IsIs

Process
Process

The Define
Stable
Stable
??

Quality Process

Improvement Select
Measures
Model
Collect &
Interpret
Data

Is Process Stable? IsIs Investigate

No
Process
Process & Fix
Stable
Stable Special
Purpose: ?? Causes

Determine the Yes

stability of key
Is
measures of the Improve
Process
No
Process
Capable
product. Capability
?

Yes
Use SPC to
Maintain
Current
Process

6-1
 IsIs
Process
Process

Types of Variation Stable

Stable
??

Common Causes
Run Chart
Causes that are inherent in the
Quality
process over time, and affect all Characterist
outcomes of the process. ic

 Ever-present
 Create small, random
fluctuations in the process
 Lots of them
 The sum of their effects
Time
creates the expected
variability
 Predictable

6-2
 IsIs
Types of Variation Process
Process
Stable
Stable
??

Special Causes
Causes that are not present in Run Chart
the
Quality
process all the time, but arise Characterist
because of specific ic

circumstances.
 Not always present in the
process
 Can create large process
disturbances, or sustained
Time
shifts
 Relatively few in number
 Pull the process beyond the
Control charts help identify the presence of special causes.
expected level of variability 6-3
 IsIs
Process
Process
Stable
Stable
??

Control Chart Components

 Run chart of the data Control Chart

 Center Line (CL)
 UCL
A line at the average of the
data or target of the
process CL
 Upper Control Limit (UCL)
 A line at the upper limit of LCL
expected variability 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Run Order
 Lower Control Limit (LCL)
 A line at the lower limit of
expected variability
he control limits are based on data collected from the proces
6-4
 IsIs
Process
Process
Stable
Stable
??

Rules for Separating Common &

Special Causes
Two commonly used signals of special causes are:

Rule 1: Any point above the Upper

Control Limit (UCL) or below the Lower
Control Limit (LCL)

Rule 2: 8 points in a row on the same

side of the center line (CL)

Note: Additional rules do exist.

6-5
Evaluation of Individuals Data IsIs
Process
Process
Stable
Stable
??

 c
R ,n=2
  • •
•• • • • • ••
c s •
• • • • • • • ••
••• • • • •
• • • • • • • •
T X • • • • • • •
• • •• •
•• • Target
••
• • •• • • •

Order of Production

 s Measures Variation in All Data

Used to Estimate 'Spread'
Does Not Reflect 'Capability'
Should Not Be Used for Calculating Control Chart Limits

 c Measures Variation in Successive Values

Used to Estimate the Potential Capability
Should Be Used to Calculate Trial Control Chart Limits
6-6
 IsIs
Process
Process
Estimating Sigma (Standard Deviation) Stable
Stable
??

n
 Xi – X
2

i=1 Total  s
s =
n–1

n
 Xi – Xi–1
c = i=2
= R Short-Term c
n–1 1.128 1.128

In existing data, Sigma C is a better estimate of

the common cause variability… Since it eliminates
variation due to cycles, shifts, etc…(Special
Causes). Therefore, Sigma C (from edited moving
ranges) is always used to calculate control limits!
6-7
Problem: Individuals Chart Calculations IsIs
Process
Process
Stable
Stable
??

CO N TR OL C HA R T F O R Line 1 - First 25 Points Only Problem #13

X & MR
F req ue nc y = D aily

D ate
T im e
O pe rator
Line 1
Me asur em en t ( X) 87.6 91.2 94.0 91.6 81.6 89.1 90.9 94.0 94.4 91.0 84.2 89.5 86.6 92.9 97.4 94.2 81.6 85.6 88.7 88.8 87.7 79.9 96.6 89.3 93.2
Mo ving R ang e (MR ) - 3.6 2.8 2.4 10.0 7.5 1.8 3.1 0.4 3.4 6.8 5.3 2.9 6.3 4.5 3.2 12.6 4.0 3.1 0.1 1.1 7.8 16.7 7.3 3.9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

MR

6-8
 IsIs
Line 1 - First 25 Points Only
Control Chart for _______________________________ Process
Process
Stable
Stable
Individuals X & MR CHARTS - Calculation Worksheet ??

Chart
MR = Current Measurement – Previous Measurement
Calculations
R = Total of MRs = =
Total number MRs
X = Total of Measurements = =
Total number of Measurements

UCL MR = 3.267  R LCL MR = 0

= 3.267 
=

 c = 1.128
R =
1.128
=

UCL X = X + 3 c LCL X = X – 3 c

UCL X = + 3( ) LCL X = – 3( )

UCL X = + LCL X = –

UCL X = LCL X =

6-9
Minitab: Creating Individuals Control Charts IsIs
Process
Process
Stable
Stable
??
• Open Minitab Software and the Line 1.MTW Worksheet.
• Create an Individuals Control Chart following the commands in the notes.
• Your output should look like the charts below:

I-MR Chart of X
UCL=103.03
100
I ndividual Value

_
90 X=89.66

80
LCL=76.30
1 3 5 7 9 11 13 15 17 19 21 23 25
Observation

1
16 UCL=16.42
Moving Range

12

8
__
MR=5.03
4

0 LCL=0
1 3 5 7 9 11 13 15 17 19 21 23 25
Observation
6-10
Minitab: Creating Individuals Control Charts IsIs
Process
Process
Stable
Stable
??

•Open Problem 14.MTW located in the

Minitab Datasets folder.

•Use Minitab to create an Individuals and

Moving Range control chart for X in
column C1.

•What do you notice about the X and MR

Charts?

•What should you do to establish control

limits?
6-11
Minitab: Creating Individuals Control Charts With IsIs
Process
Process
Range Edited Limits Stable
Stable
??

•As you noticed the moving range control chart for problem 14 has two
ranges that are above the upper control limit.

•So, a special cause source of variation is included in the limits

calculation.

•The special cause needs to be removed and the limits re-calculated.

•Row 24 is the data point causing the moving ranges to be out of the
limits.

•Use the brush tool to select and update the control chart or create a
new column without data point #24 (Remember to use the Backspace).

•These were taught in the Introduction to Minitab Course which is a pre-

requisite for the SPC course.
•Brush tool – Page 13 Introduction to Minitab book

6-12
Minitab: Creating Individuals Control Charts With IsIs
Process
Process
Range Edited Limits Stable
Stable
??

•The chart below shows the updated control charts without point #24.

I-MR Chart of X_ 1
66 1 1

UCL=65.261
65
I ndividual Value

2
2 2
2 2
64 2
_
X=63.528
63

62
LCL=61.796
1
1
1 5 9 13 17 21 25 29 33 37
Observation

1
1
2.4 1 1

UCL=2.128
Moving Range

1.8

1.2
__
0.6 MR=0.651
2
2 2
2 2
2 2
0.0 LCL=0
2
1 5 9 13 17 21 25 29 33 37
Observation

•The updated moving range chart shows more moving ranges outside of
limits.
•These are caused by rows 7 and 29.
6-13
•Remove the data points and update the control charts again.
Minitab: Creating Individuals Control Charts With IsIs
Process
Process
Range Edited Limits Stable
Stable
??

•The second updated Moving Range chart does not have any points outside
of limits
I-MR Chart of X_ 1
65 1

2 UCL=64.579
I ndividual Value 2 2
2 2
64 2
2 _
X=63.411
63

LCL=62.242
62 1

1
1
61
1 5 9 13 17 21 25 29 33 37
Observation

1.6
UCL=1.436
1.2
Moving Range

0.8
__
0.4 MR=0.439

0.0 LCL=0
1 5 9 13 17 21 25 29 33 37
Observation

•The objective is to calculate control limits that represent common cause

sources of variation only.
•However, stop editing data points once 10 to 20% of the data has been
edited.
•If the initial data has this many special causes, the limits will identify6-14
plenty
 Minitab: Obtain Statistics to Calculate Limits for IsIs
Process
Process
Continuous Process Monitoring Stable
Stable
??

lect I-MR Options in the I-MR dialog box

oose Storage and select Means and Standard deviations

6-15
Minitab: Obtain Statistics to Calculate Control IsIs
Process
Process
Limits Continued Stable
Stable
??

Two new columns are created

Mean1 – Average of your data
STDE1 – Sigma_C

6-16
 IsIs
Process
Process
Stable
Stable
??
Process Stability

Stable Process
A process in which the key measures of the output
from the process show no signs of special causes.
Variation is a result of common causes only.

Unstable Process
A process in which the key measures of the output
from the process show signs of special causes in
addition to common causes. Variation is a result of
both common and special causes.

6-17
 IsIs
Process
Process
Process Stability Stable
Stable
??

STABLE vs. UNSTABLE PROCESSES

STABLE

 Constant
 Constant

UNSTABLE

 Constant
 Sustained Shift

 Constant
 Irregular Shift

 Constant
 Trend

 Increase
 Constant

 Irregular
 Irregular

6-18
A Stable Process IsIs
Process
Process
Stable
Stable
??

UCL
• •
• • • •
• • • •• •
• • •• • • • • • • • •
•• • • • • • • • • • • •• • • •
• • • •• • • • • • •
• • • • • • • • • •
• •
• • • • • • • • • • • •
• • • •
LCL

Common Causes Alone Are At Work:

• Behaves in a Random Manner
• No Cycles
• No Runs
• No Trends
• No Shifts
• No Defined Patterns 6-19
A Stable Process: Sigma S = Sigma C IsIs
Process
Process
Lower Upper Stable
Stable
Spec Spec
??

Centering O.K.
Capability Adequate
No Action Needed
3c X 3c
CAPABILITY
SPREAD
Lower Upper
Spec Spec

Centering Off
Capability Adequate
Shift Centering By
Altering Aim of
Process
Lower Upper
Spec Spec

Centering O.K.
Capability Inadequate
Change Process
6-20
Un-Stable Process IsIs
Process
Process
Stable
Stable
??

UCL • • ••
• ••
• • • • • •
• •
•• • •• • • •
• • ••
• • •
•• • • • • • • • • •• • • • •
• • • • •• • • •• • •• • • • • • •
• •• • • • •• •
• • • • •
• •
LCL

Assignable Cause(s) Are Present In Addition To

Common Cause Variation

Look For:
• Points Outside the Control Limits
• Shifts
• Cycles
• Runs
• Trends
6-21
Un-Stable Process: Sigma S Not Equal to IsIs
Process
Process
Stable
Stable
Sigma C Lower
Spec
Upper
Spec
??

Spread Within
Specifications
Determine Cause of
Instability and Correct
If Economically
Feasible
CAPABILITY
SPREAD

Lower Upper
Spec Spec

Spread Outside
Specifications
Capability Adequate
Determine Cause of
Instability and Correct

Lower Upper
Spec Spec Spread Outside
Specifications
Capability Inadequate
Change Process -
Attempt to Achieve
At Least Partial
Improvement 6-22
 IsIs
Process
Process
Stable
Stable
??

Advantages of Stable Processes Are:

6-23
 IsIs
Process
Process
Stable
Stable
??
Polymer Manufacturing Data
Control Chart
5
b*
Histogram 4

LS US 3

UCL=2.2
2
Avg=1.4
1
LCL=0.5

0 1 2 3 4 5 20 40 60 80 100 120 140

b* Sample

Note: b* is a measure of yellowness

Histogram does not show whether the process is stable!

6-24
What’s Wrong With Putting Specification IsIs
Process
Process
Limits on Control Charts? Stable
Stable
??

Case 1: (Specifications wider than Control Limits)

USL
x
UCL
x x
x CL
x
LCL
x
LSL
x

Case 2: (Control Limits wider than Specifications)

UCL
x
USL
x x
x CL
x
LSL
x
LCL

In both cases, specification limits on control charts

cause you to take the wrong action.
6-25
 IsIs
Process
Process
Stable
Stable
??
Histograms & Control Charts

Histograms Control Charts

 Plot past data  Real-time
 Cannot tell if evaluation
process is stable  Help identify
 Only useful for presence of special
prediction if the causes
process is stable  Assess past and
present stability of
process

6-26
 IsIs
Process
Process
Stable
Stable
??
Pump Maintenance Data

20
18
16
Number 14
of 12
UCL=11.4
Failures 10
8
6
Avg=4.8
4
2
0 LCL=None
2 4 6 8 10 12 14 16 18 20 22 24
Week

Are there any signals of special causes? Circle them.

6-27
 IsIs
Process
Process
Stable
Stable
Driving to Work Data ??

55

Time UCL=51.6
(Minutes) 50

Avg=45.9
45

40 LCL=40.2

35
5 10 15 20 25 30 35

Day

The next 5 observations are: 47, 46, 43, 52, 45. Plot them.
Are there any signals of special causes? Circle them.
6-28
 IsIs
Process
Process
Stable
Stable
??
Purchase Order Data

14
13
12
11
Time 10
UCL=9.5
(Days) 9
8
7
6
5 Avg=5.0
4
3
2
1 LCL=0.5
0
2 4 6 8 10 12 14 16 18 20

Week Sample Taken

Are there any signals of special causes? Circle them.

6-29
 IsIs
Process
Process
Stable
Stable
??
Shipping Data

0.30

0.25 UCL

p 0.20
(fraction
nonconforming) 0.15
Avg=0.123
0.10

0.05

0.00 LCL
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Week

Are there any signals of special causes? Circle them.

6-30
 IsIs
Process
Process

Quality Improvement Stable

Stable
??

Types of Control Charts

Counting Measures Instrument Measures

p charts x (X-bar) charts
np charts Individuals (x) charts
c charts Range (R) charts
u charts Moving Range (MR) charts
Arithmetic Moving Average
charts
Exponentially Weighted Moving

Average charts
Cusum charts

“When you have a problem to

solve, you want to choose the
6-31
 IsIs

Exercises
Process
Process
Stable
Stable
??

Circle any signals of special causes you find in

the following control charts.

Example 1 Example 2

•
% of • • ••
Customers • • •• • •••
Ranking • • • • Monthly • • • • •
Eastman • • • • Sales • • • • • •
as #1
Supplier •

Time Time

6-32
 IsIs
Process
Process
Stable
Stable
??
Skill Check - Continued

Example 3 Example 4

• • •
• Number
% • • • • •
• • • of Lost-
Defective
• • • Time •
Accidents • •
• • •
• • •
• ••
•
• • •
•
•
Time Time

6-33
 IsIs
Process
Process
Stable
Stable
??
Exercises

1.) Your Catapult Team should complete page 9 of

the “Catapult Process” handout.

2.) Be ready to present your results in PowerPoint

Limit yourselves to 10 minutes for this exercise.

6-34