Chapter 10
Quality Control
McGraw-Hill/Irwin
Copyright © 2009 by The McGraw-Hill Companies, Inc. All Rights Reserved.
Chapter 10: Learning Objectives
• You should be able to:
–
–
–
–
–
–
List and briefly explain the elements in the control proces
Explain how control charts are used to monitor a process
Explain the concepts underlying the use of control charts
Use and interpret control charts
Understand the use of run tests
Assess process capability
10-2
Statistical Process Control (SPC)
• Quality control seeks
– Quality of Conformance
• A product or service conforms to specifications
• A tool used to help in this process:
– SPC
• Statistical evaluation of the output of a process
• Helps us to decide if a process is “in control” or if corrective
action is needed
10-3
Process Variability
• All processes generate output that exhibits
some degree of variability
• The fundamental question:
– Is the variation within acceptable boundaries?
10-4
Control Chart
Abnormal variation
due to assignable causes
Out of
control
UCL
Normal
variation
due to
chance
Mean
LCL
Abnormal variation
Each point on the control chart represents a sample of n
observations
10-5
Control Charts for Variables
• Variables generate data that are measured
– Mean control charts
• Used to monitor the central tendency of a process.
– X bar charts
– Range control charts
• Used to monitor the process dispersion
– R charts
10-6
Establishing Control Limits
k
k
x
xi
i 1
k
where
R
i
R i 1
k
where
x Average of sample means
R Average of sample ranges
x i mean of sample i
k number of samples
Ri Range of sample i
10-7
X-Bar Chart: Control Limits
• Used to monitor the central tendency of a
process
x chart Control Limits
UCLx x A2 R
LCLx x A2 R
where
A2 a control chart factor based on sample size, n
10-8
Range Chart: Control Limits
• Used to monitor process dispersion
R Chart Control Limits
UCLR D4 R
LCLR D3 R
where
D3 a control chart factor based on sample size, n
D4 a control chart factor based on sample size, n
10-9
Control Charts for Attributes
• Attributes generate data that are counted.
– p-Chart
• Control chart used to monitor the proportion of
defectives in a process
– c-Chart
• Control chart used to monitor the number of defects per
unit
10-10
Process Capability
• Once a process has been determined to be stable, it is necessary
to determine if the process is capable of producing output that is
within an acceptable range
– Tolerances or specifications
• Range of acceptable values established by engineering design or
customer requirements
– Process variability
• Natural or inherent variability in a process
– Process capability
• Process variability relative to specification
10-11
Cp : Process Capability Ratio
UTL - LTL
Cp
6
where
UTL upper tolerance (specifica tion) limit
LTL lower tolerance(specification) limit
10-12
Cpk : Process Capability Index
• Used when a process is not centered at its
target, or nominal, value
C pk min C pu , C pl
UTL x x LTL
min
,
3
3
10-13
Taguchi Loss Function
10-14
Operations Strategy
• Quality is a primary consideration for nearly all
customers
– Achieving and maintaining quality standards is of
strategic importance to all business organizations
• Product and service design
• Increase capability in order to move from extensive use
of control charts and inspection to achieve desired
quality outcomes
10-15