SPC

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FUNDAMENTALS OF STATISTICS


Origin of Statistics Statistics stems from the latin word Status, which was originally meant to determine the status of a nations population in connection with the description in public economics.

Types of Statistics
Descriptive Statistics: Recording, arranging & representing data Eg: recording grinding time of AC2 for one month
 

Inductive Statistics : Analysis ,evaluation & interpretation of data Eg: After analyzing Viscosity of AC2 of this month it is found that there is trend (ie moving towards upper limit)

Types of Data


Variable data: Data that can be expressed in numbers. eg: Viscosity, RS. Attribute: Data in subjective terms. eg: Ok/Not Ok , Close match to standard.

Variation


What is Variation? Difference between batches in characteristics is variation. Usually samples representing batches are taken for analysis to establish compliance /Variation. This is known as sampling Reducing Variation = Improvement

Variation Analysis


Central tendency: One of the important characteristics of distribution of sample data is that most of the observations tend to concentrate in the center of the distribution. This characteristic is called as central tendency How is Central tendency measured Mean: Median: Mode:

   

Central Tendency


Mean: Average of given set numbers Xavg= (X1+X2+X3)/3

Median: Center of given set of numbers which are arranged in ascending or descending order ( if there are n observations of the variate and they are arranged in ascending order ,then median is (n+1)/2 th value if n is odd. If n is even then the median is average of n/2 th and (n/2) +1 Mode: In given set of numbers, the number with highest frequency is mode

Examples
 

Calculate mean, median & mode 2,3,2,4,5,2,7,6,2,4,2 Median =3 Mode =2 Mean = 3.545

Variation analysis


Dispersion The extent to which the data is scattered about the zone of central tendency is known as dispersion. How to measure it? a) Range b) Standard deviation c) variance

a) Range: In a given set of data, Range= Max-Min Maxb) Standard deviation: Sigma = sqrt [(Xi-Xavg)2 /n] [(Xi-

Variation analysis
a) Range: Range= XMax- XMin b) Standard deviation: Sigma = sqrt [(Xi-Xavg)2 /n] [(XiC) Variance = Sigma 2 Where X are observed Values n number of observations

Probability Distribution
Probability Distribution : Is a mathematical model that relates the value of the variable with the probability of occurrence of that value in Population. Eg: Imagine diameter of pail as variable, because it takes on different values in the population according to some random mechanism, and then the probability of occurrence of any value of pail diameter in the population.

Probability Distribution
Types of Probability distribution : a) Continuous distribution : When the variable being measured is expressed on a continuous scale, its probability Distribution is called a Continuous distribution. eg: pail diameter Some continuous distribution are Normal distribution, Exponential distribution, Weibul distributions

Probability Distribution
b) Discrete distributions: When the parameters being measured can only take on certain values such as the integers 0,1,2 , the probability distribution is called discrete distribution. eg: Number of defects in painted surface Different discrete distributions  Hyper geometric distribution  Binomial distribution  Poisson distribution

Normal Distribution

Normal distribution
Bell shaped curve 9 8 7 6 f(X) 5 4 3 2 1 0 10.05 10.10 10.15 X 10.20 10.25

7 Quality Improvement tools



7 Quality Improvement Tools PDCA Cycle : (Plan,Do Check and Act) Right First time and every time. Next process is your customer Rules of QC : No inspection without recording No recording without analysis No analysis without action

1
2 3

7 Quality Improvement tools

4

Questions of QC : Can we do it ok? Are we doing it ok? Have done it ok? Can we do it better?

5 Quality Environment : 5S ( Seiri, Seiton ,Seiso, seiketsu, Shitsukue) 6 7 5W 1H ( who where why when what & How) 7 basic tools of QC  Check sheet  Cause and effect diagram  Control Charts, graphs & charts  Histogram  Pareto chart  Stratification  Scatter Diagram

7 QC Tools
Sr Tool No 1 Check sheet Key Words
Counting and accumulating data

Details
Check sheet is a systematic method of collecting, recording and presenting relevant data in a simple manner y y Establish what information is needed 5W-1H ( why data, what type,where to collect,Who to collect ,How and how much to collect) Construct check sheet Test check sheet Standarize and use check sheet Use the information( remember rule of QC)

y y y y

2 3

Control Chart Cause and effect diagram Histogram Pareto Chart

Understanding and reducing variation Identify and Cure causes Charting Dispersion Vital few and trival many

It is a run chart used for studying process performance over time in order to understand and reduce variation. A diagram which represents meaningful relationship between an effect and its causes Type of bar chart representing the frequency distribution of data from process. Diagram that shows the order of the largest number of occurrences by item or by classes and the cumulative total . (20% of causes/input/effort gives 80% effects/outputs/results) A chart used to study and identify the possible relationship between two variables A technique used to divide data into sub-categories or classification to provide useful insight into the problem

4 5

6 ,7

Identifying Scatter correlation Diagram Stratification Divide and Conquer

Check Sheet


What is check sheet? Check sheet is a systematic method of collecting, recording and presenting relevant data in a simple manner

Steps in preparing check sheet 1. Establish what information is needed 2. 5W-1H ( why data, what type, where to collect, Who 5Wto collect ,How and how much to collect) 3. Construct check sheet 4. Test check sheet 5. Standarize and use check sheet 6. Use the information( remember rule of QC)

Pareto Chart


Vital few and trivial many

Pareto chart is a diagram that shows the order of largest number of occurrences by item or by classes, and the cumulative sum total Vilfredo Pareto (1848-1923), an Italian economist (1848discovered in 1897 that 80% of a nations wealth was owned by 20% of population

Pareto Chart


Dr Joseph M Juran applied this principle to Quality Management and called it Pareto principle Pareto Principle
Inputs Causes Efforts 20% Outputs Effects Results

80%

Pareto Chart

Steps in constructing Arrange data in descending order (frequency of observation) Find out cumulative frequency Translate cumulative frequency in % Cumulative frequency

1.

2. 3.

Pareto Chart
4. 5.

Plot observation against respective frequency Superimpose % cumulative frequency against observation.

Construct pareto for following: COA : 5 FTC : 12 PTC : 6 Testing: 53

Pareto Chart
FTC/PTC share in appr val

er f c

Nu

Type of approva Count Percent Cum %

Testing . .

FTC . .

PTC . .

COA . .

Percen

Cause and effect diagram

Diagram

which represents meaning full relation between effect and its causes

JIS Definition A Diagram which shows the relation between a Quality Characteristic and cause factors.

Dr. Kaoru Ishikawa developed the first cause and effect diagram in 1943 while consulting for Kawasaki steel works Dr Juran named it as Ishikawa diagram

Cause and effect diagram

Diagram

which represents meaning full relation between effect and its causes

JIS Definition A Diagram which shows the relation between a Quality Characteristic and cause factors.

Dr. Kaoru Ishikawa developed the first cause and effect diagram in 1943 while consulting for Kawasaki steel works Dr Juran named it as Ishikawa diagram

Cause and effect diagram

Let us take one practical example Imagine reasons for Stamping defect in HSPM ( 5 W 1H )
Category Parameter How it affects
Affects rotation pattern intermittently Affects rotation pattern intermittently.

Radial Run out of drive roller

Cylindricity of the circle enveloping drive and ( it is often noted that if container idler roller. ( This is like a inscribed circle with touches idler roller at an angle, stamping shifts) three rollers forming vertex of triangle) Rollers (drive & idler rollers)

Height at which idler roller is positioned with respect to drive roller

Load of Drive roller on container needs to balanced by idler rollers ( otherwise rotation pattern of container gets affected) Affects rotation pattern intermittently ( specially for 1 liter) Slight shake will result in parameter change

Conveyor Flatness of table where container rotates table

Rigidity in camera fixing Room to fix camera ( needed to focus Zebra Data capture will not be correct union) Orientation of camera focus and zebra union Camera Printer Angle of camera focus Distance of printer from container

If zebra union is horizontal then focual area should be horizontal during trials this improved results

Distance of printer should be adjusted to get correct font size

Cause and effect diagram

Analy i
Measurements

in Stamping in HSPM
Men

Material

Container ovality monitoring of stamping Zebra union quality Un skilled /not trained

sensing system inadequacy

Zebra union position

Extent of allowed dev ( Tolerance of shift)

Mix up of new and old design in one batch Spray ink quality

Importance of stamping not known

Improper teaching preventive mainteance

Stamping Missing/Shift ing/Line Capability of Machine mark Ht of idler rollers w.r.t drive rollers
Flatness of table where container Run out of rollers Alignment of drive & idller rollers ( Clamping method of camera ( C camera should be setting ( focus

daily mainteance Cleaniness level parameter selection printer distance from container extent coverage of reference image reference image selected

Camera position (should be st or at Speed of conveying

Env ironment

Methods

Machines

Control chart
Understand and Reduce variation

It is a type of run chart used for studying process performance over time in order to understand and reduce variation.

Dr Walter A . Shewart invented the Control Chart

Control chart
How to construct Control chart( X R chart)? a) Design check sheet for data collection b) Plan the data collection methodology (Maxm Homogeneity within subgroup, Heterogeneity between sub group ) C) Find Range. d) Calculate Control limits X chart: UCL= Xavg + A2 * Ravg LCL = Xavg - A2 * Ravg R Chart LCL= D3* R UCL= D4 *R

Constants

Sub group size A2 2 3 4 5

D3 1.88 1.023 0.729 0.577 0 0 0 0

D4 3.267 2.574 2.282 2.114

d2 1.128 1.693 2.059 2.326

### # ## # # ## ## #&# # &# #

Observation

     
7 7 . . 6 1 .34

 
16,39 6,934 ,7

 6    6  !  6  !
Defect in PPM for Two Specifications

   
Cp

 

 

     7  
Part N ty I s Pr j ct d

Sub Group No

 

          !        
9

SrNo

ct d

1- 4

Control chart

I s By A r v d By

Dat

Control Chart

35,7 9

967 31

Grand Av 9

"

 !  

    !                                

9 9

                 !   !   !   !                                                                                                                       
9 9 9 9 9 9 9 9

    !                          

9 9

    !                            

9 9

Range

# & (#$'& ) %##$#

LCL -X

UCL -X

Average UCL R

23. 3 23. 2 23. 1 23

X Chart

. 5 . . 15 . 1 . 5 .

Range Chart

96

ange UCL

Range

&

Pr c ss capability St dy l ranc Standard Deviation Pr c ss capability Ind x

1 2

average

Sub Group

ucl

lcl

reject

is 2700

CB B

A@9

33%43 $# 3%''##$# &#$#

1 0

10 5 1 0

Sub Group No

# # #

Process capability


Comparing process dispersion with specification is process capability When process is in statistical control process capability is Tol/(6 * sigma) Process capability Index Cp= {T/(6 *sigma)} Process performance Index Cpk= Min { (USL- X avg)/3*Sigma , (USL(Xavg(Xavg-LSL)/(3*Sigma)}

ABC ANALY I
RULE:A RULE:B RULE:C Average Wt of the container should be equal or more than the required Wt. Omitted

Pkg.Machine No. : DFM-5

Any package/container should not have an error in defeciency greater than the maximum permissible error.

Date Product B.NO. MIX.NO. Shift

W

24.03.07 ACE WT
cba

QTY (LITRE) WPL

d

Grand A g
UC of X LCL of X

Sub Group r
G

2 3 4 5

27.780 27.765 27.770 27.7 0 27.8 5 27.765 0.130 27.8000

27.760 27.7 5 27.760 0.035 27.7780

27.800 27.800 27.755 0.045 27.7680

27.780 27.780 27.730 0.050 27.7670

27.715 27.840 27.715 0.125 27.7830

Min Range A g
D

RE ULT Rule A

Rule C

PA

PRQ P PQ I I

Cpk (Process Performance Capability Index

R Q QP I I I I

PA

Max

27.7 0

27.8 5

27.785 27.760 27.7 5

27.755 27.760 27.765 27.760

27.730 27.770 27.780 27.775

27.780 27.785 27.840 27.7 5

27.770 27.780 27.760 27.860 27.775 27.860 27.760 0.100 27.78 0

Cp ( Process Capability Index)

First

Second

Third

Fourth

Fifth

ixth

Officer QA

DILLIBABU.K

Upper Limit (Kg)

.989 eventh

Sigma Eighth

0.0 Ninth

27.775 27.770 27.775 27.780 27.770 27.780 27.770 0.010 27.7740

27.760 27.735 27.745 27.770 27.815 27.815 27.735 0.080 27.7650

27.760 27.765 27.850 27.720 27.780 27.850 27.720 0.130 27.7750

.0

V U

Officer Packing

P AKAS

Lower Limit (Kg)

LCL of

A ociate
WW

IYYAPPAN

Tolerance (Kg)

0.55424

UCL of

0.1712 0.0000

Requirred Wt.(KG)

QV R U I

XR R I I X

11

Tolerance (%)+/

t. of Container (g)

30.000

.00% .

Grand Range

PQ V X

. 8

V RR R U I

27.8210 27.7276

0.08 0

8 Tenth

27.675 27.750 27.780 27.775 27.740 27.780 27.675 0.105 27.7440

DFM5 - ACE WT (S430) Mix no : 119

27.82 Sample M ean 27.80 27.78 27.76 27.74 LC L=27.7264 1 2 3 4 5 Sample 0.20 U C L=0.1757 Sample Range 0.15 0.10 0.05 0.00 1 2 3 4 5 Sample 6 7 8 9 10 LC L=0 _ R=0.0831 6 7 8 9 10 _ _ X=27.7743 U C L=27.8222