BJMQ 3013-Topic 9 - A162 (SPC For Variable)

BJMQ 3013 - PENGURUSAN KUALITI
Lecturer : Dr. Rosman Bin Iteng

Room No : 4052
H/P : 016 395 2955
email : rosman@uum.edu.my
Ext. 7068
School of Technology Management and Logistics / Pusat Pengajian
Pengurusan Teknologi dan Logistik.
Kolej Perniagaan, UUM.
2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 1

Chapter Nine
STATISTICAL PROCESS CONTROL

(SPC) FOR VARIABLE DATA
Lecturer : Dr. Rosman Bin Iteng

School of Technology Management and Logistics / Pusat Pengajian
Pengurusan Teknologi dan Logistik.
Kolej Perniagaan, UUM.

9.0 Statistical Process Control (SPC) for
Variable Data
Topics
9.1 Statistical Fundamentals
9.2 Process Control Charts / SPC
9.3 Developing Control Chart for Variables
9.4 Process Capability for Variables
9.5 Interpreting Control Chart for Variables

Chapter Objectives
At the end of this chapter students are

expected to be able to:
1. Explain the procedure for Statistical Process
Control
2. Calculate process capability for variable data
3. Apply SPC to evaluate quality in the process

Data are required to obtain the average

dimensions and the degree of dispersion (in
process) so that we can determine ..
Whether the production process used for
manufacturing the lot was suitable, of if some
action must be taken. In other words, action
can be taken on a process on the basis of
data gained from the samples.
Kaoru Ishikawa

1. What Is Statistical Thinking

Is a decision-making skill demonstrated by the
ability to draw conclusions based on data.
Statistical thinking is based on three concepts:
All work occurs in a system of interconnected

processes.
All processes have variation (the amount of
variation tends to be underestimated).
Understanding variation and reducing variation are
important keys to success.

2. Why Do Statistics Sometimes Fail in the

Workplace?
Lack of knowledge about the tools.

General disdain for all things mathematical
creates a natural barrier to the use of
statistics.

3. What Do We Mean by the Term

Statistical Quality Control?

4. Understanding Process Variation

Processes involve variation. Some variation
can be managed and some cannot.
If too much variation, the process not fit
correctly., product not function properly and
firms will, get bad reputation/image.
TWO types of variation commonly occur:
1. Random variation
2. Non-random variation

Random Variation
Is uncontrollable
In centered around a mean and
occurs with a somewhat consistent
amount of dispersion.
The amount of random variation in
a process may be either large or
small

Non-Random
Variation
The event may be shift in
a process mean or some
unexpected occurrence.

Process Stability
Means that the variation we observe in the
process is random variation (common cause)
and not nonrandom variation.
To determine process stability, we use process
chart.
Process charts are graphs designed to signal
process workers when nonrandom variation is
occurring in a process.

Process Control Charts / 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

Histograms vs. Control Charts

Histograms do not take into account changes over
time.
Control charts can tell us when a process changes

Control Chart Applications

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

Process capability calculations make little

sense if the process is not in statistical
control because the data are confounded by
special causes that do not represent the
inherent capability of the process.

Capability Versus Control
Control
Capability In Control Out of Control
Capable IDEAL
Not Capable

DETERMINE Selection for Use of Control Chart

CHARACTERISTICS
TO BE CHARTED
NO IS THE INTEREST NO IS THE INTEREST

ARE
IN NONCONFORMING IN NONCONFORMITIES
THE DATA
UNITS I.E. PERCENT I.E. DISCREPANCIES /
VARIABLE?
BAD PARTS PARTS?
YES YES
YES
NO
IS THE NO IS THE SAMPLE SIZE USE u
SAMPLE SIZE USE p CONSTANT? CHART
CONSTANT? CHART
YES
YES
USE np
USE c
OR p
OR u
CHART
CHART

A Selection for Use of Control Chart
IS IT HOMOGENEOUS IN
YES CAN
NATURE OR NOT CONDUCIVE
SUBGROUP AVERAGES NO USE
TO SUBGROUP SAMPLING
BE CONVENIENTLY MEDIAN
e.g. CHEMICAL BATH, PAINT
COMPUTED? CHART
BATCH,ETC.?
YES
IS THE NO
USE X-bar
SUBGROUP SIZE
R
9 OR MORE?
NO CHART
YES
IS THE ABILITY
TO CONVINIENTLY NO USE X-bar
USE CHART FOR
COMPUTE s FOR EACH R
INDIVIDUALS : X-MR
SUBGROUP?
CHART
YES
USE X-bar S
CHART

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)

Variables data
Is a continuous measurement
such as weight, height, or volume.
Attribute data
Is an either-or situation OK or
Not OK, Good or Bad

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

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

5. Use as a problem-solving tool

- Continue to collect and plot data
- Take corrective action when necessary
6. Compute process capability

General Procedure for Developing Process

Control Charts
Identify critical operations
Identify critical product characteristics
Determine whether variable @ attribute
Select the appropriate chart
Establish control limits
Update limit.


Process Capability Calculations

Process Capability Calculations


Important Remark
When a process is in statistical
control, the points on a control chart
fluctuate randomly between the
control limits with no recognizable
pattern.

Typical Out-of-Control Patterns (Interpreting

Control Charts)
Point outside control limits
Sudden shift in process average
Cycles
Trends
Hugging the center line
Hugging the control limits
Instability
Shift in Process Average

Identifying Potential Shifts

Cycles

Trend

Important Remark
Control charts indicate when to take
action, and more importantly, when to
leave a process alone.

Interpreting Control Charts
Test 1 One Point Beyond Zone A
UCL A
B
CL C
C
B
LCL A
Test 1 One Point Beyond Zone A

When points are above or below the control limits, it is obvious that
something is out of control
Require an investigation into the assignable cause and corrective action to
be taken
Point above UCL
X UCL UCL
X X X
X X X
X X MEAN X MEAN
X X X
X X X X
X X
LCL LCL
X
Point below LCL


Test 2 Seven points in a row on same side of centerline
UCL A
B
CL C
C
B
LCL A
Test 2 Seven points in a row on same side of centerline

When several points occurs in a row on the central line, it is referred to as a run
If a run of nine points happens, this contradicts the laws of probability thus,
indicating some abnormality occurring.
Seven points above centre line

UCL UCL
X X X
X X X X MEAN X X X MEAN
X X X X X X X X X
X X
LCL LCL
Seven points below centre line


Test 3 Six Points In A Row Steadily Increasing or Decreasing
UCL A
B
CL C
C
B
LCL A
Test 3 Six Points In A Row Steadily Increasing or Decreasing

A series of points showing a continuous rise or fall is known as a trend
Under the law of probability, six points is the key number that would indicate an
abnormality exists.
Immediate investigation and corrective actions need to be taken to prevent the
trend to continue until it goes out of control.
Six points in a upward direction
UCL UCL
X X X X X
X X MEAN X X X X X MEAN
X X X X
X X X X X LCL
LCL
Six points in an downward
direction


Test 4 Fourteen Points In A Row Alternating Up and Down

UCL
A
B
C
CL
C
B
A
LCL
Test 4 Fourteen Points In A Row Alternating Up and Down
One of the characteristics of a natural pattern is that the point-to-point
fluctuation is unsystematic or unpredictable
When fourteen consecutive points alternate up and down, the pattern
becomes predictable (i.e. not natural), thus, some assignable cause must
be present.


Test 5 Two Out Of Three Points In A Row In Zone A

UCL
A
B
C
CL
C
B
A
LCL
Test 5 Two out of three points in a row in Zone A or beyond

When the above pattern occurs in a control chart, it is unusual as it does
not conform to the normal conditions and deserve further investigation
for its occurrence

Test 6 Four Out Five Points In A Row In Zone B or Beyond

UCL
A
B
C
CL
C
B
A
LCL
Test 6 Four Out of Five points in a row in zone B or beyond

When the above pattern occurs in a control chart, it is unusual as it does
not conform to the normal conditions and deserve further investigation for
its occurrence

Test 7 Fifteen points in a row above and below central line in Zone C
UCL A
B
CL C
C
B
LCL A
Test 7 Fifteen points in a row above and below central line in Zone C
When fifteen consecutive points lie above and below central line in
Zone C it reflects a process having a significantly small variation.
This is unusual and very likely there is some abnormality occurring.
Fifteen points in a row above and below central line in Zone C

UCL
X X X X X X X X
X X X X X X X X X
X
X X
X
LCL

Test 8 Eight Points In A Row On Both Sides Centre Line With None In
Zone C
UCL
A
B
C
CL
C
B
A
LCL
Test 8 Eight Points In A Row On Both Sides Of Central Line With None In
Zone C
When the points tend to fall near the high and low edges of the control
limits with an absence of normal fluctuation near the middle, obviously
some abnormality is occurring.
This test shows when the observation have been taken from two (or more)
sources with different means.
Control Chart Formulas

Control Chart Design Issues

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

In determining the method of sampling,

samples should be chosen to be as
homogeneous as possible so that each
sample reflects the system of common
causes or assignable causes that may be
present at that point in time.

In practice, samples of about five have

been found to work well in detecting
process shifts of two standard deviations
or larger. To detect smaller shifts in the
process mean, larger sample sizes of 15
to 25 must be used.

Special Variables Control Charts

x-bar and R charts
X and Moving Range (MR) charts

Thank You

BJMQ 3013-Topic 9 - A162 (SPC For Variable)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BJMQ 3013-Topic 9 - A162 (SPC For Variable)

Uploaded by

Copyright:

Available Formats

BJMQ 3013 - PENGURUSAN KUALITI

Lecturer : Dr. Rosman Bin Iteng

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 1

STATISTICAL PROCESS CONTROL

Lecturer : Dr. Rosman Bin Iteng

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 2

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 3

At the end of this chapter students are

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 4

Data are required to obtain the average

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 5

1. What Is Statistical Thinking

All work occurs in a system of interconnected

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 6

2. Why Do Statistics Sometimes Fail in the

Lack of knowledge about the tools.

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 7

3. What Do We Mean by the Term

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 8

4. Understanding Process Variation

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 9

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 10

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 11

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 12

Process Control Charts / Statistical

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 13

Histograms vs. Control Charts

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 14

Control Chart Applications

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 15

Process capability calculations make little

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 16

Capability Versus Control

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 17

DETERMINE Selection for Use of Control Chart

NO IS THE INTEREST NO IS THE INTEREST

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 18

A Selection for Use of Control Chart

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 19

Commonly Used Control Charts

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 20

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 21

Developing Control Charts

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 22

3. Determine trial control limits

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 23

5. Use as a problem-solving tool

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 24

General Procedure for Developing Process

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 25

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 31

Process Capability Calculations

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 32

Process Capability Calculations

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 33

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 34

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 35

Typical Out-of-Control Patterns (Interpreting

Shift in Process Average

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 37

Identifying Potential Shifts

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 38

2016 DR ROSMAN BIN ITENG @ UUM BJMQ 3013 (PENGURUSAN KUALITI) 39