IsIs

The Define
Process
Process
Capable
Capable
??

Quality Process

Improvement Select
Measures

Model
Collect &
Interpret
Data

Is Process Capable? Is Investigate &

No
Process Fix Special
Stable Causes
?
Purpose: Determine the adequacy
of the process with Yes

respect to customer No IsIs

Improve
Process
Process
/management needs. Process
Capable
Capable
Capability
??

Yes
Use SPC to
Maintain
Current
Process

8-1
 IsIs
Process
Process
Capable Process Capable
Capable
??

A stable process that meets customer requirements.

Histogram
Control Chart

UCL

CL

LCL
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Run Order Lower Spec Upper Spec
Target

Capability assessments for unstable processes, may not be indicative of

how the process is actually performing.
8-2
 IsIs
Process
Process
Capable
Capable
??

Assessing Process Capability

 Counting Measures
 The average percent defectives.
 The average number of defects.

 Instrument Measures
 Comparing both the center of the process and the process
variation

8-3
Capability Assessment for Counting Measures IsIs
Process
Process
Capable
Capable
“Order Entry Process” ??

Week # Errors
1 15
2 22 Control Chart
35
3 18
4 10 30
UCL=28.0
5 13 Number 25
6 9 of Errors
20
7 27 Avg=16.0
15
8 12
9 24 10
10 22 5 LCL=4.0
11 8
0
12 8 5 10 15 20
13 26 Week
14 16
15 20
16 10 Is this process adequate as is?
17 16
18 9 Should it be improved?
19 15
20 20
Total 320
8-4
Measures of Process Capability IsIs
Process
Process
Capable
Capable
USL - LSL
Cp = Specification Range =
??
True Process Range 6c

Cp < 1.0 Process is not capable of meeting specs

Cp = 1.0 Process is marginally capable
Cp > 1.0  Process is capable of
meeting specs
Problem: We are assuming the process has a
in the
target center of the specification range, and that
thethat is
process is in fact centered on that target.

Distance from process average

Cpk = to closest specification limit = min (USL - x , x - LSL)
1 True Process Range 3c
2
Note: a negative result is possible if the process average is outside specifications


Cpk < 1.0 Process is not capable of meeting specs

Cpk = 1.0 Process is marginally capable

Cpk > 1.0 Process is capable of meeting specs
Benefits:
• Optimal values are attained by running exactly
between specs.
• Can (must) be used for 1-sided specifications
Warning: Capability assessments for unstable processes, may not be
indicative of how the process is actually performing. 8-5
 IsIs
Process
Process
Capable
Capable

Process Capability ??

LSL USL
USL
LSL

How much material is out of spec?

 In the short term?
 In the long term?

8-6
 IsIs
Process
Process
Process Capability Ratios Capable
Capable
??

LSL
LSL USL
USL

Voice of The Process

Voice of The Customer

8-7
 IsIs
Process
Process
Capable
Capable
??

8-8
 IsIs
Process
Process
Capable
Capable

Process Capability - The Strategy ??

Centering –The Process Is On Target

Spread – Reduce The Variation

Defects Defects

LSL USL

8-9
Process Capability Ratios IsIs
Process
Process
Capable
Capable
??

2 Key Metrics for Measuring Capability

USL  LSL
Cp 
6c

X- LSL USL- X
Cpk  Min( , )
3c 3c

8-10
 IsIs
Process
Process

Process Capability Ratios - Concept Capable

Capable
??

USL  LSL
Cp 
6c

Total Tolerance
Cp 
Process Spread

8-11
 IsIs

CP & CPK Measure Short-term

I Chart for C1 Capability
Process
Process
Capable
Capable
??
39
3.0SL=37.36

Individual Value 34
Is The Process
In Control ?
X=30.60
29
Is It Producing
Defects ?

24 -3.0SL=23.84

0 5 10 15 20 25 30 35
Observation Number

A Short-term Capability study covers a relatively

short period of time (days, weeks) generally
consisting of 30 to 50 data points. The actual
number depends on the subject under study.

8-12
Long Term Performance
I Chart for C3 IsIs
Process
Process
Capable
Capable
??
50
3.0SL=47.12

Individual Value 40
Short term
Is The Process Capability
In Control ? X=33.80

30
Is It Producing
Defects ?

20 -3.0SL=20.49

0 50 100
Observation Number

A long-term capability study covers a relatively long

period of time (weeks, months) generally consisting of
100-200 data points. Again, the actual amount depends
on the subject under study.

8-13
A Further Look at Capability IsIs
Process
Process
Capable
Capable
??

Compare the estimates of the process deviations

from the short-term and long-term data

Descriptive Statistics

Variable N Mean StdDev

short term 30 30.6 2.23
long term 180 33.8 4.44

What
Whatis
isthe
thedifference
differencebetween
betweenthe
theshort-term
short-termand
andthe
the
long-term
long-termdata?
data?
What
Whatimplication
implicationdoes
doesthis
thishave
havein
indoing
doingcapability
capability
studies?
studies?

8-14
Measures of Process Performance IsIs
Process
Process
Specification Range = USL - LSL Capable
Capable
Pp = ??
True Process Range 6s


P p < 1.0Process Performance is not meeting specs

P p = 1.0Process Performance is marginally meeting specs

P p > 1.0 Process Performance is meeting specs

Problem: We are assuming the process has a

in the
target center
that is of the specification range, and that
the process is in fact centered on that target.

Distance from process average

to closest specification limit min (USL - x , x - LSL)
P pk = 1 =
True Process Range 3s
2

Note: a negative result is possible if the process average is outside specifications


Ppk < 1.0Process Performance is not meeting specs

Ppk = 1.0Process Performance is marginally meeting specs

Ppk > 1.0 Process Performance is meeting specs

Benefits:
• Optimal values are attained by running exactly
between specs.
• Can (must) be used for 1-sided specifications 8-15
Performance vs. Capability IsIs
Process
Process
Capable
Capable
??

CO2Sales
Days Levels for 55 Timefor
Outstanding Points
55 Days

14

13
CO2-Shrt
DSO

12

11

10
Index 10 20 30 40 50

These data show that the process, if well controlled can

perform much better than it currently is

8-16
 IsIs

Capability vs. Performance Process

Process
Capable
Capable
??

CO2Sales
Days Levels for 55 Timefor
Outstanding Points
55 Days

14

13
CO2-Shrt
DSO

12

11

10
Index 10 20 30 40 50

Capability: Only Process Performance:

random or short Total Variation including
term variability shifts and drifts
(Cp & Cpk) (Pp & Ppk)
8-17
Process Performance Ratios IsIs
Process
Process
Capable
Capable
??

USL  LSL
P p 
6s

X- LSL USL- X
P pk  Min( , )
3s 3s

The P-family of indices are computationally the same as

the C-family of ‘capability’ indices, but use the observed
long-term standard deviation.
8-18
WARNING!!! IsIs
Process
Process
Capable
Capable
??

Statistical Assumptions Made In Capability Studies

1. Data Comes From a Stable Process

 If not, work towards getting the process in
control
 Don’t despair, you can still make some
assumptions about your process in the mean
time

8-19