Process Capability

Prof G R C Nair
Whats the Difference?


Process
Control
Process
Capability
vs
What about consistent and predictable junk?
Prof G R C Nair
Process Control ability of a process to produce a predictable
set of outputs having more or less the same characteristics
Customer Specifications (Engineering Tolerance):
USL - Upper Specification Limit
LSL - Lower Specification Limit
LSL USL
-3 -2 -1 +
1
+2 +3
s
Process Capability Study
Actual (Natural)Process Variation: 6 Standard Deviations = + 3s
Prof G R C Nair
Example
Consider two parts run on the same machine. The
natural process variation for part A is the same for part
B, but the tolerances are different.

CAPABILITY
TOLERANCEPARTA
TOLERANCEPARTB

Prof G R C Nair
Nominal
value
Green Zone
Yellow Zones
Red
Zone
Red
Zone
LTL UTL
Prof G R C Nair
Capability ensures aligning the mean of the products
value with the mean of the specification
Example
Scrap and/or rework is inevitable for Part B
CAPABILITY
TOLERANCE PART A
TOLERANCE PART B
Prof G R C Nair
Troubleshooting
If the process is in statistical control but not capable of
meeting specifications, any one of the following (or both)
could be the problem:
a) Process variability is too large relative to tolerances
LSL USL
Scrap/Rework
Prof G R C Nair
b) Process is not centered at nominal (target)
LSL USL
Nominal
Scrap/Rework
B
Prof G R C Nair
Troubleshooting
Process is just capable






Must remain centred at all times. Needs to
be watched carefully .
LSL USL
Prof G R C Nair
Remedies
Continue to sort by 100% inspection
Use a different process to reduce process variation
Widen the tolerances (specification limits)
Use statistical methods to determine how to
reduce the natural variation of the process
Prof G R C Nair
Process Capability
If the process is capable of consistently
giving quality product as per the
specification, the process is said to possess
the required capability.
The natural tolerance limits of the process
should be with in the specification
/tolerance limits.
Prof G R C Nair
Prof G R C Nair
Prof G R C Nair

Prof G R C Nair

Prof G R C Nair
Relationship between Capability and Control
Process Capability is not the same as the
statistical control

However, a process must be in statistical
control before an assessment of process
capability can occur
Prof G R C Nair
Specification Limits vs. Control Chart Limits
Specification Limits
characteristic of the part/item in question
based on functional considerations
related to/compared with an individual part
measurement
used to establish a parts conformability
Should not appear on control charts

Control Limits
characteristic of the process in question
based on the process variability
dependent upon sampling characteristics, namely,
sample size
used to identify presence/absence of significant
variation in the process
Prof G R C Nair
For a process, n = 7, K= 30 X = 157.95
R=22.275
Specification of the part to be made is 5+1.25mm.
Is the process capable of giving the required
quality?

Exercise
Prof G R C Nair

Ans: First find the R & X X = 5.265mm, R = 0.7425
Then find the process capability (natural tolerance limits).
s =R/d
2

= 0.2746
Natural tolerance limits of the out put = X + 3 s = 4.44 to 6.08 mm
Desired /Specification tolerance limits = 3.75 to 6.25 mm
As the natural tolerance limits of the process are well within the
specified limits ,the process is capable of giving the quality
specified, (if it is in control.)
Prof G R C Nair
1. Capability Index Cp = USL-LSL
6s
If Cp < 1, the process is not capable of giving
the consistent quality- causes rejection
If Cp > 1, the product will have consistent
quality but still can give rejects , if the process
mean is not centred at or near the specification
mean.
Cp value can be increased by reducing the s or
variation in products or enlarging the tolerance
Process Capability Indices
Prof G R C Nair
2. Capability Index Cpk takes care of the
centring aspect as well
Cpk= Min of {(USL-Xbar) or (Xbar LSL)}
3s
If Cpk >1, the process is considered capable of meeting
the specs- it will produce < 0. 27% scrap.
If Cpk< 1, it will produce > 0.27% scrap.

Prof G R C Nair
1. Cp does not change with centring
2.Cp = Cpk, if process is perfectly centred
3. Cpk is always < Cp
4. Cpk value of zero shows the actual mean is
equal spec limit
5. A negative Cpk means the actual mean
falls out side a spec limit

Characteristics of Indices
Prof G R C Nair
A job has a design specification of 15 + 0.6
Find Cp and Cpk, if a process produces,
a) 15 + 0.7
b) 14 + 0.2
c) 15.6 + 0.3
d) 15 + 0.3
Rank the processes in the order of minimum scrap they produce

Example
ans : take in each case 3s as max variation.
a) Cp= 6/7, Cpk = 6/7
b) =3 = -2
c) =2 = 0
d) =2 = 2
Prof G R C Nair