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Width of landing
strip 1/2 Width
of landing
strip
5000
discharges
4000
3000
2000
1000
0
230
201
201
172
No of cylinders
144 132
115
86
57
28
0
1 7
Month
No of setup in CNC3
ge
230
an
Ch
201
172
No of setup
144
115
86
57
28
00
1 2 3 4 5 6 7 8 9 10 11 12
Month
70 63
60
50 45
No of tubes
40
30
20
10
0
1 7
Month
100
90
80
70
Percentage
60
50
40
30
20
Ch
an
10 ge
0
1 2 3 4 5 6 7 8 9 10 11 12
Month
Controller ●
Lower Control Limit
Samples
A B C D E L M N O P
Controllable factors Uncontrollable factors
- Assignable causes - Common causes
- Adjustable - Noise
- Special - Inherent causes
When the Lord created the world and people to live in it, he
reasoned with himself as follows:
they will gradually discover that there is no rational basis for any
decision whatsoever and, as in the first case, they will thereupon
have no motive to do anything at all.
They will then, amongst many other things, have the very
important task of finding out which is which.
Metallized Ceramics Division
Understanding Variation
Variation is natural……
Variation is inherent to a process……
120
100
average
80
Min. 60
40 School holidays
20
Borrowed helicopter
0
35
30
Upper
Control
Routine variation
Journey Time (hours)
Limit
25
20
Median Unless the
15 Lower
process is
10 Control
Limit
changed it will
continue to
5
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 operate this way
Patient number
in the future
35
Exceptional
variation
Upper
30 Control
Journey Time (hours)
Limit
25
20
Median Attributed to
15 Lower assignable causes
10 Control
5
Limit
Seek to identify
0 assignable causes -
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
Patient number eliminate if bad,
learn from if good
Dominant cause-
and-effect
relationships
Metallized Ceramics Division
My trip to work
Upper Process
120 Limit
100
80 Av
Min. 60
Lower
40 Process
Limit
20
Special Causes
Non-random variation (unusual)
May exhibit a pattern
Assignable, explainable, controllable
Adjusting the process decreases its variation
Shot a rifle?
Played darts?
Jack
Jill
Observations Deviations
Jack
10 10 - 8.4 = 1.6
9 9 - 8.4 = 0.6
8 8 - 8.4 = -0.4
8 8 - 8.4 = -0.4
Observations Deviations
Jack
7 7 - 6.6 = 0.4
7 7 - 6.6 = 0.4
7 7 - 6.6 = 0.4
7
6 6 - 6.6 = -0.6
6
6 6 - 6.6 = -0.6 7
averages 6.6 0.0 7
6 Jill
Metallized Ceramics Division
Variability
8
Variance = average distance 7
between observations and the mean 10
8
squared 9
Jack
Observations Deviations Squared Deviations
10 10 - 8.4 = 1.6 2.56
9 9 – 8.4 = 0.6 0.36
8 8 – 8.4 = -0.4 0.16
8 8 – 8.4 = -0.4 0.16
7 7 – 8.4 = -1.4 1.96
averages 8.4 0.0 1.0 Jill
Jack
Average Variance Standard
Deviation
Jack 8.4 1.0 1.0
Jill 6.6 0.24 0.4898979
Jill
If we take the height of all the people of India and draw a distribution
Of frequencies it will tend to follow a normal distribution
Mean
X-bar
Mean
X-bar USL
LSL
LSL and USL are those specification limits beyond which your
product doesn’t have a salable value in the market
Metallized Ceramics Division
Normal Distribution
Mean
X-bar USL
LSL
34.13% 34.13%
13.60% 13.60%
2.14% 2.14%
0.13% 0.13%
95.46%
99.73%
y
1SD= 68% DATA
3SD = 99%DATA
0
x
Metallized Ceramics Division
Normal Curve – Yield/Rejection
1 , 2 , 3 , 4 , 5 ; Mean = 1+ 2 + 3 + 4 + 5 = 15/5 = 3
X = X =
n
Mean of Sample, i x1 +x2 +x3 +x4+……..xn
I=1
n
b.) Median : The Median term of the given data is given by
Median = n + 1 th term, where n is the number of
2
Observations in the given data(arranged in increasing order).
Median Term = 4.5th Term = 4th Term + 0.5 ( 5th - 4th Term ) = 3 + 0.5 ( 4- 3) = 3.5
Metallized Ceramics Division
Measures of Central Tendency of Data
X
6 125 –25 625
7 127 –23 529 Sample Mean i
8 145 –5 25
X= i =1
(X - X )
2
(X - X )
2
n
150 (X - X )
2
Mean
i
i 1
652
S2
n 1
S1 25.53
n
(X - X )
2
i
i 1
n 1
Metallized Ceramics Division
Exercises
Calculate Mean, Standard Deviation for the data given
in the Exercise 1
Process variability
SPECIFICATION WIDTH
Metallized Ceramics Division
Process Capability Analysis - Cp
Process Capability Ratios
The greater the design margin, the lower the Total Defects Per Unit
Specification Width
Cp = USL - LSL
Process width X Cp =
-3 +3
Process Width
Specification Width
CP > 1 (Traditional)
CP >= 2 (Six sigma)
Metallized Ceramics Division
Process Capability Analysis - CpK
LSL USL
Process variability
SPECIFICATION WIDTH
Metallized Ceramics Division
Process Capability Analysis - CpK
From a statistics perspective, There are only two problems.
Desired
Desired
Current
Current situation
situation
Shift
μ
μ target
target
Width of landing
strip 1/2 Width
of landing
strip