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PROCESS CAPABILITY
By Sachin Modgil

Thursday, July 26, 2012

Parul Institute of Management, Vadodara

Contents
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1. Process Capability 2. Control Limits Vs Specification Limits 3. Tolerance 4. Example

5. Things to Remember
6. Conclusion
Thursday, July 26, 2012

Process Capability
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Even when the process operates under the influence of chance causes, certain amount of variation is inherent. This inherent variability of a process in a machine or equipment is referred to as the process or machine or equipment capability Or Process Capability measures the extent to which the voice of the process is aligned with the voice of the customer

Thursday, July 26, 2012

Introduction
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Control Limits (Manufacturer) Vs Specification Limits (Customer) Type of Specifications (USL & LSL) Tolerance: USL-LSL Natural tolerance range is the range of three standard deviations from the mean on either side. Standard indexes are used: Cp, Cpk, Pp and Ppk. These can be converted into ppm. Thursday, July 26, 2012

Example
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Cp is capability index Cp= T/6 Pp is performance Index Example: 30 Samples of size 4 each were taken. Sample average (X bar) as deviation from 100 microns and sample range (R) values in microns are given

Thursday, July 26, 2012

Sample No 1
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X Bar 9.5 18.25 20.75 21.25 24.25 25.25 26.50 28.25 22.75 28.75 33.00 15.00 22.50 18.75 21.75

R 15 10 8 9 10 15 19 22 6 20 10 17 11 10
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2 3 4 5 6 7 8 9 10 11 12 13 14 15

Sample No. 16 17
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X bar (Microns) 12.50 22.75 21.50 15.75 17.00 20.75 17.50 20.25 18.25 20.50 28.75 15.50 14.50

R (Microns) 10 14 18 20 7 12 7 15 14 24 5 20 3

18 19 20 21 22 23 24 25 26 27 28

29
30

22.75
30.50

23
16
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Total

608.25

413

Example
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If the Specification for land width is 0.1200.020 mm from the above data, compute process capability (6), measure of precision(Cp) and measure of Accuracy (Cpk) and interpret them. Now 608.25/30= 20.3 , Hence X double Bar= 0.1203 Average Range= 413/30=13.77 We have D4 R bar= (2.28)(13.77)=31.4 microns Also D3 R bar= (0) (13.77)=0
Thursday, July 26, 2012

Example
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Since all the ranges are in limits, we compute process capability 6= 6(Rbar/d2)=(6 X13.77)/2.059=40 microns Tolerance (T) = USL-LSL= 0.140-0.100= 0.04mm= 40 microns Cp=T/6= 40/40=1.0, which means process is just able to meet the tolerance Hence 6= Tolerance (T)

Thursday, July 26, 2012

Example
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Cpk= min(X double bar-LSL/3 ,USL- X double bar/3) Min (0.1203-0.1000/0.02 ,0.1400-0.1203/0.02) Min (1.015,0.985) 0.985~ 1.0 Indicates process is fairly centered

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Meaning of Cp, Cpk, Pp and Ppk

1 2

CAPABILITY
Short Term In Control Pooled std dev

PERFORMANCE
Long Term Not in Control Total / overall std dev

How a much variability

How centred

compares spec range (tolerance) to process width how close process centre is to nearest spec limit

Cp

Pp

Cpk

Ppk

Thursday, July 26, 2012

Remember
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The following chart is used as a rule of thumb

Cp Red (Bad) Yellow (OK) Green (Good) < 1.00 1.00 - 1.33 > 1.33 Cpk < 1.00 1.00 - 1.33 > 1.33 Pp < 1.33 1.33 - 1.67 > 1.67 Ppk < 1.33 1.33 - 1.67 > 1.67 Sigma < 4.5 4.5 - 5.5 > 5.5

( Cpk x 3 ) +1.5 = sigma

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Conclusuion
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A Process Capability study is the end result of the analysis done on process output data. A Process Capability study reflects what our customer sees. It indicates what our short term and long term situation looks like. Recognise however that our processes need to be stable (in statistical control) as well as capable.
Thursday, July 26, 2012

Questions ?

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Thursday, July 26, 2012