Professional Documents
Culture Documents
(SPC)
Presented By: Aditya Meena Abhishek Raj
What is SPC?
SPC stands for
Statistical
Process
Control
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.
Diagram
Histograms
Control Chart
Check Sheets
Pareto diagram
Percent from each cause
70 60 50
(64)
A pareto diagram is a graph that ranks data classifications in descending order from left to right.
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30 20 10 0 (13)
Pareto diagram
Sometimes a pareto diagram has a cumulative line. This line represents the sum of the data as they are added together from left to right.
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Histogram
The histogram, graphically shows the process capability and, if desired, the relationship to the specifications and the nominal.
It also suggests the shape of the population and indicates if there are any gaps in the data.
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Histogram
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Histogram
Data Range
Frequency
1 3 6 4 2
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Cause-and-Effect Diagrams
Show the relationships between a problem and its possible causes. Developed by Kaoru Ishikawa (1953) Also known as Fishbone diagrams Ishikawa diagrams
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Quality Problem
People
Equipment
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Fishbone Diagram
Measurement
Faulty testing equipment
Human
Machines
Out of adjustment Tooling problems Old / worn
Incorrect specifications
Improper methods
Quality Problem
Defective from vendor Not to specifications Materialhandling problems Poor process design Ineffective quality management
Environment
Materials
Process
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Cause-and-Effect Diagrams
Advantages
making the diagram is educational in itself diagram demonstrates knowledge of problem solving team diagram results in active searches for causes diagram is a guide for data collection
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Cause-and-Effect Diagrams
To construct the skeleton, remember: For manufacturing - the 4 Ms man, method, machine, material For service applications equipment, policies, procedures, people
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Check Sheets
Check sheets explore what and where an event of interest is occurring. Attribute Check Sheet
Order Types Emergency Nonemergency Rework Safety Stock Prototype Order
7am-9am 9am-11am 11am-1pm 1pm-3pm 3pm-5-pm
Other
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15
19
20
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Flowcharts
Graphical description of how work is done. Used to describe processes that are to be improved.
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Flowcharts
Activity
Decision
Yes
No
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Flowcharts
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Flow Diagrams
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Transportation
Delay Storage
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Scatter Diagram
.
(a) Positive correlation (b) No correlation (c) Curvilinear relationship
The patterns described in (a) and (b) are easy to understand; however, those described in (c) are more difficult.
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6
Target Spec
3
Lower Control Limit
Lower Spec Limit
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Out of control !
Target
LCL
Time Samples
Natural variation
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Using p-charts
Find long-run proportion defective (p-bar) when the process is in control. Select a standard sample size n Determine control limits
UCL p z p LCL p z p
p(1 p) n
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Using c-charts
Find long-run proportion defective (c-bar) when the process is in control. Determine control limits
UCL c z c LCL c z c
c c
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Examples
Weight of a box of corn flakes (food processing) Departmental budget variances (accounting Length of wait for service (retailing) Thickness of paper leaving a paper-making machine
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R R/ n
UCL D4 R
LCL D3 R
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UCL x A2 R
LCL x A2 R
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Benefits of SPC
Factual decision Waste reduction IMPROVEMENT PERFORMANCE Increased monitoring Operator involvement
benefits
Provides surveillance and feedback for keeping processes in control Signals when a problem with the process has occurred Detects assignable causes of variation Reduces need for inspection Monitors process quality Provides mechanism to make process changes and track effects of those changes Once a process is stable, provides process capability analysis with comparison to the product tolerance
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SUMMARY
SPC using statistical techniques to
measure and analyze the variation in processes to monitor product quality and maintain processes to fixed targets.
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SUMMARY
A primary tool used for SPC is
the control chart, a graphical representation of certain descriptive statistics for specific quantitative measurements of the process.
These descriptive statistics are displayed in the control chart in comparison to their "in-control" sampling distributions. The comparison detects any unusual variation in the process, which could indicate a problem with the process.
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Inhibitors of SPC
The most common inhibitor of SPC is lack of resources. Capability in Statistics: Many organizations do not have the in house expertise in statistics that is necessary for SPC. Misdirected Responsibility for SPC: The process operators will require help from the statistician and others from time to time, but they are the appropriate owners of SPC for their processes. Failure to Understand the Target Process: A good SPC system cannot be designed for a process that is not fully understood. Failure to Have Process Under Control: Before SPC can be effective, any special cause of variation must be removed. Inadequate Training and Discipline: Everyone who will be involved in the SPC program must be trained. Measurement Repeatability and Reproducibility: Before a gauge is used for SPC it should be calibrated and its repeatability certified. Low Production Rates: Low rates of production offers an opportunity for taking a 100% sample.