability: Only Process Performance:

random or short Total Variation including
term variability shifts and drifts
(Cp & Cpk) (Pp & Ppk)
8-24
Process Performance Ratios IsIs
Process
Process
Capable
Capable
??

USL  LSL
P p 
6s

X- LSL USL- X
P pk  Min( , )
3s 3s

The P-family of indices are computationally the same as

the C-family of ‘capability’ indices, but use the observed
long-term standard deviation.
8-25
How Does Process Capability Relate to IsIs
Process
Process
Six Sigma? A goal of Six Sigma is to have: Capable
Capable
??

Cp = 2.0
Cpk = 1.5
Cpk is 1.5 to allow for a 1.5 sigma shift from target.
If the six-sigma goal is achieved, the 1.5c drift can
occur with a low risk of producing material out of
specification.
Example: The target viscosity for a plastic is 0.76.
c from the process is 0.01. The lower and upper
spec from the process are 0.70 and 0.82, respectively.
0.82 - 0.70 0.12
Cp   2.0
6x(0.01) 0.06
0.82 - 0.775 0.045
C pk (target  1.5c )   1.5
3(0.01) 0.03
LSL USL

0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82
T-1.5c T T+1.5c 8-26
Six Sigma Goals (Defect Level) IsIs
Process
Process
Capable
Capable
??

The Quality goal of six sigma corresponds to 3.4ppm

defect level.

For attributes data, the ppm level is calculated by:

Number of Defects
x 1,000,000
Defect Opportunities

For variables data, the ppm level is calculated using

the normal table.

8-27
Minitab: Process Capability Analysis IsIs
Process
Process
Capable
Capable
??

Process Capability Sixpack of X

I Chart Capability Histogram
LSL USL
UCL=103.03
I ndividual Value

100 Specifications
LSL 75
Is it in 90
_
X=89.66 USL 105
control ?
80
LCL=76.30
1 3 5 7 9 11 13 15 17 19 21 23 25 76 80 84 88 92 96 100 104

Moving Range Chart Normal Prob Plot

1
UCL=16.42
AD: 0.301, P: 0.554
16
Moving Range

Is it in 8
__ Is it
control ? MR=5.03
Normal ?
0 LCL=0
1 3 5 7 9 11 13 15 17 19 21 23 25 80 90 100

Last 25 Observations Capability Plot

100 Within Within Overall
StDev 4.45479 StDev 4.66887
Values

90 Cp 1.12 Pp 1.07
Overall
Cpk 1.1 Ppk
Cpm *
1.05
How does
80 Specs the
5 10 15 20 25
Observation process
variation
compare to
the
spec limits ?
8-28
WARNING!!! IsIs
Process
Process
Capable
Capable
??

Statistical Assumptions Made In Capability Studies

1. Data Comes From a Stable Process

 If not, work towards getting the process in
control
 Don’t despair, you can still make some
assumptions about your process in the
mean time

2. Data are Normally Distributed

 If not, transform it (ask the instructor)

If Items #1 and #2 aren’t met, results will be misleading

8-29
 IsIs

Minitab: Process Capability Analysis Process

Process
Capable
Capable
??

 Minitab has many tools

that will help you in this
area. We will find
Process Capability
under:
Stat>Quality Tools>
Capability Sixpack>
Normal

Open Line1.MTW in the

Mintab Datasets Folder
and go to the Capability
Sixpack

8-30
 IsIs

Minitab: Process Capability Analysis Process

Process
Capable
Capable
??

Enter the information shown below and select OK

8-31
Minitab: Process Capability Analysis IsIs
Process
Process
Capable
Capable
??

Your output should look like this:

Process Capability Sixpack of X

I Chart Capability Histogram
LSL USL
UCL=103.03
I ndividual Value

100 Specifications
LSL 72
_
90 X=89.66 USL 108

80
LCL=76.30
1 3 5 7 9 11 13 15 17 19 21 23 25 72 78 84 90 96 102 108

Moving Range Chart Normal Prob Plot

1
UCL=16.42
AD: 0.301, P: 0.554
16
Moving Range

8
__
MR=5.03

0 LCL=0
1 3 5 7 9 11 13 15 17 19 21 23 25 80 90 100

Last 25 Observations Capability Plot

100 Within Within O verall
StDev 4.45479 StDev 4.66887
Values

90 Cp 1.35 Pp 1.29
O verall
Cpk 1.32 Ppk 1.26
Cpm *
80 Specs
5 10 15 20 25
Observation

8-32
Example - Capability Study Results IsIs
Process
Process
Capable
Capable
??

 Notice that both Cp / Cpk and Pp / Ppk values are

given

 The data shows that the Capability of the process

(Cpk) is 1.32 and the Entitlement (Cp) is 1.35
 This shows that the process is on target. Why?

 The data also shows the Performance of the

process (Ppk) is reasonably capable with a value of
1.26

 This indicates the process is in control. Why?

 But how good should a process get… Next Slide?

8-33
Process Performance and Capability IsIs
Process
Process
Capable
Capable
??
 The Ppk can closely approach the Cp when
 The Customer specifications truly reflect customer
requirements
 The process in under statistical control
 The data approximate the normal distribution
 The process average is very close to target.

 The Cp is like a benchmark or entitlement

 Sigma capability is driven primarily by random error
(Common Cause Sources of Variation)

 We would like Ppk to be very close to a Cpk of

1.5
 This would be a process that is performing at a Six-
Sigma level

8-34
Test Method Capability IsIs
Process
Process
Capable
Capable
??
Variation Variation can be broken down into two types, process and test. These
Types two types are listed and described below:
Variation Type Component(s)
Process The variation due to the:
• process itself
• raw materials
• Sampling ?

Test All other types of variation,

including:
• Sampling ?
• Sample preparation
• Between analysts
• Within analysts
• Test Equipment
• Environment
• Any other variation not part of
the process
NOTE: Test variation may not be just variation due only to test, it
encompasses all sources other than process. 8-35
 IsIs

Total Variability Components Process

Process
Capable
Capable
??

 2 2 2
 process  test
total
Where: 2  c2 (Assumes process is stable)
total
 2  S2 (For Unstable Processes)
total
2 Can be estimated three ways:
 test
1) Standard Reference Material – Repeated Sampling
2) Half-Blind Technique
3) Gauge R&R

 2process
(Estimated by subtracting test from total variability

8-36
Repeated Sampling (SRM) Technique IsIs
Process
Process
Capable
Capable
??

Advantages
Long-term estimate of test
variability
Easy to administrate
Can be used to assess accuracy
(known value)
Can be used to test experimental
bias (known value)
Can be used as a SPC monitor

Disadvantages
Only one level of the process is
studied
People get used to what value
"should be"

8-37
Half-Blind Technique IsIs
Process
Process
Capable
Capable
??

Advantage
Long-term estimate of test
variability

Multiple levels of the

process are represented by
using different samples

Disadvantage
Hard to administrate
Cannot be used to
test accuracy

8-38
Gauge R&R Technique IsIs
Process
Process
Capable
Capable
??
Advantages
Quick initial estimate of test
variability
Can be used to assess accuracy
(known value)
Can be used to test experimental
bias (known value)
Analyst portion can be estimated
Multiple process levels studied

Disadvantages
Hard to administrate

Short-term estimate of test

variability
Detailed experimental plan
needed.
Analysis more difficult
8-39
Measures of Test Method Capability IsIs
Process
Process
Capable
Capable
??

Eastman has traditionally used:

 2

 test  100% Percent of variation due to test method
total 

Six Sigma uses the following measures:

  
 test
 

 100% Percent Gauge R&R

 total 

 5.15 * 
 test  100% Precision to Tolerance
 Tolerance  Ratio
 
8-40
How Good is Good? … The Debate is On IsIs
Process
Process
Capable
Capable
??

Eastman has traditionally used:

Percent Test Variability: Goal is 20 to 30%

Six Sigma uses the following measures:

Percent Gauge R&R: Less Than 30%

P/T Rate: Best Case 10%, Acceptable 30%

Problem: 30% Gauge R&R translates to

9% Percent Test Variability (Unrealistic
for a lot of tests in Chemical Industry)
Note: Initial analysis is showing that processes can be monitored with SPC
techniques even when the percent test variability is as high as 50%! 8-41
Resources Allocation? IsIs
Process
Process
Capable
Capable

Two-Dimensional Guidelines ??

Cp=0.5
100

90

Improving process variation will help, Cp=1.0

Test is primary
Poor

80 but test will still need to be improved

limitation on further
(BOTH)
process capability
70
Improvement
(TEST)
60
Cp=1.5
Work on
P/T Ratio

Focus on process variation first,

50 Test may become limiting after both process
Marginal

some level of process variation and test

(BOTH) Cp=2.0
40 Improvement
(PROCESS)
30
Focus on Process,
20 Test is Adequate
Adequate

(PROCESS) Sigma Level > 6

10

0
0 10 20 30 40 50 60 70 80 90 100
% Gage R&R
Adequate Marginal Poor 8-42
Review IsIs
Process
Process
Capable
Capable
??
•Indices to measure processes capability
Cp – Goal is 2, Short Term Sigma used in Estimate

Cpk – Goal is 1.5, Short Term Sigma used in Estimate

Pp – Approach Cp, Long Term Sigma used in Estimate

Ppk – Approach Cpk, Long Term Sigma used in Estimate

Note: All of the above are equal for stable processes on target

•Indices to measure test method capability

Percent Test Variation – Goal is 20 to 30%

Percent Gauge R&R – Less than 30% (Percent Test < 9%)
50% may be more reasonable

P/T Ratio – Best Case 10%, Acceptable at 30%

8-43
Exercise IsIs
Process
Process
Capable
Capable
??

1.) Your Catapult Team should complete page 11 of the “Catapult

Process” handout.

Limit yourselves to 30 minutes for this exercise.

8-44