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Session 04 - Fall 2023 - Statistical Process Control

This document provides an overview of statistical process control (SPC) concepts for quality management. It discusses the need for quality control, elements of the control process, and how control charts are used to monitor processes. Control charts plot sample statistics over time to distinguish between random and nonrandom variability. The document defines different types of control charts and error types. It also covers process capability and using metrics like Cp and Cpk to determine if a process can meet specifications. In-class problems are provided for additional practice with SPC applications.

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Nivedha Kartheepan
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20 views

Session 04 - Fall 2023 - Statistical Process Control

This document provides an overview of statistical process control (SPC) concepts for quality management. It discusses the need for quality control, elements of the control process, and how control charts are used to monitor processes. Control charts plot sample statistics over time to distinguish between random and nonrandom variability. The document defines different types of control charts and error types. It also covers process capability and using metrics like Cp and Cpk to determine if a process can meet specifications. In-class problems are provided for additional practice with SPC applications.

Uploaded by

Nivedha Kartheepan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 14

8/16/2023

INTRODUCTION TO OPERATIONS
MANAGEMENT– MBA 2023

Session 04 – Statistical Process Control

Learning Objectives

• Explain the need for quality control


• List and briefly explain the elements of the
control process
• Explain how control charts are used to
monitor a process, and the concepts that
underlie their use
• Use and interpret control charts
• Assess process capability

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What is Quality Control?

○ A process that evaluates output relative to a standard


and takes corrective action when output doesn’t meet
standards
■ If results are acceptable no further action is

required
■ Unacceptable results call for correction action

○ Inspection alone is not is generally not sufficient to


achieve a reasonable level of quality
■ Most organization rely upon some inspection and a

great deal of process control to achieve an


acceptable level of quality

Statistical Process Control (SPC)

● Quality control seeks


○ Quality of Conformance
■ A product or service conforms to specifications
● A tool used to help in this process:
○ SPC
■ Statistical evaluation of the output of a process
to determine if it is acceptable
■ Helps us to decide if a process is “in control” or
if corrective action is needed

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Process Variability
● Two basic questions: concerning
variability:
Q1. Issue of Process Control
■ Are the variations random? If nonrandom
variation is present, the process is said to be
unstable.
Q2. Issue of Process Capability
■ Given a stable process, is the inherent variability
of the process within a range that conforms to
performance criteria?

Process Variability (Cont’d)

● Variation
○ Random (common cause) variation:
■ Natural variation in the output of a process, created
by countless minor factors
○ Assignable (special cause) variation:
■ A variation whose cause can be identified.
■ A nonrandom variation
● Managements first job is to get rid of special cause
variation
● Once a process is “in control,” the only way to improve
performance is to reduce common cause variation

Examples?

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The Control Process

● Sampling and corrective action are only a part of the


control process
● Steps required for effective control:
○ Define: What is to be controlled?
○ Measure: How will measurement be accomplished?
○ Compare: There must be a standard of comparison
○ Evaluate: Establish a definition of out of control
○ Correct: Uncover the cause of nonrandom variability and fix it
○ Monitor: Verify that the problem has been eliminated

The Voice of the Process: Control Charts


● Control Chart
○ A time ordered plot of representative sample statistics obtained from an
ongoing process (e.g. sample means), used to distinguish between
random and nonrandom variability
○ Control limits
■ The dividing lines between random and nonrandom deviations from
the mean of the distribution
■ Upper and lower control limits define the range of acceptable
variation

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Type I & Type II Error


● Type I error
○Concluding a process is not in control when it actually is.
○ The probability of rejecting the null hypothesis when the null
hypothesis is true.
○ Manufacturer’s Risk
● • Type II error
○ Concluding a process is in control when it is not.
○ The probability of failing to reject the null hypothesis when the null
hypothesis is false.
○ Consumer’s Risk

Two types of risks are involved in controlling quality. These risks have been given names to
identify the injured party. If a process is deemed to be out of control when it in fact is performing
correctly, a Type I error has occurred, which is the producer’s risk. If a process is deemed to be
functioning properly when it in fact is out of control, a Type II error has occurred, which is the
consumer’s risk.

Types of Control Chart


● Control charts for means fall into two categories based on the
type of performance measure. Variable control charts (X-bar
chart) and (R-chart) record measurements that permit fractional
values, such as length, weight, or time. An attribute control chart
(p-chart) records discrete data, such as the number of defects or
errors as a percentage
● The purpose of the X-Bar chart is to detect changes in the
process mean of a continuous variable (e.g., ambulance response
time)
● The R-chart for the continuous variable measures the process
Dispersion
● The R-chart is frequently constructed prior to determining the X-
bar chart in order to ensure that the process variability is under
control
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Control Chart for Mean: X̅ Chart

11

Control Chart for Range: R Chart

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Control Chart Factors

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Using both Mean & Range Chart

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P-Chart

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P-Chart: Example

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c-Chart
● Use only when the number of occurrences per unit of
measure can be counted; non-occurrences cannot be
counted.
○ Scratches, chips, dents, or errors per item
○ Cracks or faults per unit of distance
○ Breaks or Tears per unit of area
○ Bacteria or pollutants per unit of volume
○ Calls, complaints, failures per unit of time

UCL c  c  z c
LCLc  c  z c
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c-Chart: Example

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Process Capability

● The ability of a process to consistently produce a


good or deliver a service with a low probability of
generating a defect
● Specification limits – range of variation that is
considered acceptable by the designer or
customer
● Process limits – range of variation that a process
is able to maintain with a high degree of certainty

19

Process Capability

● The ability of a process to consistently produce a


good or deliver a service with a low probability of
generating a defect
● Specification limits – range of variation that is
considered acceptable by the designer or
customer
● Process limits – range of variation that a process
is able to maintain with a high degree of certainty

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Process Capability

● The ability of a process to consistently produce a


good or deliver a service with a low probability of
generating a defect
● Specification limits – range of variation that is
considered acceptable by the designer or
customer
● Process limits – range of variation that a process
is able to maintain with a high degree of certainty

21

Process Capability (Cont’d)

Process control limits exceed specification limits – process is not


capable of meeting requirements

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Process Capability (Cont’d)

Specification control limits exceed process limits (for improved process) – process is
capable of meeting requirements

23

Process Capability Index – Process Centered Around


the Mean

UTL - LTL
Cp 
6
where
UTL  upper tolerance (specification) limit
LTL  lower tolerance(specification) limit

> 1.33 for the process to be capable

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Process Capability Index – Process NOT Centered


Around the Mean

C pk  minC pu , C pl 
 UTL  x x  LTL 
 min  , 
 3 3 

> 1.33 for the process to be capable

25

In Class Problems…

● Stevenson (12th Edition) page


444 - 447
● Problems 2, 3, 4 & 6

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27

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