INTRODUCTION TO SQC &SPC & CONTROL CHARTS

LAKSHMAN SINGH JWM/OFILKN

FOR ANY MANUFACTURING CONCERN

DRAWINGS & SPECIFICATIONS PRODUCTION INSPECTION

Are the three closely related functions

INSPECTION Traditional Method of Inspection Inspection with the help of SQC Techniques

Statistical Quality Control

A quality control system performs, inspection and analysis to concludes whether the quality of each product is as per the laid standard or not. It is called Statistical quality control (SQC), when statistical techniques are employed to control quality or to solve quality problems. Statistics is based on the law of large numbers and mathematical theory of probability. It is in this sense the adjective statistical is accurately used in SQC. It is systematic as compared to guess work of haphazard inspection. The statistical approach neutralized personnel bias and poor judgment.

 Variation is a fact of life.

CONCEPT OF VARIATION

Production process are not exception to this.

No two items can ever be made exactly similar in all respect.

VARIATION IN QUALITY
Chance causes of Variation Inherent to the Process Can not be economically eliminated Assignable causes of Variation

External to the Process

Can be found out & economically eliminated

Sources of variation
Material
Assemblies Components Suppliers Consumables

Methods
Procedures Policies Accounting

Environment
Noise level Humidity Temperature Lighting

Variation

Man
Training Experience Skill
Attitude

Machine
Technology Variability Tooling
Fixtures

Measurement
Counting Instruments Gauging
Tests

MEANING OF CONTROL

If variation are unavoidable, then how much variation to be tolerated in a process ? Answer to this question leads to meaning of word CONTROL

Objective :
Assignable causes Behind technique of control chart is to separate out & eliminate causes of variation from chance causes of variation during the course of production

Activities of SQC

There are three activities SQC:(1) Systematic collection and graphic recording of accurate data. (2) Analyzing the data. (3) Practical engineering or management action on the information obtained i.e. deviation from the specified limits.

Modern techniques of statistical quality and acceptance of sampling have an important part to play in the improvement of quality and enhancement of the industrial economy of the country. Relying on the probability theory, SQC evaluates batch quality and controls the quality of process and products. It has three scientific techniques namely:(a) Sampling inspection. (b) Analysis of data. (c) Control charts.

Techniques of SQC

USES OF SQC
SQC method can be used in arriving at (1) Proper specification. (2) Design of product. (3) Purchase of raw material. (4) Purchase of semi-finish or finished product. (5) Manufacturing process. (6) Inspection and packaging. (7) Sales and service.

BENEFITS OF SQC

The benefits of SQC are as follows:(a) SQC ensures rapid and efficient inspection at minimum time. (b) It uncovers the causes excessive variability in manufacturing of products, forecasting trouble before rejection occur. Acceptance of sampling exert more pressure for quality improvement than 100% inspection. In control charts (x,r,p,c) when points fall above UCL or below LCL, it indicates for corrective action.

BENEFITS OF SQC

Increases out-put and reduces wastes, machine and man-hours. Gives higher productivity. Gives customer satisfaction. Eliminate bottlenecks in process of manufacturing. Creating quality awareness in employees. Points out when and where 100% inspection is required.

WHAT IS SPC ?
STATISTICAL PROCESS CONTROL IS A PROCESS OF MONITORING AND MEASURING VARIABILITY IN THE PERFORMANCE OF A PROCESS OR A MACHINE THROUGH THE INTERPRETATION OF STATISTICAL TECHNIQUES.

STATISTICAL PROCESS CONTROL IS A PROCEDURE IN WHICH DATA IS COLLECTED, ORGANISED, ANALYZED AND INTERPRETED SO THAT PROCESS CAN BE MAINTAINED AT A PRESENT LEVEL OF QUALITY OR IMPROVED TO A HIGHER LEVEL OF QUALITY.

OBJECTIVES OF SPC

COLLECTING THE DATA & DRAWING MEANINGFUL CONCLUSION. FINDING ROOT CAUSES OF PROBLEMS. CONTROLLING OF PERFORMANCES. PREDICTING FUTURE TENDENCIES. UNDERSTANDING & MANAGING VARIABILITY IN A PROCESS.

WHY SPC ?

IMPROVE PRODUCTS & SERVICES REDUCE WASTE & REWORK IMPROVE PRODUCTIVITY REDUCE COST INCREASE PROFITS

SPC TOOLS

CONTROL CHARTS HISTOGRAM CAPABILITY ANALYSIS PARETO CHARTS

CONTROL CHARTS

IT IS AN IMPORTANT STATISTICAL DEVICE FOR STUDY AND CONTROL OF THE RESPECTIVE PROCESSES. IT WAS DEVELOPED BY DR. WA SHEWART IN 1924

CONTROL CHARTS

Shewhart's discovery statistical process control or SPC, is a methodology for charting the process and quickly determining when a process is "out of control" (e.g., a special cause variation is present because something unusual is occurring in the process). The process is then investigated to determine the root cause of the "out of control" condition. When the root cause of the problem is determined, a strategy is identified to correct it

CONTROL CHARTS

A simple chart familiar to us is the one kept near to a patient in a hospital or nursing home. At regular intervals, a nurse checks the patients temp. blood pressure, urine output an so on and take a note of these in the chart. This chart tells the attending doctor the state of health of the patient so that he can take a decision on the further course of treatment. Similarly, in a production or a non production work area, control charts are displayed which monitor the quality of the process (work) in progress.

CONTROL CHARTS

A control is a simple graphical device for knowing at a given instance of time, whether or not a process is under control. In any manufacturing process there is some variation from piece to piece. There can be two causes for these variations. a) Chance Causes b) Assignable Causes CHANCE CAUSES Depending upon the working conditions, there are some inherent variations which are inevitable and are beyond control. These causes are known as Chance Causes.

CONTROL CHARTS

ASSIGNABLE CAUSES: These are not present under normal working condition. They suddenly creep in due to various reasons causing changes in the control parameters. These can be due to Setting change in the machine Change in operation / process Change in raw material batches Operators error Assignable causes can be discovered and corrected. For this purpose, results of the measurements are recorded and graph is plotted. When no assignable causes of variation are present in a process and it operates only under a constant system of chance causes, the process is said to be in state of Statistical Control.

CONTROL CHARTS

Variable control charts: If the quality characteristic can be measured with the help of an instrument, equipment or measuring process, it is called a measurable characteristic. Example: diameter, length, resistance, carbon content etc. The X bar and R chart is the most popular chart in the variable control charts. Attributes control chart: Some quality characteristic may not be possible to measure on a quantitative scale. In such cases we classify the product as good bad, acceptable or not acceptable, pass or reject et, control charts for such attributes are called are called Attribute control charts. Example: p chart: fraction defective chart, c chart number of defects, etc.

Commonly Used control charts and their Purposes:-.

Data type Variable

Chart Name X & R Chart X & S Chart p Chart n p Chart c Chart u Chart

Value charted Sample means and ranges Sample Means & S.D. Proportion or percentage of Units defective per sample. No. of Units defective per sample. No. of defects per insp. unit. Average number of defects per production unit.

Attributed

OBJECTIVES OF THE CONTROL CHARTS

WHETHER THE GIVEN PROCESS CAN MEET THE EXISTING SPECIFICATION. TO SECURE INFORMATION USED IN ESTABLISHING OR CHANGING PRODUCTION PROCEDURES. TO PROVIDE A BASIS FOR CURRENT DECISIONS ON ACCEPTANCE OR REJECTION.

A CONTROL CHART CONSIST OF FOLLOWING THREE HORIZONTAL LINES:

THE

A CENTRAL LINE TO INDICATE DESIRED STANDARD . UPPER CONTROL LIMIT (UCL) LOWER CONTROL LIMIT (LCL)

Zones for Mean Control Chart

Zone - 3 Zone - 2 Action Warning Continue

UCL UWL Target

Sample Mean

Zone - 1 Zone - 1 Zone - 2

Continue Warning Action

LWL LCL

Zone - 3

Sample Number

Interpreting Control Chart

One point outside control limit

UCL

UWL Statistics Target

LWL LCL

3 4 5 Sample Number

Interpreting Control Chart

A single point above or below the control limits. Probability of a point falling outside the control limit is less than 0.14%. This pattern may indicate: - a special cause of variation from a material, equipment, method, operator etc. - mis-measurement of a part or parts. - mis-calculated or mis-plotted data point.

Interpreting Control Chart

Seven consecutive points on one side of the centre line

UCL UWL

Statistics

Target
LWL LCL

3 5 4 Sample Number

Interpreting Control Chart

Seven consecutive points are falling on one side of the centre line. Probability of a point falling above or below the centre line is 50-50. The probability of seven consecutive points falling on one side of the centre line is 0.78% ( 1 in 128) This pattern indicates a shift in the process output from changes in the equipment, methods, or material or shift in the measurement system.

Interpreting Control Chart

Two consecutive points between warning limit and corresponding control limit

UCL UWL

Statistics

Target
LWL LCL

5 3 4 Sample Number

Interpreting Control Chart

Two consecutive points fall between warning limit and corresponding control limit. In a normal distribution, the probability of two consecutive points falling between warning limit and corresponding control limit is 0.05% (1 in 2000).

This could be due to large shift in the process, equipment, material, method or measurement system.

Interpreting Control Chart

Two points out of three consecutive points between warning limit and corresponding control limit

UCL UWL

Statistics

Target
LWL LCL

Sample Number

Interpreting Control Chart

Two points out of three consecutive points fall between warning limit and corresponding control limit. This could be due to large shift in the process, equipment, material, method or measurement system.

Interpreting Control Chart

Seven consecutive points having upward trend UCL UWL

Statistics

Target
LWL LCL

3 4 5 Sample Number

Interpreting Control Chart

Seven consecutive points having downward trend

UCL UWL
Statistic s

Target
LWL LCL

Sample Number

Interpreting Control Chart

A trend of seven points in a row upward or downward demonstrates non-randomness. This happens when - Gradual deterioration or wear in equipment. - Improvement or deterioration in technique. - Operator fatigue.

INTERPRETATION OF X BAR AND R CHARTS

THE PROCESS IS IN CONTROL, IF BOTH THE CHARTS SHOWS A STATE OF CONTROL.

R-CHARTS

X-BAR CHART

INTERPRETATION

IN CONTROL

POINTS BEYOND LIMITS ONLY ON ONE SIDE POINTS BEYOND LIMITS ON BOTH THE SIDES POINTS BEYOND LIMITS ON BOTH SIDES RUN OF 7 OR MORE POINTS ON ONE SIDE

LEVEL OF PROCESS HAS SHIFTED LEVEL OF PROCESS IS CHANGING IN ERRATIC MANNERFREQUE ADJUSTMENT VARIABILITY HAS INCREASED SHIFT IN PROCESS LEVEL

IN CONTROL

OUT OF CONTROL

IN CONTROL

PROCESS CAPABILITY STUDY

PROCESS:- A COMBINATION OF EQUIPMENT, MATERIAL, PEOPLE, METHOD AND ENVIRONMENT THAT ACT TOGETHER TO PRODUCE AN OUTPUT. THE QUALITY OF THE PROCESS IS JUDGED BY THE QUALITY (CHARACTERISTIC) OF THE OUTPUT. PROCESS CAPABILITY:- THE RANGE OF QUALITY VARIATION OR PROCESS SPREAD WITHIN WHICH M/C OR PROCESS CAN BE EXPECTED TO VARY. MATHEMATICALLY PC=6 SIGMA =6 X R BAR / d2

NEED FOR PROCES CAPABILITY

FOR MEETING CUSTOMER RQUIREMENTS/ SPECIFICATION. TO COMPARE ACTUAL PEFORMANCE OF EQUIPMENT WITH MANUFACTURES CLAIM. TO COMPARE THE PERFORFORMANCE OF TWO PROCESSES. TO PROVIDE MORE REALISTIC TOLERANCES FOR COMPONENT DIMENSIONS. TO PROVIDE A BASIS FOR PROCESS CONTROL.

FACTORS INFLUENCING PROCESS CAPABILITY

CONDITION OF MACHINE/EQUIPMENT. TYPE OF OPERATION & OPERATIONAL CONDITION. RAW MATERIALS. SKILL OF OPERATERS. MEASUREMENT METHOD/INSTRUMENTS. INSPECTORS SKILL.

INTERPRETATION OF PC
IF

PC IS INFERIOR TO SPECIFICATION TOLERANCE, ALL EFFORT SHOULD BE DIRECTED TO REDUCE PROCESS VARIABILITY.
IF

PC IS SUPERIOR TO SPECIFICATION TOLERANCE, PROCESS IS AT AN ECONOMICAL LEVEL.

IF

PC IS JUST EQUAL TO SPECIFICATION TOLERANCE, GREATER ATTENTION IS NEEDED FOR CENTERING THE PROCESS.

PROCESS CAPABILITY RATIO (Cp)

IT IS THE RATIO OF SPECIFICATION TOLERANCE TO PROCESS SPREAD.

Cp=SPECIFICATION TOLERANCE PROCESS SPREAD

= USL-LSL/6 SIGMA ( R Bar/ d2) = TOLERANCE / 6 SD (Std. Deviation)

INTERPRETATION OF Cp
IF Cp > 1 THEN PROCESS IS CAPABLE OF MEETING SPECIFICATION. IF Cp = 1 THEN PROCESS IS JUST CAPABLE. IF Cp < 1 THE PROCESS IS INCAPABLE.

PROCESS CAPABILITY INDEX (Cpk)

Cpk TAKES INTO ACCOUNT THE LACK OF CENTERING OF THE PROCESS. CALCULATE Cpu AND Cpl, THE SMALLER OF TWO WILL BE Cpk. LARGER Cpk VALUE IS BETTER. IF Cpk<1, WORK TO REDUCE VARIATION OR TO BE CENTRE THE PROCESS WITHIN SPECIFICATION.

CALCULATION OF Cpk
Cpu = USL X 3 SIGMA

Cpl= X LSL 3 SIGMA

Cpk = SMALLER (Cpu, Cpl VALUE)

COMPARISON OF SIGMA LEVELS

Quality Level 2 Sigma 3 Sigma 4 Sigma 5 Sigma 6 Sigma Cp 0.17 0.50 0.83 1.17 1.50 Defective PPM 308538 66807 6210 233 3.4