Process Capability

Module 6 – Quality Control

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Learning Outcomes
 After completing this module, you will be able to:
 Understand the concep of process capability and its
importance for quality control
 Measure and analysis the process capability of a given
process

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Introduction
Variability in the process
is a measure of the uniformity
of output
Two ways to think of this variability:
1.Natural or inherent variability in a
critical-to-quality characteristic at a
specified time (instantaneous)
2.Variability in a critical-to-quality
characteristic over time

Process capability
refers to the uniformity of the
process

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 It is customary to take the six-sigma spread in the
distribution of the product quality characteristics as a
measure for process capability

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 Process capability analysis is an engineering
study to estimate process capability.
 In the form of probability distribution (shape)
 Center (mean)
 Spread (standard deviation)

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Uses of process capability data:
 Predicting how well the process will hold the tolerances.
 Assisting product developers/designers in selecting or
modifying a process.
 Assisting in Establishing an interval between sampling for
process monitoring.
 Specifying performance requirements for new equipment.
 Selecting between competing vendors.
 Planning the sequence of production processes when there is
an interactive effect of processes on tolerances.
 Reducing the variability in a manufacturing process.

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Techniques used in process
capability analysis

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Histogram Plot
 The histogram along with the sample mean and
sample standard deviation provides information
about process capability.
 The process capability can be estimated as:
x  3s
 The shape of the histogram can be determined
(such as if it follows a normal distribution)
 Histograms provide immediate, visual
impression of process performance.

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Example

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x  264.06
s  32.02

Process capability:
264.06 + 3(32.06)  264 + 96

It means that approximately 99.73% of the bottle

manufactured by this process will burst between
168 to 360 psi

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Process Capability Ratio
 A convenient, simple and qualitative way to express
process capability
 If USL = Upper Specification Limit
 LSL = Lower Specification Limit
 Then, process capability ratio is:
USL  LSL
Cp 
6

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 If the standard deviation  is not known; it can be
estimated by calculating
̂ S or R / d2
 The process capability ratio

USL  LSL
Ĉ p 
6ˆ

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Example

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Process Capability Ratio:

USL  LSL
Ĉ p 
6ˆ

ˆ 2.00  1.00
Cp   1.192
6(0.1398)

Useful practical interpretation:

 1  1
P
C
100

P 100  83.8
 p  1.192
Percentage of specification used up by the process:
83.8%

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One-sided Process Capability
Ratio
 For one-sided specification (upper or lower
specification limit only):

USL  
C pu 
3
  LSL
C pl 
3

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Interpretation of PCR

The greater the

value of Cp the
process getting
more capable

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Assumptions for Interpretation

If any of these
assumptions
are violated,
the resulting
quantities may
be in error

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Recommendations

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Process Capability Ratio and Off-
Center Process
 Cp does not take process
centering into account
 It is a measure of
potential capability, not
actual capability

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A Measure of Actual Process
Capability
 A process capability ratio that does take into account
centering is Cpk defined as:

Cpk = min(Cpu, Cpl)

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Interpretations of Cpk

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 Cpk alone is still an inadequate measure of process
centering
 Cpk must be compared to Cp.

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Example

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Example

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The Use of Control Chart and Cpk

 It is recommended to use the control chart and

calculate the process Cpk for better understanding of
the process and to able to control the process properly
 On every sample, calculate standard deviation and
then mean of the sample. Use it for control chart.
Calculate Cpk

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LSL Spec USL

Capable and centered

Capable, but not centered

Not capable, and

not centered

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Example

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• Since LSL = 200

Process in control but not capable

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Normal Assumption
 The normal distribution of the process output is an
important assumption
 If the distribution of the process output is not normal
then the formula cannot be used
 Other process capability indices must be employed

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