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ABSTRACT
Different methods are used in an organization to grace full production process. Therefore, the main aim
improve productivity, one such method is Statistical of SPC is to identify and cure the assignable causes as
process Control (SPC).Statistical process control is a soon as possible for an acceptable quality as per
collection of tools, that when used together can result industrial standards.
in process stability and variance reduction, thereby
leading to a more streamlined production process. Process capability study is a technique of combining
This paper presents a case studyy of SPC to improve the statistical instrument developed from the normal
the performance of current process by reducing the curve and control charts with good engineering
variability in the dimension of parts produced, there judgment to interpret and analyze the data
by diminish rejections and improving the process. By representing
ting a process. The purpose of the process
carrying out mathematical calculations and using capability study is to determine the variation spread
various SPC tools, process capability
pability study was done and to find the effect of time on both the average and
under existing conditions, some improvements were the spread.
done in the existing welding fixture used for
producing the part to improve their capabiliti
capabilitiy indices. In this case study, process capability analysis was
In this study after the application of SPC tools and carried out in an sheet metal pressed components
c
integrating the suggested changes in existing process, manufacturing company to determine the variance
great improvements were seen, as such the capability included in the critical dimensions of various parts in
indices which were 0.1.1&0.38 respectively for the production. The entire production line was first
existing process, increased to 1.91&1.50 respectively reviewed to understand the position and importance of
for the improved process, thereby representing good each operation involved in the manufacturing.
manufact The
process performancece with higher strength. process capability indices for the current process have
been estimated to decide the current extent of the
Keywords: Statistical Process Control, Control process. Various SPC tools have been used for
Charts, Process Variation, process capability indices, analyzing the data and process improvement. The
rejection rate. collected data included, rejection data for past
periods, measurements of different dimensions of
1. INTRODUCTION different parts for the first 50 parts build on the
Statistical process control is a quality control machine for starting the mass production run by
technique which uses various statistical methods to collecting the data and then performing the beginning
analyze, monitor and control an ongoing process to SPC study for various dimensions of various parts
p and
shield that it operates at its full potential in order to then calculating the capability indices and plotting
produce parts conforming to the specifications. other control charts for the studied dimensions and
Statistical process control is a collection
tion of tools that determining the current performance of the process as
when used together can result in process stability and such the process capability indices are up to the
variance reduction and thereby leading to a more necessary level or not and if they aren’t
ar up to the
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
However, the Utility of the check sheet may be limits and the target value. The mean and standard
significantly enhanced in some instances by deviation of the sample values are calculated, which
incorporating a depiction of the system under analysis defines the spread of the process. It shows the current
into the form. process spread with respect to the acceptable
performance spread. A process where almost all the
Pareto chart measurements fall inside the specification limits is
Pareto is a bar chart comparing the causes of called a capable process.
problems with their frequencies. Based on Pareto
principle, 80% of results rise from 20% of factors, in
other words, although there may be many factors for
existing problems, a few of them are important and
most problems can be solved by removing them.
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
1 ≤ CPK < Process is adequate which are having major problems and accounting to
1.33 rejections and from the past data. We came to know
CP ≥ 1.33 Process is satisfactory enough that there is a single critical dimension of 57mm
having tolerance of (±0.8mm) that was leading to
CP ≥ 1.66 Process is very satisfactory maximum rejections of the part as this dimension
affected the mounting of part in its final place of
CPK ≠ Process is not enough, a new application. Also major rejection of this part was due
CPK process parameter must be to this single dimension and therefore we focused our
selected study on this part for the 5mm dimension to proceed
for our SPC study. The data collected for this part is
METHODOLOGY shown below in Table 2. This shows that from all the
The study was carried out in a small scale industry critical dimensions, the dimension of 57mm has
dealing in production and supplying of sheet metal maximum rejection rate of about 40%.
press components, machined components with
fabricated steel assemblies for automobile industry. In Table 2: Data collected
this case study, Statistical process control study was Past rejection data for the part No.9139.
implemented in the industry to improve the
Dimensions parts %
performance of the process involving rejection and
rejected values
rework. For progressing in our study we collected the
A(60 mm) 160 12.99
data for past period and did a detailed analysis of the
data to find out the current performance of the parts. B(57 mm) 150 12.18
We did rejection data analysis and plotted paretto C ( 178 mm) 215 17.45
chart to find out the part involving high rejection rate D (88 mm) 212 17.21
and also to determine the critical parts in it. From the E ( 57 mm) 495 40.18
analysis, we found out that out of several parts being Total 1232 100
produced, part no.9139 involved very high rejection
rate and accounted to a major share of total parts With help of various measuring instruments (vernier
being rejected .Therefore we selected this part for our height gauge, magnetic v-blocks, vernier calipers, dial
study. Initially we did the SPC study for a part having height gauges, etc.) we took 50 continuous readings of
number. 9139. the part dimension. Table 3 gives detail about the part
and its specifications whereas the readings are shown
In methodology, study of process characteristics of below in Table 4.
part has been done. Collection of data about forming
process of child parts was carried out. Also the Table 3: information of part under study
collection of readings of critical dimension i.e. 57 was Part number: 9139
done and afterwards X and R charts were plotted for Product dimensions : 57±0.8mm
the respective dimension. After plotting the control
charts next step was to calculate process capability Chart Name :
indices (cp, cpk, pp, ppk ). The results which were Upper spec limit 57.8mm
obtained help to identify the scope of improvement Target 57mm
and do the same. After required improvement next
step was to carry out the SPC study again for the lower spec limit 56.2mm
critical dimension and check whether the process was
under control or not. Different SPC tools such as Table 4: continuous 50 readings of the part for 5mm
histogram, pareto chart, control charts, cause and dimension
effect diagram, process capability studies were used. Part Dimension Part Dimension
Aim of the study was to improve the process Number in mm Number in mm
capability and to reduce the rejection rate. 1 57.7 26 57.6
2 57.6 27 57.3
4. DATA COLLECTION AND ANALYSIS 3 57.7 28 57.19
We collected the past data for this part from the
4 58.6 29 57.5
quality control department to know the dimensions
5 57.3 30 57.45
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
2456
6 57.2 31 57.4 x bar and Rbar charts and showing histogram
7 57.4 32 57.44 embedded in the normal distribution curve.
8 57.3 33 57.62
9 57.2 34 57.62 This shows
ows that there variation in the data and the
10 57.7 35 57.34 process is slightly shifted towards the USL of the
dimension and is producing parts with dimension
11 57.5 36 57.78
ranging in positive tolerance zone. This can also be
12 57.6 37 57.62
seen in the capability six pack study using Minitab.
13 57.7 38 57.7 Thus itt paves us the way to further synthesize the
14 57.6 39 57.6 process and find out the causes due to which there is
15 57.7 40 57.36 presence of variation in the data. For this purpose we
16 57.2 41 57.78 did a root cause analysis and plotted a cause and
17 57.4 42 57.62 effect diagram for listing various causes for the
18 57.3 43 57.7 problem
oblem as well as determining the most important
19 57.4 44 57.4 one.
20 57.3 45 57.36
21 57.7 46 57.5
22 57.6 47 57.36
23 57.7 48 57.2
24 58.6 49 57.45
25 57.3 50 57.33
_ LSL 56.2
_
57.5 X=57.54 U SL 57.8
57.0 LCL=57.031
1 3 5 7 9 11 13 15 17 19 21 23 25 56.4 56.8 57.2 57.6 58.0 58.4
R Chart N
Normal Prob Plot
1
1 A D: 2.009, P : 0.076
1.0
Sample Range
UCL=0.885
0.5
_
R=0.271
0.0 LCL=0
1 3 5 7 9 11 13 15 17 19 21 23 25 57.0 57.5 58.0 58.5
Last 25 Subgroups C
Capability Plot
58.5 Within Within Overall
StDev 0.24 StDev 0.2808
Values
Cp 1.11 Pp 0.95
58.0
Cpk 0.36 O v erall Ppk 0.31
PPM 139330.26 Cpm *
57.5 PPM 177220.31
Specs
5 10 15 20 25
Sample
In order to understand the problem, we made one part Table 5: Readings for part made using improved
without using fixture and by arranging all the welding fixture
parameters manually to as close as possible to the Part Dimension Part Dimension
required dimension. After the part was produced, we Number in mm Number in mm
placed the part in the same existing welding fixture. 1 57.78 26 57.6
After placing the master Part in the existing welding 2 57.62 27 57.3
fixture, we noticed that there is a gap at one side 3 57.7 28 57.19
between the fixture support and the face of child part 4 58.6 29 57.5
that should rest on the welding fixture support. This 5 57.36 30 57.45
was the main cause, and due to this extra gap the child
6 57.2 31 57.4
parts when clamped, used to get pushed on one side
7 57.45 32 57.44
more than on other thus causing the error. The
existing welding fixture is shown in fig 4. below. 8 57.33 33 57.62
Thus improvements were to be made in this welding 9 57.2 34 57.62
fixture in order to achieve a high process capability 10 57.7 35 57.34
with very less variability from mean position. We 11 57.5 36 57.78
discussed this suggestion with our industry 12 57.6 37 57.62
counterparts and after the permission, and the 13 57.78 38 57.7
suggested changes, the welding fixture was improved 14 57.62 39 57.6
further as shown in fig 5. 15 57.7 40 57.36
16 57.2 41 57.78
17 57.45 42 57.62
18 57.33 43 57.7
19 57.4 44 57.4
20 57.35 45 57.36
21 57.78 46 57.5
22 57.62 47 57.36
23 57.7 48 57.2
24 58.6 49 57.45
25 57.36 50 57.33
Fig 4:Part fixed in the welding fixture before
improvement
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
After taking the readings of part made using improved dimension the 57mm dimension was the major cause
welding fixture, the next step was to perform the for rejection of part and therefore we chose this
analysis for the collected data. By using Process dimension for our further analysis.
Capability sixpack feature of MINITAB, we did the
capability analysis as well as performed an SPC We came to a conclusion that this problem was due to
analysis. the Results for the analysis are shown below problem in the welding fixture used to manufacture
in the figure.6. the part. After implementing the discussed
improvements and incorporating the changes in the
Shown below is the graph from Minitab showing all welding fixture we did the SPC study again by again
the Capability Sixpack Values and charts. taking 50 readings for the part produced using
improved fixture. By plotting the control charts and
Process Capability Sixpack of C1, ..., C2 performing the process capability analysis, we found
Xbar Chart Capability Histogram
57.4
UCL=57.4670
LSL USL
Specifications
out that the process capability indices improved
Sample Mean
LSL 56.2
57.2
_
_
X=57.17 U SL 57.8 considerably.
57.0
LCL=56.8730
1 3 5 7 9 11 13 15 17 19 21 23 25 56.40 56.64 56.88 57.12 57.36 57.60
R Chart
1
Normal Prob Plot
A D : 0.605, P: > 0.250
The process showed high stability and most of the
UCL=0.5160
data falling closer to mean resulting in a high process
Sample Range
0.50
0.25 _
R=0.1579 Capability (Cp=1.90 Cpk=1.51 & Pp=Ppk=1.67)
0.00 LCL=0
1 3 5 7 9 11 13 15 17 19 21 23 25 57.0 57.3 57.6
where Cp & Cpk are process capability indices and Pp
Last 25 Subgroups Capability Plot
57.4
Within
StDev 0.14
Within Overall
StDev 0.1476
& Ppk are process performance indices.
Values
Cp 1.90 Pp 1.81
57.2 Cpk 1.50 Ppk 1.42
Overall
PPM 3.40 Cpm *
57.0
PPM 9.83
5 10
Sample
15 20 25
Specs This paper has presented the case study on the
Fig.6: Capability analysis sixpack with results for applicability of the process capability analysis in a
improved data using MINITAB. small scale industry manufacturing auto components.
Briefly, the development of this work led to a
deepening of knowledge around the management
5. DISCUSSION ON RESULTS :
method or set of tools for managing processes-the
The main goals of SPC is an identification of
statistical process control (spc) with respect to its
abnormal variability caused by assignable causes with
scope, its embracement and its implementation in the
the aim to Making the process stable, Minimize the
reality.
process variability and Improve the process
performance. The case study throws a light on the
The main objective of this paperis to present the
applicability of the process capability analysis and
application of a systematic approach to the used of
other SPC tools in improving the performance of
statistical process control across the several stages of
existing process by finding causes of variation and
production of specific “x” piece in plant with the
eliminating thereby providing a more capable process
purpose of improving the quality in its manufacturing
with reduced variation and rejections. In our study we
processes.
considered a single part having a critical dimension of
5mm for doing SPC study. In our initial study we
Using means of control charts this approach, allows
collected 50 readings for the part and then performed
the identification of problems into the company’
SPC study. In the study we found out that the Process
production process. by applying this model, it was
capability ratios (Cp, Cpk, Pp, Ppk) were quite low
possible to put into practice what has been presented
than the required level. Thus giving us a instance that
and studied in theory ,increase knowledge and
there is some problem in the ongoing process and due
learning through the difficulties and challenges
to which the capability indices were low.
encountered in each step of application of the
statistical process control. Thus, it is possible to show
Thus the next step was to find out the causes due to
that depending on each case the researcher should
which the process capability was low. For this,
develop alternatives to make spcapllicable to different
initially we procured the past data for the part and
kind of companies since they could have different
plotted the rejection data in a table to find the critical
processes, routines and particularities, requiring
dimension due to which the part was being rejected.
specific adaptations.
From this chart we found out that from all the
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International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
2456
After a application of SPC there was a appreciable 6. Phyanthamilkumaran, S. Z. and Fernando, Y.
improvement in the process capability results (2008), “The role of cultural change in the
(CP=1.90 Cpk =1.51). relationship between critical factors with the
success of Statistical Process control (SPC)
After the rectification and effort taken there was a projects”, Proceedings of Annual London
significant increase in the process capability supreme Conference on Money, Economy and
to improved value of Cp and Cpk. On the whole, the Management, Vol.3 No.4,pp. 1-11.
1
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7. Prabhuswamy, M. (2010), “Process variability
improvement could be achieved economically by reduction through statistical process control for
employing
mploying SPC using its entire tools and analyzing all
quality improvement”, International Journal for
the involved parameters. Quality research, Vol.4, No. 3, pp.35-43.
pp.35
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