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STATISTICAL PROCESS CONTROL

TOTAL QUALITY MANAGEMENT

Introduction to S.P.C.
ABSL Quality Solutions 2007 STM Power Limited

What is meant by Statistical Process Control?

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Statistical Process Control (S.P.C.)

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This is a control system which uses

statistical techniques for knowing, all the time, changes in the process.
It is an effective method in preventing

defects and helps continuous quality improvement.

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What does S.P.C. mean?

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Statistical:
Statistics are tools used to make

predictions on performance. There are a number of simple methods for analysing data and, if applied correctly, can lead to predictions with a high degree of accuracy.
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What does S.P.C. mean?

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Process:
The process involves people, machines,

materials, methods, management and environment working together to produce an output, such as an end product.

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What does S.P.C. mean?

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Control:
Controlling a process is guiding it and

comparing actual performance against a target. Then identifying when and what corrective action is necessary to achieve the target.
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S.P.C.

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Statistics aid in making decisions about

a process based on sample data and the results predict the process as a whole.

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The Process

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People

Machines

Material

Output Management Methods Environment

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Definition

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S.P.C. is statistical analysis

of the predictability and capacity of a process to give a uniform product.

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The Aim of S.P.C. - Detection Strategy

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Detection:

This focuses on identification of problems after production, by 100% inspection or by customer complaints.
It is a historically-based strategy.

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The Aim of S.P.C. - Detection Strategy

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Detection Drawbacks: Production is already made. Customer dissatisfaction. Inflated costs - rework; inspection. Repetitive problems. Neglected improvements.

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The Aim of S.P.C. - Prevention Strategy

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Prevention:

This focuses on in-process production and identification of problems through analysis of process capability.
It is a future-orientated strategy.

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The Aim of S.P.C. - Prevention Strategy

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Prevention Benefits: Improved design and process capability. Improved manufacturing quality. Improved organisation. Continuous Improvement.

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S.P.C. as a Prevention Tool

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The S.P.C. has to be looked at as a

stage towards completely preventing defects. With stable processes, the cost of inspection and defects are significantly reduced.

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The Benefits of S.P.C.

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Assesses the design intent.

Achieves a lower cost by providing an

early warning system. Monitors performance, preventing defects. Provides a common language for discussing process performance.

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Process Variations

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Process Element

Variable Examples

Machine.Speed, operating

temperature, feed rate Tools..Shape, wear rate Fixtures..Dimensional accuracy MaterialsComposition, dimensions OperatorChoice of set-up, fatigue MaintenanceLubrication, calibration EnvironmentHumidity, temperature
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Process Variations

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No industrial process or machine is able

to produce consecutive items which are identical in appearance, length, weight, thickness etc. The differences may be large or very small, but they are always there. The differences are known as variation. This is the reason why tolerances are used.
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Stability

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Common causes are the many sources of

variation that are always present. A process operates within normal variation when each element varies in a random manner, within expected limits, such that the variation cannot be blamed on one element. When a process is operating with common causes of variation it is said to be stable.

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Process Control

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The process can only be termed under

control if it gives predictable results.

Its variability is stable over a long

period of time.

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Process Control Charts

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Graphs and charts have to be chosen

for their simplicity, usefulness and visibility. They are simple and effective tools based on process stability monitoring. They give evidence of whether a process is operating in a state of control and signal the presence of any variation.
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Data Interpretation

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Consider these 50 measurements

Bore Diameter 36.32 0.05mm (36.27 - 36.37mm) 1 2 3 4 5 6 7 8 9 10 36.36 36.34 36.34 36.33 36.35 36.33 36.33 36.34 36.35 36.35 11 12 13 14 15 16 17 18 19 20 36.37 36.35 36.32 36.35 36.34 36.34 36.35 36.33 36.32 36.35 21 22 23 24 25 26 27 28 29 30 36.34 36.37 36.34 36.35 36.34 36.35 36.36 36.33 36.36 36.38 31 32 33 34 35 36 37 38 39 40 36.35 36.35 36.36 36.37 36.34 36.36 36.38 36.34 36.35 36.35 41 42 43 44 45 46 47 48 49 50 36.36 36.37 36.37 36.35 36.37 36.36 36.35 36.34 36.35 36.34

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Data Interpretation

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As a set of numbers it is difficult to see

any pattern. Within the table, numbers 30 and 37 were outside the tolerance but were

they easy to spot?

A way of obtaining a pattern is to group

the measurements according to size.

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Data Interpretation Tally Chart

36.39 36.38 36.37 36.36 36.35 36.34 36.33 36.32 36.31 36.30 36.29 36.28

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The tally chart groups

the measurements together by size as shown. The two parts that were out of tolerance are now easier to detect (36.38mm).

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Tally Chart - Frequency

36.39 36.38 36.37 36.36 36.35 36.34 36.33 36.32 36.31 36.30 36.29 36.28

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2 6 7 16 12 5 2

The tally chart shows

patterns and we can obtain the RANGE 36.32mm to 36.38mm.

The most

FREQUENTLY OCCURRING size is 36.35mm.

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Tally Chart - Information

The number of bores at each size;

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The tally chart gives us further information: The number of bores at the most common

size; The number of bores above and below the most common size (36.35mm) number above 36.35mm is 7+6+2=15 number below 36.35mm is 12+5+2=19
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Histogram

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We can redraw the frequency chart as a bar chart known as a histogram:

16 14 12 10 8 6 4 2 0 36.31 36.32 36.33 36.34 36.35 36.36 36.37 36.38 36.39

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Smoothed Frequency

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If we now draw a smooth curve through the top of each box we get a bell-shaped pattern:
16 14 12 10 8 6 4 2 0 36.31 36.32 36.33 36.34 36.35 36.36 36.37 36.38 36.39

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Distribution

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The bell-shaped pattern is fairly typical of

most industrial processes. There is a central value at the highest point of the curve and the pattern of results spread out equally on both sides of the central value. The further we move from the central value, the fewer values we will find. This bell-shaped pattern is known as the NORMAL DISTRIBUTION.
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Normal Distribution

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The bell-shaped pattern known as Normal

Distribution is one that we would expect to see where the process is running in a stable condition.
Where you work in a manufacturing

environment, why not perform the exercise on 50 parts for yourself and see if your process is in a stable condition!
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Self-test (1 of 9)

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S.P.C. is a very effective method in

preventing _______. defects

S.P.C. uses statistical techniques for

knowing _______________. process variation

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Self-test (2 of 9)

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Controlling a process is guiding it and

comparing ________________ against a actual performance target and identifying when and what ______________ is necessary to corrective action achieve the target.

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Self-test (3 of 9)

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The process may involve a combination

of people, machines, ________, materials methods, management and ___________ working together to environment produce an output such as an end product.

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Self-test (4 of 9)

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S.P.C. is a statistical analysis of the

predictability __________ and capacity of a process to give a _______ product. uniform

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Self-test (5 of 9)

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Disadvantages of 100% detection

inspection are that production is ___________ already made and that it is historically __________ based.

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Self-test (6 of 9)

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An advantage of prevention inspection

quality is that _______ is improved. future It is a strategy that is _____ orientated.

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Self-test (7 of 9)

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No industrial process is able to

produce consecutive items which are _______. identical

There are always differences, known

as variation _______.

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Self-test (8 of 9)

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The process can only be termed under

predictable control if it gives __________ results.

Its variability is ______ over a long stable

period of time.

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Self-test (9 of 9)

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A frequency chart drawn with bars is

known as a _________. histogram

A smooth curve drawn in a bell-shaped

pattern is known as the ______ normal distribution curve.

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