STATISTICAL PROCESS

CONTROL
FQA LEC 5
STATISTICAL PROCESS CONTROL (
SPC )
( GATCHALIAN)

 the application of statistical principles using

relatively easy to use but powerful tools for
the control of PROCESSES.

 The full benefits of statistical methods to

improve quality, increase productivity , and
reduce cost is realized when you focus your
efforts on the processes which generate the
output.
 WHY DO WE NEED PROCESS CONTROL ?

 Improve Decrease Improve

Quality Costs Productivity

Capture the Market More Profits Provide

with better Quality Stay in jobs
and
and lower Price Business more jobs

DR. DEMING’S CHAIN REACTION

 PROCESS CONTROL OPTIONS
In practice you have three choices:
1. No process control ( what can you predict about
quality?)
2. External process control ( also known as inspection)
3. Internal process control ( assurance)
Material
Material In Measured VS Out Quality
Do a Bit Desired Outcome Assured

Feedback Loop

INTERNAL PROCESS CONTROL

USES OF STATISTICAL QUALITY
CONTROL
 1. To bring about an understanding of
variations in quality characteristics as they
are affected by the four M’s in
manufacturing( men, materials, methods,
and machines). These variations are of two
types:
 Chance or random Variations- These are due
solely to chance causes and are either
uncontrollable or very difficult to control. It might
therefore be uneconomic to try to eliminate them.
Accdg to Juran and Gryna ( 1981), when random
variations are present, the process is operating at
its best and that if defectives continue to be
produced, a basic process change must be made or
the specifications revised.
SQC….
 Assignable Variations- These are due to
detectable causes which can be corrected by
appropriate measures when fully identified. The
presence of assignable variations indicates that the
process is not operating at its best.
o 2. To help identify assignable causes of
variations and thus to facilitate the setting of
control limits when developing and
standardizing product specifications.
o 3. To determine the quality level of a process
through time. This can provide the basis for
decisions on whether to leave a process alone
or to institute changes.
DEFINITION OF TERMS:
 ATTRIBUTE- Classification of items
inspected as defective or non-defective, or as
rejected or accepted. The total quality
characteristic ( for go/ no go decision).
 VARIABLES- a specific quality characteristic
(weight, length, volume, moisture content, pH
level, sugar concentration, etc.) that can be
measured by instruments. The quantified
results of sensory evaluation can also be
utilized with the control chart.
TERMS…..
 INHERENT VARIABILITY- the total effect of
chance variations which is seldom possible to
estimate. It is sometimes referred to as the
“residual effect” and is best left uncorrected .
We can’t do anything about it. It may be
uneconomic to try to eliminate chance or
random variations.
 STATE OF STATISTICAL CONTROL- The
condition in which variations in successive
observations of the identified characteristic
are attributable to a system of chance or
random causes which indicates that the
process should be left alone.
TERMS . . .
 ASSIGNABLE OR SPECIAL CAUSE- Can
be pinpointed or corrected. An excellent tool
for this is a control chart by means of which
it is possible to follow the process and
describe graphically how it varies with time.

 USES OF CONTROL CHART:

1. To analyze a process in order to:
a. establish specifications
b. gather information as a basis for
improvement.
c. obtain data necessary for product
acceptance or rejection.
USES OF CONTROL CHART

 2.Basis for making decision whether to

remove or minimize variation.

 3. To develop a basis for accepting or

rejecting certain production outputs at a
specified time.

 To take corrective action on the basis of a

control chart , answers to the following
questions are required:
CONTROL CHART….
 In regard to the process :
o Is there a need to re-compute for a process

average after a series of observations during the

initial stages of the use of the control chart?

 Is there a need to remove the assignable causes

whose presence is indicated by points outside the
control limits given in the control chart?

 Is the observed process dispersion so wide that a

further analysis of the company’s processing
capability is required or does it indicate a need to
improve?
CONTROL CHARTS . . .
 In regard to processing specifications:
 What are the capacities of the machines ? These
should be established before specification limits
are set.

 Is the manufacturing process able to meet

specification limits? If not , a review of such
limits may be necessary.

 Is there a need to change specification limits

because of wide variations in the limits computed
from the results of actual operations?
VARIATIONS EXISTS BECAUSE
CONDITIONS ARE ALWAYS CHANGING ...
 People change ( mood, illness, tiredness, age,
gender.
 Equipment changes (due to use, maintenance, age
)
 Materials change ( batch, age, supplier, handling,
storage )
 Methods change ( operator, equipment,
improvement)
 Environments change ( temperature, humidity,
dust )
 Production changes ( plan, flow, layout )

 Customers change ( farmers, city people )

BENEFITS OF CONTROL CHARTS
 Control charts allow you to make visible
COMMON CAUSE and SPECIAL CAUSE
process VARIATION and in so doing, provide
a means to control the process and the
quality of its output.

 The basic statistics and chart details allow

timely and valid ACTION to be taken to
effect prompt and timely PROCESS
ADJUSTMENT.
SIMPLE CHART SHOWING THE UCL , CL, &
LCL

UCL

Center
Line CL

LCL

If the plots fall randomly within the control limits, the

process is said to be “ in control “.
TYPES OF CONTROL CHARTS….

 1. Charts for Variables- This is used when the

intention is to monitor changes in specific quantifiable
product charcteristics that are considered critical to
the maintenance of an acceptable quality level. Charts
for variables are used for measurements. Example is
moisture content, fill-in weight, net weight, pH, etc.

 2. Charts for Attributes- This require no

measurements. Information on the number of
defectives or defects is used. More appropriate when
the intention is to use the quality level of a product as
a basis for making a go or no go decision on a
production lot or a process.
ATTRIBUTES CHART

 TYPES OF ATTRIBUTES CHART:

1. Fraction defective : p chart
2. Number of Defectives: np chart
3. Defects per Unit: u chart
4. Number of Defects : c chart
 A chart for attributes is normally established for
a certain inspection station. It can be drawn up
for one or more charcteristics, sampling or 100 %
inspection.
CONTROL CHART FOR ATTRIBUTE
SUB GROUP SIZE
TYPES OF CONSTAN
DATA T VARIABLE
DEFECTS C chart U chart
No. of No. of
Defects defects/unit
DEFECTIV np chart p chart
E No. of Fraction
Defectives Defective
VARIABLES CHART . . .
 - Their most common forms, the X ( X bar )
and R charts- represent the typical
application of control charting to process
control.

 Variables Data Numeric measurements are a

typical example of variables data (
temperature in degrees, length in meters,
weight in kgs., etc.

 Variables data is quantitative data usually of

a continuous nature within limits.
THREE OUT OF CONTROL CONDITIONS:

CONDITION XX CHART R /S or MR
CHART
1 OUT OF IN CONTROL
CONTROL
2 IN OUT OF
CONTROL CONTROL
3 OUT OF OUT OF
CONTROL CONTROL
CONTROL CHART WARNING SIGNS
 1.Any point beyond the control limits.
 2. Seven or more consecutive points above or
below the centerline.
 3. Seven consecutive increasing or decreasing
points.
 4. Two out of three beyond two sigma on the
same side of the centerline.
 5. Four out of five beyond one sigma on the
same side of the centerline.
 6. Ten out of 11 consecutive points on the
same side of the centerline.
CONTROL CHART WARNING SIGNS

 7. Twelve out of 14 consecutive points on the

same side of the centerline.
 8. A series of points hugging the centerline.

 9. A series of points hugging the control

limits.
 10. Fourteen consecutive points alternating
up and down ( saw-tooth pattern).
 11. Any nonrandom pattern ( such as a cycle)
WHAT YOUR CONTROL CHART CAN TELL YOU
 1. Is the chart indicating an in-or- out –of –
control situation?
Documented criteria( presence of outliers,
points near the warning limits) that provide
operators with guidelines for determining what
constitutes an in-or-out-of control situation
should be available.
2. Are out-of-control situations being
investigated?
Operators should document, preferably on
the chart itself, what action is being taken in
response to these out-of-control situations.
WHAT YOUR CONTROL CHART CAN TELL
YOU
3. Is the process doing what it is supposed to do?
A well-designed control chart will provide
operators with the information they need to
manufacture high
Quality products. Identify the significant variable
that will contribute to process or product quality.
 4. Are there specifications?

Operators need to know about specifications

whether they be manufacturing specs, release specs,
or customers specs. Check to see that specs are
current and documented.
Operators should know the relationshipdifferences
between specs and control chart limits.
WHAT YOUR CONTROL CHART CAN TELL
YOU

 5. What is the capability of the process being

charted?
Process capability refers to the variation
inherent in the process that is operating in a state
of control.
Operators must understand what his process
is capable of?
 6. If the process is not in control, what is being
done to determine the cause?
It is helpful for the operator to have a
flowchart or other type of guideline to provide
them with a series of steps to follow in the event
of a problem.
WHAT YOUR CONTROL CHART CAN TELL
YOU

 7.
Have enough data been plotted to be able to
draw conclusions about the process from the
control charts?

If there is an adequate amount of data, is

it being fully utilized? At least 20
observations and 3 subgroups for the data
collected to be valid.
Information can be extracted, such as day-
to-day variability in quality, machine-to-
machine comparisons, from the charts.
WHAT SHOULD BE DONE TO SUSTAIN
CONTINUED USE OF CONTROL CHARTS
 1. Determine the status of the control chart
system.
A control chart is a dynamic part of the
process leading to continuous process
improvement. Be aware of signs that indicate if
operators are just going through the motions.
 2. Review the control limits

It is helpful for the operator to have a

flowchart or other type of guideline to provide
them with a series of steps to follow in the
event of a problem.
WHAT SHOULD BE DONE TO SUSTAIN
CONTINUED USE OF CONTROL CHARTS …

 3.Have enough data been plotted to be able to

draw conclusions about the process from the
control charts? If there is an adequate amount
of data, is it being fully utilized?

Information can be extracted , such as day

to day variability in quality, machine to
machine comparisons, from the charts.
STRATEGIES FOR REDUCING VARIATIONS

 1. Make visible the nature of VARIATION, i.e. collect

data

 2. Eliminate undesired outcomes due to SPECIAL

CAUSE VARIATION,i.e. control processes

 3. Plan system reconfiguration to reduce COMMON

CAUSE VARIATION, i.e. continuous improvement
IMPORTANT BENEFITS PROVIDED BY
CONTROL CHARTS ……
 1. A proven tool for understanding process variation
and gaining control of a process SIGNIFICANT
CHARACTERISTICS.

 2. Can be maintained by OPERATORS who can give

reliable information for ACTION

 3. Statistically STABLE PROCESSES provide

producer and customer with consistent quality levels
and stable costs.
IMPORTANT BENEFITS PROVIDED BY
CONTROL CHARTS ……
 4. Facilitate continuous improvement of processes
through elimination of special cause variation. Allow
time and attention to be directed to SYSTEM
improvement.

 5. A common means of COMMUNICATION among all

process STAKEHOLDERS

 6. Indicate PROBLEMS likely to require intervention

by management and those capable of a local solution,
thus minimizing frustration and wasted time.