Professional Documents
Culture Documents
OCAP should be living document so that it can be modified over time with the aid
of new knowledge and understanding. So, an initial OCAP is required when a CC
is introduced.
Measurement system
No
Is data entered Edit data to correct entry
correctly?
Yes
Range
Which test/action Contact process engineering
failed?
Average
Yes
Is an No
equipment/instrumen Contact process engineering
t in calibration?
Yes
Yes
Is the calibrated Contact process engineering
item adjusted?
No
Adjust pressure per specification
table. Reset and enter new data
Figure: Single point outside control limits (Source: James, R. and Wiliam, M., 1999)
Figure 2.16 Shift in process average (Source: James, R. and Wiliam, M., 1999)
Figure: Examples of out-of-control indicators (Source: James, R. and Wiliam, M., 1999)
Cycle
Cycles are short and repeated in the chart with alternating high peaks and low valleys (refer
Figure 2.18). These patterns are the result that comes at a regular basic. This is caused by the
operation rotation or fatigue at the end of a shift and different gauges used by different
inspectors, seasonal effects. For example, temperature or humidity or differences between day
and night shift. In the R-chart, cycles are rotation of fixtures or gauges differences between
shifts, operator fatigue and maintenance schedules.
Figure :Hugging the control limits (Source: James, R. and Wiliam, M., 1999)
Instability
This characteristic is caused by unnatural and erratic fluctuations on both sides of the chart
over a period of time. Points are often lying outside both the upper and lower control limits
without consistent pattern, as shown in Figure 2.22. Assignable causes are more difficult to
identify in his case when specific patterns are present. A frequent cause of instability is over
adjustment of a machine or the same reasons that cause the hugging the control limits.
Figure: Instability (Source: James, R. and Wiliam, M., 1999)
Apart from that, when a process is in control, there occurs a natural pattern of variation.
Natural pattern has:
About 34% of the plotted point in an imaginary band between 1s on both side CL.
About 13.5% in an imaginary band between 1s and 2s on both sides CL.
About 2.5% of the plotted point in an imaginary band between 2s and 3s on both side CL.
The percentage of cases under portions of the normal curve is shown in Figure2.23
Western Electric rules can also be used to interpret the control chart. The control chart is
being split into three areas or zone above and below the centerline. The zones are sometimes
referred to as Zone A , Zone B and Zone C, and or sometime it is refer to one sigma zone, two
sigma zone, etc. Zone C is the region within 1 sigma of the centerline. Zone B is the region
between 1 and 2 sigma of the centerline. Zone A is the region from 2 to 3 sigma from the
centerline. There are 4 basic rules with respect to how the data is situated on a control chart to
indicate if it is not in statistical control (i.e. special causes of variation are present instead of
random sources). The rules are:
Rule 1: Any single data point falls outside the 3-sigma limit from the centerline (i.e., any
point falls outside Zone A, beyond either the upper or lower control limit);
Rule 2: Two out of three consecutive points fall beyond the 2-sigma limit (in zone A or
beyond), on the same side of the centerline;
Rule 3: Four out of five consecutive points fall beyond the 1-sigma limit (in Zone B or
beyond), on the same side of the centerline;
Rule 4: Nine consecutive points fall on the same side of the centerline (in Zone C or
beyond);
cavity 1
Mean=35.2272
Median=35.22
Frequency of occurrences
30
Mode= 35.2
Range=0.04
Standard deviation= 0.09316 20
0.4 35.227
i 0.05
1+3.322*log150 10
0.4
h 1 =9
0.05 0
35.000 35.100 35.200 35.300 35.400
a.ii Bottle thread outer diameter for Bottle thread outer diameter for cavity No.2
cavity 2 35.252
Mean=35.2516 30
Median= 35.25
Frequency of occurrences
Mode= 35.2
Range = 0.36 20
Standard Deviation=0.08021
0.36
i = 0.04 10
1+3.322*log150
0.36
h= 1 10
0.04 0
35.100 35.200 35.300 35.400