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Statistical Process Control): a Quality Control Technique for Confirmation to Ability of Process

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Statistical Process Control): a Quality Control Technique for Confirmation to Ability of Process International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 06 | June-2016 www.irjet.net p-ISSN: 2395-0072 SPC (Statistical Process Control): A Quality Control Technique for Confirmation to Ability of process Er. Harpreet Singh Oberoi1, Mamta Parmar2, Harpreet Kaur3, Rahul Mehra4 1,4 Assistant Professor, Department of Mechanical Engineering 2, 3 Assistant Professor, Department of Applied Sciences Chandigarh Engineering College, Landran, Punjab, India --------------------------------------------------------------------------- Abstract-Variability in process performance often Common causes are evidenced by a stable, repeating results in waste and rework. For improvement in quality pattern of variation. Real quality improvement requires and productivity process variation needs to be reduced. a continual focus on reducing the common cause Many techniques are available for quality improvement. variation. Statistical Process Control (SPC) is one such TQM Special causes of variation are a signal that technique which is widely accepted for analyzing quality something has changed in process. Special causes are problems and improving the performance of the evidenced by a disruption of the stable, repeating production process. Statistical Process Control (SPC) is pattern of variation Special causes of variation result in methodology using control charts for assisting operators, unpredictable performance and must therefore be supervisors, and managers to monitor the output from a identified and remove before taking other steps to process to identify and to eliminate the cause of improve quality. variations. SPC is a proven technique for determining the A process is called “under control” when process capability and predicting the yield from a process. deviation in output is the result of chance variations. In industry, suppliers are required to provide evidence of When the pattern of output does not follow the statistical process control to their customers. Survivors in distribution expected from chance causes, the process is highly competitive markets will be those firms that can considered “out of control” and the cause is probably demonstrate their quality capability. In this paper need of assignable. SPC, types & procedure of plotting control charts and process capability confirmation by SPC as a quality Here is the answer of the above: SPC (Statistical Process control tool is discussed. Control) Typical questions that are answered by statistical Keywords: UCL, LCL, SPC, Cp, Cpk, Cpl, DMAIC process capability study are: - Where the process centered? 1. INTRODUCTION: How much variability exists in the process? Is the performance acceptable? 1.1 Need of Process Control:- Is the process stable? What factors contribute to variability? Variation is fact of life it is everywhere & it is Many reasons exist for conducting the process unavoidable. Attaining consistent product quality capability study. Manufacturing may wish to determine a requires understanding, monitoring & controlling performance base line for a process, to prioritize variations. Attaining optimal product quality requires a projects for quality improvements, or to provide never ending commitment to reducing variations. Where statistical evidence of quality for customer. Purchasing does variation come from ? may conduct a study at a supplier plant to evaluate a Walter Shewhart, founder of SPC recognized that new piece of equipment or to compare different variations has two broad causes suppliers. 1. Common causes also called chance ,random or unknown 1.2 Statistical Process Control 2. Special causes also called assignable causes. Common causes are inherent in the process and Statistical process control made form three can be thought of as “natural rhythm of the process”. words & they are stand for © 2016, IRJET | ISO 9001:2008 Certified Journal | Page 666 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 06 | June-2016 www.irjet.net p-ISSN: 2395-0072 Statistical: We collect large amounts of data about our Process capability index memory products from experiments. We study that data The importance of process capability is in assessing the to learn how our actions affect the performance of our relationship between the natural variation of the process products. and the design specifications. This is often quantified by Process: The method of doing something. a measure known as the Process capability index. The Control : We use the data to adjust the process to process capability index CP is defined as the ratio of achieve the desired results. Those results are dependent specification in a single quantitative measure. on customer requirements, efficiency, quality, and reliability. UCL-LCL So SPC is a technique which is based on collection of data CP = ____________ and used for attaining the desired result in the process. 6σ Statistical Process Control (SPC) is a powerful collection UCL = Upper control limit of problem-solving tools useful in achieving LCL = Lower control limit manufacturing process stability and improving σ = Standard deviation of process capability through the reduction of variability . It may be Two important facts about the CP index should be used when a large number of similar items is being pointed out. One relates to the process conditions and produced. The underlying assumption is that good items others relates to the interpretation of the values that are produced when processes are in control with respect have been calculated. First, the calculation of CP has no to target values. The main objective of SPC is to give a meaning if the process is not under statistical control. signal when the process changes, i.e. its mean moves The natural spread 6 sigma should be calculated using a away from the target value and/or its variability sufficient large sample to get a meaningful estimate of increases. the population standard deviation “sigma”. Second, a CP of 1.00 would require that the process be perfectly 1.3 Process Capability: centered on the mean of the tolerance spread to prevent Process capability is the range over which the some units from being produced outside the limits with natural variation of the process occurs as determined by a CP of 1.33, and still easier with a CP of 2.00. Clearly, the the system of common causes. It is the ability of the value of CP does not depend upon the mean of the combination of people, machine, methods, material and process. To include the information on the process measurement to produce a product that will consistently centering, one-sided indexes are often used. One-sided meet design specifications. The proportion of output that process capability indexes are as follows: - can be produced within design specifications measures UTL-LTL process capability; in other words it is measure of Cp = ____________ uniformity of process. Process capability can be 6σ measured if all special causes have been eliminated and UTL = Upper tolerance limit the process is in the state of statistical control. Process LTL = Lower tolerance l limit capability is important to both product designer and σ = Standard deviation of process manufacturing engineer. A process capability study allows one to predict, quantitatively, how well a process UTL– X BAR will meet designed to yield specific information about Cpu = the performance of the process under specified 3 σ operating conditions. X BAR – LTL The six steps involved in the process capability study Cpl = are: - 3 σ 1. Choose the representative machine or segment CPk = min (CPu; CPl) of the process. Two statistical techniques are used to establish process 2. Define the process conditions. capability. One is the frequency distribution histogram & 3. Select a representative operation. other is the control chart. Control Charts are the main 4. Provide materials that are of standard grade statistical technique used to conduct process capability with sufficient amount for uninterrupted study. 5. Specify the gauging or measurement method to 1.4 Theory Of Control Charts: be used. 6. Provide a method of recording measurements Control chart is a graphic aid to detect quality and conditions, in order, on the unit procedure. variation in output from a production process. As © 2016, IRJET | ISO 9001:2008 Certified Journal | Page 667 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 06 | June-2016 www.irjet.net p-ISSN: 2395-0072 opposed to the aim of acceptance sampling (to accept or reject products already produced), control chart help Values of constants: produce a better product. The charts have three main σ = Rbar /d2 applications: (1) to determine the actual capability of UCL XBAR = X bar + A2 * Rbar production process (2) to guide modifications for LCL XBAR = XDbar + A2 * R bar improving the output quality of process, and (3) to UCL r = D3 * Rbar monitor the output. The monitoring function shows the LCL r = D4 * Rbar current status of output quality and provides an early σ = estimated standard deviation warning of deviation from quality goals. R bar = Mean of ranges X bar = Mean of means of individuals 1.4.1 Types of control charts: UCL XBAR = Upper control limit for means LCL XBAR = Lower control limit for means Control charts have two principle divisions: attributes UCL r = Upper control limit for ranges and variables. Attribute control can be further divided LCL r = Lower control limit for ranges into charts for percentage defectives and chart for the D4,D3,A2,d2 =Values of constants number of defects per unit. The main interest in the variables is control over changes in the average and the range of measurements. Control chart for all these considerations follows the same basic format of mean value bounded by upper and lower control limits. It is the calculation of the control limits that distinguishes the type of chart. Chart -1: Show the Control Chart Sample 2. PROCEDURE FOR CONFIRMATION OF PROCESS CABALITY 2.1 Plotting Of Control Chart The procedure followed to plot and to find out Fig-1: Shows the selection criteria of control charts on the Control limits for all the charts are almost same.
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