SPC: Interpretation of Control Charts

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Interpretation of Control Charts INTRODUCTION

 Proper interpretation of control charts is essential in order for SPC to be effective.  Control charts provide us with a graphical record of process behavior over a given period of time.  After establishing proper control limits that take into account inherent variation, the control chart should reveal any process that is out of control.
You must determine if the patterns you see are related to Common or Special Causes.

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Interpretation of Control Charts RANDOM CAUSES OF VARIATION

& If the data on the control chart forms a natural pattern, the points will fluctuate at random and tend to cluster around the centerline. A few points may spread out toward the control limits, however, none of the points should exceed the control limits. Examples: - The X-bar chart is a measure of the average. A random X-bar chart pattern indicates that the process average did not change during the time plotted and that most of the parts were near the average. - A stable pattern on an R chart is an indication of process uniformity. It could represent the operators technique on the machine. It can compare different operators or different machines. The R chart is a measure of the spread of the distribution. - A stable pattern on a p chart is an indication that there was a constant percentage of non-conforming parts and that the sampling was random.

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Interpretation of Control Charts RANDOM CAUSES OF VARIATION

& Control charts with common patterns indicate there is a steady, stable process running that is not being disturbed by special causes.
Common Pattern

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Interpretation of Control Charts SPECIAL CAUSES OF VARIATION

& Data that fluctuates too widely or fails to balance itself around the centerline is characteristic of special case patterns. Several types of special case patterns have been classified. Identified Patterns of Special Causes of Variation: & Trends & Cycles & Grouping & Strays & Sudden Shift in Level & Mixture

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

TRENDS
& Trends: Defined as a long series of points that lack a change of direction. There is a continuous movement of points up or down the control chart. Points will move toward one side of the centerline.

Trends

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

TRENDS (cont.)
Typical causes of trend patterns:

X-Bar Chart Tool wear / thread wear Aging Seasonal effects Operator fatigue Change in standards Inadequate maintenance Gradual introduction of new material

R Chart Something loose Gradual wear Dulling of tool Gradual change in operator technique or skill level Effect of process controls in other areas

p Chart Introduction of different material / tools Tightening / loosening of requirements Better / poorer work Increased / decreased skill of operators

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

CYCLES
& Cycles: Defined as short trends in the data that occur in repeated patterns, so that the pattern becomes predictable or systematic. There is an indication of an assignable cause because a characteristic of a random pattern is that it does not repeat. The cause of cycles are processing variables that come and go on a regular basis.
Cycles

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

CYCLES (cont.)
Typical causes of cycle patterns:

X-Bar Chart Seasonal effects Worn threads on locking devices Gage differences Voltage fluctuations

R Chart Maintenance schedule Rotation on fixtures or gages Wear of tool or die Differences between shifts

p Chart Sorting practices Sampling practices Differences between suppliers

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

GROUPING AND STRAYS
& Grouping: Occurs when measurements cluster together in a non-random pattern. This clustering can be indicated by an introduction of a different system of causes. For example, if a box of rejected parts gets thrown in accidentally, bunching may be observed on the control chart. & Strays: Result from a single measurement that is greatly different from the others. Occasionally, an apparent stray is the result of a plotting error. Strays are among the easiest of the patterns to recognize because they are so different from the other readings in the process.
Grouping or Strays

Grouping

Stray

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

GROUPING AND STRAYS (cont.)
Typical causes of Grouping patterns:
X-Bar Chart Measurement difficulty Different person making measurements Change in calibration of a measuring instrument R Chart Mixture of different lots p Chart Change in technique of classification Changes in sorting of product

Typical causes of Stray patterns:

X-Bar Chart Wrong setting corrected immediately Error in measurement / plotting Omitted / incomplete operation
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R Chart Damage in handling Incomplete / omitted operation Setup parts included in data Mathematical error
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p Chart Variations in sample size Sampling from different distributions A very good or bad lot

Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

SUDDEN SHIFT IN LEVEL
& Sudden Shift in Level: A sudden shift in level is shown by a change in one direction. A number of points will appear on one side of the control chart.
Sudden Shift in Level

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

SUDDEN SHIFT IN LEVEL (cont.)

Typical causes of Sudden Shift in Level patterns:

X-Bar Chart Change of material New operator / inspector New machine setting Shift change Different gage New tools Change in process method R Chart New operator / equipment Change of material Inadequate / improved maintenance Decreased / increased material uniformity Change in process method p Chart New lot of material Change from one machine / operator to another Change in gage calibration Change in process method

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

MIXTURE
& Mixture: Mixture patterns fall near the control limits, with an absence of points near the centerline. This pattern can be recognized by the unnatural length of the lines joining the points to create a sawtooth effect. A mixture is actually a combination of two different patterns on the same chart - one at a high level and one at a low level.
Mixture

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Interpretation of Control Charts PATTERNS OF SPECIAL CAUSES OF VARIATION

MIXTURE (cont.)

Typical causes of Mixture patterns:

X-Bar Chart Differences in operators Differences in gages Over adjustment of process Output from two or more machines mixed together Chart placed too far downstream

R Chart Different lots of material / machines / operator Differences in gages Too much play in fixture Tool needs sharpening

p Chart Non-random sampling techniques Lots from two or more sources

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Interpretation of Control Charts

Special Causes of Variation:

WESTERN ELECTRIC RULES TO DETECT PROCESS CHANGES

UCL A B Zones C C B A LCL 1 Centerline 68% 95% 99.7% 2 3

The Western Electric Rules are based on probability theory. Specifically, the probability of getting certain plot point patterns is so low that the situation needs investigation and the process may be out of control.

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Interpretation of Control Charts

Special Causes of Variation:

WESTERN ELECTRIC RULES TO DETECT PROCESS CHANGES (cont.)

According to the rules, the following situations indicate a process might be out of control and the causes of variation should be investigated:

One point falls beyond Zone A Two out of three consecutive points fall in Zone A or beyond Four out of five points fall in Zone B or beyond 7 points in a row fall on one side of the centerline

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Interpretation of Control Charts

Special Causes of Variation:

POINTS BEYOND THE CONTROL LIMITS

& Points beyond the control limits indicate a special cause that is acting on the process and causing it to act abnormally.
One Point Falls Beyond Zone A UCL A B Zones C C B A LCL Centerline

& Some Possible Causes: - error in calculation or plotting - change in measurement system - deterioration in process performance ( over time or at that moment)

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Interpretation of Control Charts

Special Causes of Variation:

TWO OUT OF THREE CONSECUTIVE POINTS IN ZONE A OR BEYOND

& The probability of the two points happening together in Zone A is determined by multiplying their individual probabilities. ( 1/40 x 1/40 = 1/1,600). This is very, very unlikely to happen due to inherent variation with a controlled process. Most likely a shift has occurred in the process average.
2 out of 3 points in Zone A UCL A B Zones C C B A LCL Centerline

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Interpretation of Control Charts

Special Causes of Variation:

FOUR OUT OF FIVE CONSECUTIVE POINTS IN ZONE B OR BEYOND

&Through probability analysis statisticians have decided that when 4 out of five points land in the outer 1/3 of the control region, the process has shifted.
4 out of 5 points in Zone B or Beyond UCL A B Zones C C B A LCL Centerline

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Interpretation of Control Charts

Special Causes of Variation:

RUN OF SEVEN POINTS ON ONE SIDE OF CENTERLINE

&Short runs of a few consecutive points are to be expected and will occur frequently with a controlled process. However, long runs of many consecutive points are abnormal in a controlled process. In particular, a run of seven or more points in a row all on the same side of the centerline is sufficient evidence that the process has changed and action is required.
Run of seven points on the same side of the centerline UCL A B Zones C C B A LCL Centerline

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