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Statistical Process Control

Quality Series
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Outline
What is Statistical Process Control
Variability
Control Charts
Process Capability Cp
Measuring Instruments
Repeatability & Reproducibility
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Statistical Process Control (SPC)
Invented by Walter Shewhart at Western Electric
Distinguishes between
common cause variability (random)
special cause variability (assignable)
Based on repeated samples from a process

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Variability
The world tends to be bell-shaped
Most
outcomes
occur in the
middle
Fewer
in the
tails
(lower)
Fewer
in the
tails
(upper)
Even very rare
outcomes are
possible
(probability > 0)
Even very rare
outcomes are
possible
(probability > 0)
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Variability

Add up the dots on the dice
0
0.05
0.1
0.15
0.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Sum of dots
P
r
o
b
a
b
i
l
i
t
y
1 die
2 dice
3 dice
Here is why:
Even outcomes that are equally likely (like dice),
when you add them up, become bell shaped
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Normal bell shaped curve
Add up about 30 of most things
and you start to be normal

Normal distributions are divide
up into 3 standard deviations
on each side of the mean

Once your that, you know a lot
about what is going on
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Causes of Variability
Common Causes:
Random variation (usual)
No pattern
Inherent in process
adjusting the process increases its variation
Special Causes
Non-random variation (unusual)
May exhibit a pattern
Assignable, explainable, controllable
adjusting the process decreases its variation
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Control Limits
Sampling
distribution
Process
distribution
Mean
Lower
control
limit
Upper
control
limit
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Control Chart
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
UCL
LCL
Sample number
Mean
Out of
control
Normal variation
due to chance
Abnormal variation
due to assignable sources
Abnormal variation
due to assignable sources
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Process vs. control limits
Distribution of averages
Control limits
Process limits
Distribution of individuals
Specification limits
Variance of
averages <
variance of
individual items
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Shift in Process Average
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Process Capability
The ratio of process
variability to design
specifications
Text Text Text Text Text Text
Title

Upper
Spec
Lower
Spec
Natural data
spread
The natural spread
of the data is 6
-1
+2
-2
+1 +3
-3

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Repeatability and
Reproducibility Studies
Quantify and evaluate the capability of a measurement
system
Select m operators and n parts
Calibrate the measuring instrument
Randomly measure each part by each operator for r trials
Compute key statistics to quantify repeatability and
reproducibility
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