Statistical Process Control
Statistical Process Control
Statistical Process Control
A collection of problem solving tools for achieving process stability and improving capability through variability reduction.
Statistical Process Control (SPC) consists of a number of statistical analysis tools that are used to monitor the production process, ensure its stability, and control the quality and consistency of its output. While SPC is used primarily with the manufacture of the product, its relevance to IPD should not be overlooked. SPC is used to ensure that the product is manufactured within tolerance. This is achieved by measuring the output of the process, and comparing this data through statistical analysis to determine the stability of the process. (For a detailed explanation of SPC, see Out of the Crisis by Dr. W. Edwards Deming.) Through the use of SPC tools, the capability of the manufacturing process can be determined, including the tolerances feasible for the process to maintain. The capability of the manufacturing process is an important input to the designers working within the framework of IPD. By knowing the capabilities of the current process, members of the IPT can design with a realistic knowledge of what manufacturing can and cannot accomplish. Adequate training in SPC is well beyond the scope of this guide. However, a knowledge of the most basic elements should be understood to gain an appreciation of the supporting relationship between SPC and IPD. As an overview, the seven most basic SPC tools include:
PLAN
Identify Process
ACT
Type of Cause? CONTROL CHART
Common
Do
CAUSE AND EFFECT
(Fishbone) Analysis
Implement Change
PARETO ANALYSIS
to identify Big problems
NO
YES
Collect and analyze data: CONTROL CHARTS
NO
YES
Process Flow Diagrams The process flow diagram is used to express detailed knowledge of the process and identify interactions between the process steps. It is an important tool for documenting and gaining an understanding of basic system operations
Run Apex
Field
Run SAPAS Organization
Investment Section
Sort By System
Compare Reports
OK
APPROVED
Temp File
Operating Section
Mark-up Apex
CHANGES
Field
Organization
Answer Query
Field
Organization
Make Changes
Cause and Effect Diagrams The cause and effect diagram is used to identify factors and their associated relationships that may be contributing to a particular problem or situation. The backbone of the chart is the problem being addressed while the primary spines are the causes. The five general categories of causes are materials, machinery, people, environment, and method. Users complete the chart by adding secondary spines that identify potential causes of the problem under each category.
CAUSE
People
EFFECT
Policy Policy
Equipment
Check Sheets Check sheets are an important tool for collecting, organizing, and analyzing data. Check sheets are frequently useful in identifying recurring problem areas, types, or causes. The data collected in a check sheet may be used as input for a pareto chart or histogram.
Check Sheet
DEFECT 1 PARTS DAMAGED MACHINING PROBLEMS PARTS RUSTED MASKING INSUFFICIENT MISALIGNED WELD ADHESIVE FAILED PAINT OUT OF LIMITS FILM ON PARTS VOIDS IN CASTING IMPROPER TEST PROC. 1 TOTAL 2 4 4 2 1 1 2 4 4 0 0 1 5 2 2 0 2 2 2 1 2 2 1 1 2 1 2 4 1 1 1 2 1 2 3 1 1 2 3 1 1 4 5 1993 6 7 8 9 10 11 12 1 1 2 2 1994 3 1 4 5 6 TOTAL 6 2 5 3 4 6 3 3 2 4 38
Pareto Charts This chart is based on the Pareto principle that states that 80% of the problems are due to 20% of the causes. A Pareto chart is essentially a sorted histogram that is useful in identifying the most significant (i.e., vital few) problems.
Pareto Chart
PROCUREMENT DIRECTORATE AWARD FEE PROCESS MAJOR PROBLEMS.
30 25 20 15 10 5 0 FUNDING REWORK MONITOR CONTR. WORKLOADPKG LOST REPORTS REBUTTAL IN MAIL 27
Histograms Histograms are useful because they graphically portray the distribution of the data and give the analyst a feel for the central tendency (average) and dispersion (standard deviation/variance).
Histogram
SECURITY ASSISTANCE MANAGEMENT DIRECTORATE
100 100
75
SAMD AVERAGE
75
SAMD AVERAGE
50
25
H A W K
P A T R I O T
S T I N G
L A N D C
50
C H A P
25
H A W K
P A T R I O T
S T I N G
L A N D C
C H A P
Scatter Plots Scatter plots are X-Y charts that are useful for uncovering relationships between two variables.
Scatter Plot
300
Pressure
250
200
100 110 120 130 140 150 160 170 180 190 200
Temp
Control Charts Control charts are graphical tools for evaluating process performance, taking into account the natural variability of the process. When properly implemented, control charts can assist in : 1) the identification of special causes of variation, 2) improving process control, 3) identification of trends, and 4) reduction in overall system variability.
Control Chart
MICOM VECP TECHNICAL APPROVAL TIME Number of days.
600 500 400 300 200 100 165 395
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
VECP NUMBER