STATISTICAL

PROCESS CONTROL

TOTAL QUALITY MANAGEMENT

Introduction to S.P.C.

© ABSL Power Solutions 2007

 What is meant by
Statistical Process Control?
Statistical Process Control (S.P.C.)

 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.
 What does S.P.C. mean?

 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.
What does S.P.C. mean?

 Process:
 The process involves people, machines,
materials, methods, management and
environment working together to
produce an output, such as an end
product.
What does S.P.C. mean?

 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.
 S.P.C.

 Statistics aid in making decisions about

a process based on sample data and
the results predict the process as a
whole.
 The Process

People Machines Material

Output

Management Methods Environment

 Definition

S.P.C. is statistical analysis

of the predictability and
capacity of a process to give
a uniform product.
 The Aim of S.P.C.
- Detection Strategy

 Detection:
This focuses on identification of
problems after production, by 100%
inspection or by customer complaints.

 It is a historically-based strategy.
 The Aim of S.P.C.
- Detection Strategy

Detection Drawbacks:
 Production is already made.
 Customer dissatisfaction.
 Inflated costs - rework; inspection.
 Repetitive problems.
 Neglected improvements.
 The Aim of S.P.C.
- Prevention Strategy

 Prevention:
This focuses on in-process production
and identification of problems through
analysis of process capability.

 It is a future-orientated strategy.
 The Aim of S.P.C.
- Prevention Strategy

Prevention Benefits:
 Improved design and process
capability.
 Improved manufacturing quality.
 Improved organisation.
 Continuous Improvement.
S.P.C. as a Prevention Tool
 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.
The Benefits of S.P.C.
 Assesses the design intent.
 Achieves a lower cost by providing an
early warning system.
 Monitors performance, preventing
defects.
 Provides a common language for
discussing process performance.
 Process Variations
Process Element Variable Examples
Machine………………………….Speed, operating
temperature, feed rate
Tools………………………………..Shape, wear rate
Fixtures…………………………..Dimensional accuracy
Materials…………………………Composition, dimensions
Operator…………………………Choice of set-up, fatigue
Maintenance…………………Lubrication, calibration
Environment…………………Humidity, temperature
 Process Variations
 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.
 Stability

 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.
 Process Control

 The process can only be termed ‘under

control’ if it gives predictable results.

 Its variability is stable over a long

period of time.
Process Control Charts

 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.
 Data Interpretation
Consider these 50 measurements
Bore Diameter 36.32 ±0.05mm (36.27 - 36.37mm)

1 36.36 11 36.37 21 36.34 31 36.35 41 36.36

2 36.34 12 36.35 22 36.37 32 36.35 42 36.37
3 36.34 13 36.32 23 36.34 33 36.36 43 36.37
4 36.33 14 36.35 24 36.35 34 36.37 44 36.35
5 36.35 15 36.34 25 36.34 35 36.34 45 36.37
6 36.33 16 36.34 26 36.35 36 36.36 46 36.36
7 36.33 17 36.35 27 36.36 37 36.38 47 36.35
8 36.34 18 36.33 28 36.33 38 36.34 48 36.34
9 36.35 19 36.32 29 36.36 39 36.35 49 36.35
10 36.35 20 36.35 30 36.38 40 36.35 50 36.34
 Data Interpretation

 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.
Data Interpretation – Tally Chart
36.39

36.38
 The tally chart groups
36.37 the measurements
36.36 together by size as
36.35 shown.
 The two parts that
36.34

were out of tolerance

36.33

36.32

36.31
are now easier to
36.30
detect (36.38mm).
36.29

36.28
 Tally Chart - Frequency
36.39

36.38
 The tally chart shows
2
36.37
6
patterns and we can
36.36
7 obtain the RANGE -
36.35
16 36.32mm to 36.38mm.
36.34
12
36.33
5
36.32  The most
2
36.31 FREQUENTLY
36.30 OCCURRING size is
36.29
36.35mm.
36.28
 Tally Chart - Information
 The tally chart gives us further 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
 Histogram
We can redraw the frequency chart as a bar
chart known as a histogram:
16

14

12

10

0 36.31 36.32 36.33 36.34 36.35 36.36 36.37 36.38 36.39

 Smoothed Frequency
If we now draw a smooth curve through the top
of each box we get a bell-shaped pattern:
16

14

12

10

0 36.31 36.32 36.33 36.34 36.35 36.36 36.37 36.38 36.39

 Distribution

 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’.
 Normal Distribution

 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!
 Self-test (1 of 9)

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

preventing _______.
defects

 S.P.C. uses statistical techniques for

knowing _______________.
process variation
 Self-test (2 of 9)

 Controlling a process is guiding it and

comparing ________________
actual performance against a
target and identifying when and what
______________
corrective action is necessary to
achieve the target.
 Self-test (3 of 9)

 The process may involve a combination

of people, machines, ________,
materials
methods, management and
___________
environment working together to
produce an output such as an end
product.
 Self-test (4 of 9)

 S.P.C. is a statistical analysis of the

predictability and capacity of a process
__________
to give a _______
uniform product.
 Self-test (5 of 9)

 Disadvantages of 100% detection

inspection are that production is
___________
already made and that it is
historically based.
__________
 Self-test (6 of 9)

 An advantage of prevention inspection

quality is improved.
is that _______

future orientated.
 It is a strategy that is _____
 Self-test (7 of 9)

 No industrial process is able to

produce consecutive items which are
_______.
identical

 There are always differences, known

as variation
_______.
 Self-test (8 of 9)

 The process can only be termed ‘under

predictable results.
control’ if it gives __________

 Its variability is ______

stable over a long
period of time.
 Self-test (9 of 9)

 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.