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1.0 Definition:
Statistical Process Control is a proven and scientific way of determining the capability of
your process to deliver quality and tracking the process stability over time.

2.0 Process:
Convert input to output using Man, Machine, Material, Method, and Measurement.

3.0 What is SPC?

Statistical: Collection, Analysis & Implementation of Numerical data (Facts & Figures).

Process: A Combination of man, machine, material, method & equipments for producing the desired
product & Service

Control: Performance comparison with standard and taking necessary action for achieving the end
result.

4.0 What are the Prerequisites for conducting Process Capability Study?

. Trained Personnel
. Calibrated Gauges
. R & R Studies
. Computing Cm
. Computing Cp
. Computing C pk
. Computing Cmk

5.0 Points to be considered while planning for SPC:

1. Selection of Product Characteristics
2. Measuring Equipment
3. Machine
4. Types of Charts
5. Sampling

6.0Selection of Product Characteristics:

. Specification of SPC characteristics and their processes
Should be done as early as possible
Below point should be taken into account:
. Function
. Reliability
. Safety
. Consequential costs of defects
. Customer Requests

7.0 SKILL ASSESSMENT & EVALUATION FOR SPC

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1.Test to be conducted for the identified persons who under goes regular checking of SPC.
2. Skill evaluation will be done based on the test results
3. Based on the skill evaluation result sheet, skill assessment will be identified in FORM MR 52.
4. Training needs will be identified based on the skill assessment sheet.
5. Training plan will be carried out as per the training identification.
6.1 Criteria to attain minimum passing marks in skill evaluation result: A, B & C
A: ≥ 90%
B: ≥ 80% ≤90%
C: ≤ 80%

7. Definitions for A, B, C & D:

A - Expert: Who can do the work independently and can drive and train others.
B - Proficient: Who can work independently
C - Intermediate: Training required
D - Not Applicable: Person will not be allotted the topic or task

8.0 PROCESS STEPS

1 Select Sub group size
2 Based on sub group size, enter A2, D2, D3, D4 Constants as per constants Table
3 Specify USL & LSL for the characteristic for which SPC to be charted
4 Calculate UCL & LCL for X Bar & R for previous cpk.
5 Take The calculated UCL & LCL of previous cpk as UCL & LCL for current cpk
6 Collect the samples as per sub group size
7 Enter the measured values in SPC Chart table
8 Calculate the average of Sub group (X Bar)
9 Plot the Average (X Bar) on SPC X Bar -Chart
10 Check for any Out of Control condition as mentioned in SPC Chart
11 If no "Out of control" condition observed, continue process
12 If any "Out of control" condition observed , then STOP the process, Analyze the causes for
variation & take necessary actions
13 After taking actions, follow steps 6 to 12 again
14 Calculate the Range (Maximum - Minimum) from the sub group
15 Plot the Range (R) on SPC R- Chart
16 Check for any Out of Control condition as mentioned in SPC Chart
17 If no "Out of control" condition observed, continue process
18 If any "Out of control" condition observed, then STOP the process, Analyze the causes for
variation & take necessary actions
19 After taking actions, follow steps 6 to 12 again
20 Repeat Steps 6 to 19 every day /shift
21 At the end of the Month, Calculate Cp & Cpk
22 If Cpk is >1.33, then Process is Capable

9.0 Constants & Subgroop Size Calculation details

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Sub
group A2 D2 D3 D4 E2
size

2 1.88 1.128 - 3.267 2.66

3 1.023 1.693 - 2.754 1.772

4 0.729 2.059 - 2.282 1.457

5 0.577 2.326 - 2.114 1.9

10.HOW TO CALCULATE:

Average ( ) or Mean :
It simply means sum of all the individual observed data divided by the no. of observations.
X1 + X2 + X3 + - - - - + Xn
n
n = no. of Observations.
Example : Observations = 20, 24, 26, 28, 43, 18
n=6 20+24+26+28+43+18 = 26.5
6

Range (R) :
Range is measure of the variation in a set of data. It is calculated by subtracting the lowest
value in the data set from the highest value in that same set.
R = X max – X min
X max = 43, X min = 18
R = 43 – 18 = 25

Standard Deviation:

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Square root of the average squared deviation from mean Indicates on an average how much each
value is away from the Mean

11 Inferences based on Cpk :

1. Cpk = 2.00 represents a very capable process. Such an index is achieved only when you are
able to produce within 50% of tolerance.
2. Cpk = 1.33 is considered to be a minimum capability requirement and most industries demand
a Cpk of 1.33 as minimum criterion. This is achieved if you are able to produce 75% of the
tolerance.
3. Cpk = 1.00 represents a just capable process and the process can give good results only if it
is perfectly centered. Even a small deviation from the mid of specification will result in non
conformance. Here 100% of the tolerance is used. Not a very desirable solution.
4. 4. Cpk < 1.00 means that the process not capable of meeting the specified tolerance. In this
case, rework and rejection will be inevitable.

HISTOGRAM:
• Histogram is a graphical representation of data and shows the frequency of
data.
• Histogram provides the easiest way to understand the distribution of data. It gives the Birds eye
view of the variation in Data set.
• Portrays the information on location, spread and shape that enables the user to interpret the
process behavior.
• It indicates whether the process is operating under Normal /stable condition.

STEPS FOR CONSTRUCTING HISTOGRAM:

• Collect min 50 nos of readings (N). 50 readings should be continuous data.
• Determine max value and min value & Calculate Range.

Range = Max - Min.

• Record the measurement unit (MU) used. This is usually controlled by the
measurement least count.

• Determine No. of classes (k), as below.

No. of class (k) = √N
• Determine class width (CW), as below

class width (CW) = Range / k

• Construct the Frequency Distribution Table, as shown in the next slide.

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2. DATA COLLECTION:
Data is available in two types
Variable data : Data which is available in numerical form.
Attribute Data :- Data which is in term of decision and not in numerical terms.

3. CHECKING FOR PROCESS PREDICTION:

Process is said to be predictable when it is in control and stable i.e.
when all special causes are removed from the process. The process can be
Checked from control chart and Histogram.
Control Chart:
When all points are within control limits or there is no obvious run or
non-random pattern of points with in the control limits.
Histogram:
When bell shape is observed on Histogram.
REMOVING ASSIGNABLE CAUSES:
When process is fail to satisfy above requirements then existence of
special causes may be there. In this causes find special causes and remove.

4. CALCULATING PROCESS CAPABILITY:

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After removing all special causes from the process calculate the capability indices CP and CPK.
If CP and CPK is greater than 1.33 then process is said to be within acceptable capability. Based on
the priority make improvement plan for the process.If Cp and Cpk is less than 1.33, then find out
major common causes and remove it.

5. ESTABLISHING CONTROL LIMITS:

When Cp and Cpk is greater than 1.33 , Then , Establish UCL/LCL and CL marked on control chart
and Issued to operators for ongoing control.

6. PREPARE REACTION PLAN:

After deciding control limits, Corrective and disposition actions to be given to the operators for any
special causes expected to occur during the process.These corrective and disposition actions can be
documented in Reaction plan.

7. ON GOING PROCESS CONTROL:

Continuous periodical review of control chart and recorded process events to identify the preventive
action and revise the control limits.

12.. DATA COLLECTION:

X → Measure of Location R→ Measure of Spread
To analyze the particular characteristics of a process or process output, data
are collected in small subgroups of constant size (2 to 5 consecutive pieces).
Subgroups are taken periodically. Sample size should remain constant for all
subgroups.

NUMER OF SUBGROUP:

From a process standpoint, enough subgroups should be gathered to assure that the major sources
of variation have had an opportunity to appear. Generally 25 or more subgroups containing 100 or
more individual readings give a good test for stability.

Plot the averages and Ranges on the Control Charts:

Plot the averages and ranges on their respective charts. This should be done as soon as possible
after scaling has been decided. Connect the points with line to help visualize patterns and trends.
Scan the plot points, confirm that the calculation and plots are correct. Make sure that the plot points
for the corresponding X and R is vertically in line. Initial study charts used for first time capability or
for studies after process improvements/changes should be the only process control charts allowed on
the production floor which do not have control limits placed on them.

2. CALCULATE CONTROL LIMITS:

R = ( R1 + R2 +………+ Rk ) / K X = ( X1 + X2 +………+ Xk ) / K

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Where,
K is the number of subgroups.
R1 is the range of the first subgroup.
X1 is the average of the first subgroup.

Setup control charts :

X and R charts are normally drawn with the X chart above the R chart, and a data block. The values
X and R will be the vertical scales. Data block should include spare for each individual reading
average ( X ), Range ( R ) and the date/time or other identification of the subgroup.

Characteristics to be plotted are the sample average ( X ) and the sample size ( R ) for each
Sbgroup, collectively these reflect the overall process average and its variability.

Average ( X ) = ( X1 + X2 + ………+Rn ) / N Where n → subgroup sample size

Range ( R ) = Highest – Lowest
Select the Scales for control charts :
Some general guidelines for determining the scales may be helpful, although they may have to be
modified in particular circumstances.

For X Chart :
The difference between the highest and the lowest values on the scale should be at least two times
the difference between the highest and lowest of the subgroup averages ( X )

For R Chart :
Value extends from zero to an upper value about two times the largest range.
For R Chart :
UCLR = D4R LCLR = D3R
For X Chart :
UCLX = X + A2R LCLX = X – A2R

Where D4,D3,A2 are constants varying by sample size with values from sample sizes from 2 to
10.Draw the average ( R ) and process average ( X ) as solid horizontal lines. Control limits
(UCLR,LCLR,UCLX,LCLX) as dashed horizontal Lines. Label the lines.

13.INTERPRETATION FOR PROCESS CONTROL:

Since the ability to interpret either the sub group range or subgroup averages depends on the
estimate of piece variability , the R chart is analyzed first.
The data points are compared with the control limits, for points out of control or for unusual patterns
or trends.

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For Range Chart :

(a) Points beyond the control limits are primary evidence of non-control of that Point. Any point
beyond a control limit is the signal for immediate analysis of the operation for the special causes. A
point above the control limit is generally due to
Plot point may be miscalculated.
1. Piece to piece variation has increased.
2. Measurement system ha changed.
A point below the control limit is generally due to
1. Plot point is in error.
2. Piece to piece variation has decreased.
3. Measurement system has changed.

(b) Presence of unusual patterns or trend even when all ranges are within control limits, can be
evidence of change of process spread, also indicates some special causes.

(c) Runs:
1. 7 points in a row on one side of the average indicate that the process is not normally
distributed and there is shift in the process average.
2. 7 Points in a row that are consistently increasing or decreasing.

(d) Presence of cycles in the chart indicates that special causes due to machine
set up, non-uniformity in the material wear of machine.

Find and Address Special Causes.

For each indicates of special causes in the range data, conduct an analysis of the operation of the
process to determine the causes and to improve the process.A process log may also be a helpful
source of information in terms of identifying Special causes of variation. Single point out of control is
reason to begin an immediate analysis of the process.

Recalculate Control Limits:

When conducting an initial process study or a reassessment of process capability, the control limits
should be recalculated to exclude the effects of control periods for which process causes have been
clearly identified and removed.

Analyze the data on the AVERAGE CHART

When the range are in statistical control, the process spread – the within subgroup variation is
considered to be stable. The average can then be analyzed to see if the process location is
changing over time.

Control limits for X Bar are based upon the variation in the ranges. Then if the averages are in
statistical control, their variation is related to the amount of variation seen in the ranges (common
causes variation of the system). If the average are not in control, some special causes of variation
are making the process

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location unstable.
(1) Shift in process
(2) Plot points are in error.

Find and address the special causes and then recalculate the control limits eliminating the special
causes.

14. INTERPRET FOR PROCESS CAPABILITY:

Interpretation process capability is to be carried out only under the following assumptions:
(1) Process is statistically stable.
(2) Individual measurements from the process conform to normal
distribution.
(3) Design target is in the center of the specification width.
(4) Measurement variation is small.

Having determined that a process is in statistical control, the question still remains whether the
process is capable of meeting customer needs. To understand and improve the capability of a
process, one should understand that capability reflects variation from common causes and
management action on the system is required for capability improvement.

Calculate Process Standard Deviation:

Since within subgroup process variability is reflected in the subgroup average, the estimate of the
process standard deviation б can be based on the average range (R)
б = R / d2
Where
R → The average of the subgroup ranges.
d2 → the constant varying by sample size.
Capability can be described in terms of the distance of the process average
from the specification limits in standard deviation units Z

For unilateral tolerance :

Z = ( USL – X bar ) / б (or) Z = (X bar – LSL ) / б
For bilateral tolerance:
ZUSL = ( USL – X ) / б (or) ZLSL = ( X – LSL ) / б

Where,

USL → Upper specification limit

LSL → Lower specification limit
Z → Negative value of Z indicates the process average is out of
specification.
ZMIN → Minimum of ZUSL and ZLSL
Z value can be used with the table of the standard normal distribution (appendix Fin SPC manual) to
estimate the proportion of output that will be beyond anyspecification.

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The value of ZMIN can also be converted to a capability index, CPK CPK = ZMIN / 3
= Min [ (USL – X bar) / 3 б or (X bar – LSL) / 3 б ]
A process of ZMIN = 3 would have a capability index of Cpk = 1.00
If ZMIN = 4, the process would have a capability index of Cpk = 1.33

Evaluate process capability:

It is necessary to evaluate the process capability in terms of meeting customer requirement.
Fundamental goal is never ending improvement in process Performance. Improve the performance
by reducing the variation that comes from common causes, or shift the process average close to the
target. This generally means taking management action to improve the system.

Improve Process Capability:

To improve process capability, there must be increased attention on reducing Common causes.
Accounts must be directed towards the system namely, the underlying process factors which
account for the process variability such as
(1) Machine performance.
(2) Consistency of input materials.
(3) Basic methods by which process operates.
(4) Training methods.
(5) Working environment.

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