Statistical Process Control

Prof. Rushen Chahal

Prof. Rushen Chahal

Statistical Process Control (SPC)

A methodology for monitoring a process to identify special causes of variation and signal the need to take corrective action when appropriate SPC relies on control charts

Prof. Rushen Chahal

Common Causes

Special Causes

Prof. Rushen Chahal

Histograms do not take into account changes over time.

Control charts can tell us when a process changes

Prof. Rushen Chahal

Control Chart Applications

Establish state of statistical control Monitor a process and signal when it goes out of control Determine process capability

Prof. Rushen Chahal

Capability Versus Control

Control Capability
Capable In Control
IDEAL

Out of Control

Not Capable

Prof. Rushen Chahal

Commonly Used Control Charts

Variables data
x-bar and R-charts x-bar and s-charts Charts for individuals (x-charts)

Attribute data
For defectives (p-chart, np-chart) For defects (c-chart, u-chart)
Prof. Rushen Chahal

Developing Control Charts

1. Prepare
Choose measurement Determine how to collect data, sample size, and frequency of sampling Set up an initial control chart

2. Collect Data
Record data Calculate appropriate statistics Plot statistics on chart
Prof. Rushen Chahal

Prof. Rushen Chahal

Next Steps
3. Determine trial control limits
Center line (process average) Compute UCL, LCL

4. Analyze and interpret results

Determine if in control Eliminate out-of-control points Recompute control limits as necessary
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Typical Out-of-Control Patterns

Point outside control limits Sudden shift in process average Cycles Trends Hugging the center line Hugging the control limits Instability

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Shift in Process Average

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Identifying Potential Shifts

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Cycles

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Trend

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Final Steps
5. Use as a problem-solving tool
Continue to collect and plot data Take corrective action when necessary

6. Compute process capability

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Process Capability Calculations

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Excel Template

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Special Variables Control Charts

x-bar and s charts x-chart for individuals

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Charts for Attributes

Fraction nonconforming (p-chart)
Fixed sample size Variable sample size

np-chart for number nonconforming Charts for defects

c-chart u-chart
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Control Chart Selection

Quality Characteristic variable
defective n>1? yes n>=10 or no computer? yes x and s x and R no x and MR constant yes p or sample np size? no p-chart with variable sample size
Prof. Rushen Chahal

attribute
defect

constant sampling unit? yes c no u

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Control Chart Design Issues

Basis for sampling Sample size Frequency of sampling Location of control limits

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Pre-Control
LTL Red Zone UTL Red Zone

Green Zone

nominal value

Yellow Zones
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SPC Implementation Requirements

Top management commitment Project champion Initial workable project Employee education and training Accurate measurement system

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