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Cpk = Min [ USL X, X LSL ]
3s
3s
Specification Width
Process Spread
LSL
USL
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11/02-PS150
Introduction
The purpose of this guide is twofold. The first is to provide
information on the process capability index Cpk. The second is
to list various actions that can be taken or parameters checked
in order to reduce process variation.
The idea of comparing the specification of a part parameter to
the measured variation or distribution of the process producing
the parameter has been with us for many years. It has only
been in recent years that the comparison has been given a formal name and a means of calculation.
All authors and analysts writing on Cpk hasten to point out that
the index is a statistic based on measurements and, like all such
statistics, has an associated degree of uncertainty. However,
most practitioners consider Cpk to be a fixed number without
regard to the nature of the data that produced it. We will point
out the uncertainty involved in any statement of Cpk.
This guide assumes the reader has knowledge of control charts
and methods for calculating standard deviations. A good reference is the NIST/SEMATECH Handbook of Statistical Methods.
The complete Handbook is on the Internet and may be accessed
at www.itl.nist.gov/div898/handbook.
What is Cpk?
Cpk is a Process Capability Index. The term index is used
because the value is a comparison or ratio. It is the ratio of the
workpiece specification or tolerance (allowed variation) compared to the process variation (produced variation) expressed in
terms of 3 standard deviations. When standard deviation is
used in a calculation, the assumption is that the underlying
measurements form a normal distribution.
Therefore, in the case of calculating Cpk, all known assignable
causes for variation in the process should be minimized before
measurements are taken that will be used in the final calculation. In other words, the process should be stable and in statistical control.
Some processes may use a positive stop or an in-process gage
to produce part size. In those cases, the size distribution may
not be normal, and the calculations described here will not be
valid. Other sources should be consulted on how to deal with
skewed distributions.
In other cases, the specification is not bimodal nor is it given as
a range. Examples might be hardness at least or surface
finish not to exceed . In those situations a Cpk cannot be calculated since the part specification is not stated as a range. Of
course, the standard deviation for the process output can still be
calculated, and an estimate made about the probability of staying within the specification. But this is not a comparison such
as Cpk.
The importance of sample size in acquiring data cannot be over
emphasized. As we shall see, the calculated value of Cpk
depends on what is technically termed an estimate of the
standard deviation. The larger the sample size, the more accurate is the estimate.
Calculating Cpk
Once data on the process has been gathered and analyzed, and
the standard deviation calculated, a comparison to the products
specification can be made. This simple comparison yields the
process potential Cp. In some cases, the mean of the process is
at the center of the products specification limit as shown in
Figure 1. The term Cp assumes centering and should be equal
to or greater than 1.
Cp =
Specification
Width USL LSL
Specificat
ion Width
=
Process
6s
Pr ocess Spread
Spread
Cpk =
X Nearest Specificat
ion Limit
Specification
X
3s
USL X
,
3s
X LSL
]
3s
FIG. 2
Of course, if the process spread greatly exceeds the specification spread, steps must be taken to reduce the process spread.
In Figure 2, Cpk would be about 0.5. However, if the process
spread were aligned with the specification, Cpk would be about
1.0.
1.00
1.30
1.50
1.70
2.00
1.08
1.11
1.17
1.24
1.50
1.40
1.44
1.51
1.60
1.93
1.61
1.66
1.74
1.84
2.22
1.82
1.88
1.97
2.07
2.52
2.14
2.21
2.31
2.45
2.95
Most experts agree that the sample size should be at least 30.
For derivation of how to calculate the values in Tables 1 and 2
above, see the referenced NIST/SEMATECH Handbook (noted
on page 1), section 7.1.4.
Tooling
Changes in tool condition are a common source of shift in
workpiece size or surface finish. These changes can best be
analyzed from a histogram of data taken chronologically.
Changes are not limited to tool wear, but may also be created
by dirt on the toolholder, a balance condition, or repeatability
when changing inserts.
Workholding
The ability of the workholding device to position each part consistently is critical to maintaining uniform output. Tests should
be made to determine the repeatability of workholding devices.
The rigidity of the workholding device in relation to the rigidity
of the workpiece and process-induced forces can also influence
size variation.
Workpiece
Variations in workpiece initial stock conditions are a common
source of output variation. Workpieces should be checked for
incoming size and hardness. Both parameters cause changes in
process forces. Cpk of incoming parts would be desirable.