STATISTICAL

PROCESS CONTROL

STM
Quality
Limited

TOTAL QUALITY MANAGEMENT

Introduction to S.P.C.

Power Solutions
ABSL
STM Quality
Limited

What is meant by
Statistical Process Control?

STM
Quality
Limited

STM Quality Limited

Statistical Process Control

(S.P.C.)

STM
Quality
Limited

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.

STM Quality Limited

What does S.P.C.

mean?

STM
Quality
Limited

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.
STM Quality Limited

What does S.P.C.

mean?

STM
Quality
Limited

Process:
The process involves people,

machines, materials, methods,

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

STM Quality Limited

What does S.P.C.

mean?

STM
Quality
Limited

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.
STM Quality Limited

S.P.C.

STM
Quality
Limited

Statistics aid in making decisions

about a process based on sample

data and the results predict the
process as a whole.

STM Quality Limited

STM
Quality
Limited

The Process

People

Machines

Material

Output
Management Methods

Environment

STM Quality Limited

Definition

STM
Quality
Limited

S.P.C. is statistical

analysis of the
predictability and
capacity of a process to
give a uniform product.
STM Quality Limited

The Aim of S.P.C.

- Detection Strategy

Detection:

STM
Quality
Limited

This focuses on identification of

problems after production, by
100% inspection or by customer
complaints.
It is a historically-based strategy.
STM Quality Limited

The Aim of S.P.C.

- Detection Strategy

STM
Quality
Limited

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

STM Quality Limited

The Aim of S.P.C.

- Prevention Strategy

Prevention:

STM
Quality
Limited

This focuses on in-process

production and identification of
problems through analysis of
process capability.
It is a future-orientated strategy.
STM Quality Limited

The Aim of S.P.C.

- Prevention Strategy

STM
Quality
Limited

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

STM Quality Limited

S.P.C. as a Prevention
Tool

STM
Quality
Limited

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.

STM Quality Limited

The Benefits of
S.P.C.

Assesses the design intent.

Achieves a lower cost by

STM
Quality
Limited

providing an early warning

system.
Monitors performance, preventing
defects.
Provides a common language for
discussing process performance.
STM Quality Limited

STM
Quality
Process Variations
Limited
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

STM Quality Limited

Process Variations

STM
Quality
Limited

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.
STM Quality Limited

Stability

STM
Quality
Limited

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.
STM Quality Limited

Process Control

STM
Quality
Limited

The process can only be termed

under control if it gives

predictable results.
Its variability is stable over a long

period of time.

STM Quality Limited

Process Control
Charts

STM
Quality
Limited

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.
STM Quality Limited

Data Interpretation
Consider these 50 measurements

STM
Quality
Limited

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

STM Quality Limited

Data Interpretation

STM
Quality
Limited

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.
STM Quality Limited

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

STM
Quality
Limited

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).
STM Quality Limited

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

STM
Quality
Limited

The tally chart shows

2
patterns and we can
6
obtain the RANGE 7
36.32mm to
16
36.38mm.
12
5
2 The most

FREQUENTLY
OCCURRING size is
36.35mm.
STM Quality Limited

Tally Chart - Information

The tally chart gives us further

STM
Quality
Limited

information:
The number of bores at each size;
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
STM Quality Limited

STM
Histogram
Quality
We can redraw the frequency chart Limited
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

STM Quality Limited

STM
Smoothed Frequency
Quality
If we now draw a smooth curve throughLimited
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

STM Quality Limited

Distribution

STM
Quality
Limited

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.
STM Quality Limited

Normal Distribution

STM
Quality
Limited

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!
STM Quality Limited

Self-test (1 of 9)

STM
Quality
Limited

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

preventingdefects
_______.
S.P.C. uses statistical techniques for
variation
knowingprocess
_______________.

STM Quality Limited

Self-test (2 of 9)

STM
Quality
Limited

Controlling a process is guiding it

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

STM Quality Limited

Self-test (3 of 9)

STM
Quality
Limited

The process may involve a

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

STM Quality Limited

Self-test (4 of 9)

STM
Quality
Limited

S.P.C. is a statistical analysis of

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

STM Quality Limited

Self-test (5 of 9)

STM
Quality
Limited

Disadvantages of 100% detection

inspection are that production is

already
made
___________
and that it is
historically
__________ based.

STM Quality Limited

Self-test (6 of 9)

STM
Quality
Limited

An advantage of prevention

inspection
is that _______ is improved.
quality
It is a strategy thatfuture
is _____

orientated.

STM Quality Limited

Self-test (7 of 9)

STM
Quality
Limited

No industrial process is able to

produce consecutive items which

identical
are _______.
There are always differences,

variation
known
as _______.

STM Quality Limited

Self-test (8 of 9)

STM
Quality
Limited

The process can only be termed

under control ifpredictable

it gives __________
results.
Its variability stable
is ______ over a long

period of time.

STM Quality Limited

Self-test (9 of 9)

STM
Quality
Limited

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.
STM Quality Limited