Process

Capability Studies
Defini=ons

•  Process – Work performed on a set of inputs

Process Capability to produce a result.
•  Capability – The predictable result(s) of a
process allowed to operate without outside
interference.
Collated by Prof. Jerome Alvarez
•  Process Capability Study – Comparison of
process output(s) to product requirements.

“Almost all quality improvement comes via simplification of design, manufacturing…

layout, processes, and procedures.” ~ Tom Peters

The difference between

Process Capability vs. Process Control
Stability and capability
•  CONFORMANCE •  A process is capable if a given product meets
–  Ability of process to produce parts that conform specifica=ons.
to engineering specifica=ons •  A process is stable if there is a common
•  CONTROL varia=on present in the process
–  Ability of process to maintain a state of sta=s=cal
control; i.e., be within control limits

Process Capability Target and Tolerance Design

•  Process capability is defined as a how likely a •  Manufacturing specifica=ons consist of nominal
product is going to meet the design dimensions and tolerances.
specifica=on. –  Nominal refers to the ideal dimension or the
target value that manufacturing seeks to meet.
•  A sta=s=cal measure inherent in the process
–  Tolerance is the permissible varia=on, recognizing
or the natural ability of the process to
the difficulty of mee=ng a target consistently.
produce parts or services over a period of
=me.
•  Process capability is a measure of the
rela=onship between the natural varia=on of
the process and the design specifica=ons 6

1
 Tolerance
Tolerance Design
•  Comparing the control chart informa=on with the •  Tolerance design involves determining the
tolerance specifica=on tells you about the process permissible varia=on in a dimension.
capability.
–  Narrow tolerances tend to raise manufacturing
•  Design specifica=ons (tolerances): costs but they also increase the interchangeability
–  Determined by design engineers to define the of parts within the plant and in the field, product
acceptable range of individual product characteris=cs
(e.g.: physical dimensions, elapsed =me, etc.) performance, durability, and appearance.
–  Based upon customer expecta=ons & how the –  Wide tolerances increase material u=liza=on,
product works (not sta=s=cs!) machine throughput, and labor produc=vity, but
•  Process Capability = Engineering Tolerance have a nega=ve impact on product characteris=cs
Natural Tolerance
8

Sta=s=cal Measurements of
Tradi=onal Economic View of Process Capability and Process Performance
Conformance to Specifica=ons •  Cp= Process Capability: A simple and
straighZorward indicator of process capability.
•  Cpk= Process Capability Index: Adjustment of Cp
for the effect of non-centered distribu=on.
•  Pp= Process Performance: A simple and
straighZorward indicator of process
performance.
•  Ppk= Process Performance Index: Adjustment of
Pp for the effect of non-centered distribu=on.
9

Measurement of Process Capability Process Capability Ra=o

–  Cp assumes that the process is centered in the •  The formula C sub P is the tolerance divided by
specifica=on range six standard devia=ons (also known as sigma)
CP = tolerance
specification width USL − LSL
Cp = = 6-sigma
process width 6σ

•  Reveals how many six-sigma fits within a

–  Cpk helps to address a possible lack of centering of the specified tolerance
process; capability in rela=on to mean
•  In order for a product to meet specifica=ons, at
⎛ USL − µ µ − LSL ⎞ least 99.773% of produc=ons should confirm
Cpk = min ⎜ , ⎟ an=cipated opera=on condi=on.
⎝ 3σ 3σ ⎠

2
 Process Capability Ra=o Process Capability Ra=o Example
Upper Specification - Lower Specification
Cp = Process mean x = 210.0 minutes
6σ Standard deviation σ = .516 minutes
Design specification = 210 ± 3 minutes
þ  Does not look at how well the process is
centered in the specification range
þ  Often a target value of Cp = 1.33 is used Upper Specification - Lower Specification
Cp =
to allow for off-center processes. This 6σ
indicates a sigma of 4.0
þ  Six Sigma quality requires a Cp = 2.0

Process Capability Ra=o Example Process Capability Ra=o Example

Process mean x = 210.0 minutes Process mean x = 210.0 minutes

Standard deviation σ = .516 minutes Standard deviation σ = .516 minutes
Design specification = 210 ± 3 minutes Design specification = 210 ± 3 minutes

Upper Specification - Lower Specification Upper Specification - Lower Specification

Cp = Cp =
6σ 6σ
213 - 207 213 - 207
= = 1.938 = = 1.938 Process is
6(.516) 6(.516)
capable

Process Capability Index Process Capability Index

•  When Cpk index equals 1.0, the process
Upper Lower varia=on is centered within the upper and
Specification - x x - Specification
Cpk = minimum of Limit , Limit lower specifica=on limits.
3σ 3σ •  Process is producing within ±3 standard
devia=ons (fewer than 2,700 defects per
þ  A capable process must have a Cpk of at least million).
1.0
•  Cpk of 2.0 means the process is producing
þ  A capable process is not necessarily in the
center of the specification, but it falls within the fewer than 3.4 defects per million. (6 sigma)
specification limit at both extremes

3
 Interpre=ng Cpk Interpre=ng Cpk

Cpk = negative number

Cpk = zero

Cpk = between 0 and 1

Cpk = 1

Cpk > 1
Figure S6.8

Process Capability Index Example Process Capability Index Example

You are the process improvement manager and has New Cutting Machine
developed a new machine to cut insoles for the
New process mean x = .250 inches
company’s top-of-the-line running shoes. You are excited
Standard deviation σ = .0005 inches
because the company’s goal is no more that 3.4 defects
Upper Specification Limit = .251 inches (+.001)
per million and this machine may be the innova=on you Lower Specification Limit = .249 inches (-.001)
need. The insoles cannot be more than ±.001 of an inch
from the required thickness of .250”. You want to know if
you should replace the exis=ng machine, which has a Cpk
of 1.0. You decide to determine the Cpk for the new
machine and make a decision on that basis. Standard
devia=on is set at .0005”.

Process Capability Index Example Process Capability Index Example

New Cutting Machine
New process mean x = .250 inches
Standard deviation σ = .0005 inches
Upper Specification Limit = .251 inches
Lower Specification Limit = .249 inches
New Cutting Machine
New process mean x = .250 inches
Standard deviation σ = .0005 inches
Upper Specification Limit = .251 inches
Lower Specification Limit = .249 inches

(.251) - .250 (.251) - .250 .250 - (.249)

Cpk = minimum of , Cpk = minimum of ,
(3).0005 (3).0005 (3).0005

Both calculations result in

New machine is NOT
.001 capable
Cpk = = 0.67
.0015

4
 Rela=onship between Process
When Cp and Cpk are not equal
Variability and Specifica=on Width
•  Three possible ranges for Cp

–  Cp = 1, as in Fig. (a), process

variability just meets specificaAons

–  Cp ≤ 1, as in Fig. (b), process not capable
of producing within specificaAons

–  Cp ≥ 1, as in Fig. (c), process

exceeds minimal specificaAons


•  One shortcoming, Cp assumes that the
process is centered on the specificaAon
range

•  Cp=Cpk when process is centered

25

Sta=s=cal Measurements of
When Cp and Cpk are not equal Process Capability and Process Performance
•  When Cp is greater than Cpk, the mean is nearer to one
specifica=on limit or the other.
•  The farther the sample mean is from the center of the
specifica=on limits, the lower Cpk becomes.
•  The farther the mean moves away from the middle of
the specifica=on limits, the more different Cp and Cpk
become.
•  When the values are similar, the mean is close to the
middle of the specifica=on limits.

Cp and Cpk vs. Pp and Ppk

•  Within the subgroups •  Overall varia=on of all
•  compu=ng the index measurements taken
with respect to the •  Pp and Ppk are for the
subgrouping of your whole process (no
data (different shils, subgrouping).
machines, operators, •  Theore=cally includes Cp and Cpk
etc.), both the varia=on
•  Does not account for within subgroups and
EXERCISES
the shil and dril also the shil and dril
between subgroups between them
•  Short term •  Long term

5
 Exercise 1: Exercise 2:
3 boOling machines are being evaluated for possible use
at the plant. The machines must be capable of meeAng In a process of filling boxes of rice where we
the design specificaAon of 15.8-16.2 oz. with at least a measure the weight of each box, the process
process capability of 1.33 (Cp≥1.33). average is 210 grams and the specification
Machine σ range is between 198 grams and 214 grams and
A .05
the standard deviation of the process is 2 grams.
Calculate the Process Capability and Process
B .1
Capability Index. Determine if the process is

C .2 capable or not.
Which among the machines is most capable?
31

Exercise 3:
The Dollars Bank competes on customer service and is
concerned about service Ame at their drive-by windows.
They recently installed new system solware which they
hope will meet service specificaAon limits of 5 ±2 minutes
and will have a Capability Index (Cpk) of at least 1.2.
A.  Determine if the new system solware capable?
B.  The bank has done some sampling recently using 4
customers and determined that the process mean can
shil from previous 5.0 minutes to 5.2 minutes with an
overall process standard devia=on of 1.0 minute.
Compute for the Upper and Lower Specifica=on Limits
of the Control Chart under the previous and new
system.