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Copy of Prezi SPC ( Statistical Process Control)

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by

James Kiely

on 28 February 2014

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Transcript of Copy of Prezi SPC ( Statistical Process Control)

SPC
Statistical Process Control
Variation
Monitor
&
Control
Observations
Natural Variation
Special Causes Variation
Rationale
SPC
Improve
Quality
5 Key Points
Control of Variation
Continuous Improvement
Elimination of Waste
Control of Variation
Continual Improvement
Predictability of Processes
Elimination of Waste
Product Inspection
HOW ?
Predictability of Processes
SPC
- Accept orders that cannot be met
- Unpredictable processes
SPC
- Can we meet requirements
- Know your capabilities
- Reduced costs of produced goods
- Enhanced product quality
Product Inspection
- 100 % inspection
Only 80 % is discovered
Very expensive (labor/machine)
- Sampling
Faster & cheaper
Process must be under control
Statistical Control vs Capability


- Number of defects in a single piece
Other Types of Control Charts
Statistical Control II
Statistical Control I
Unstable Process
Example Control Chart
- Pareto charts
- Cause-and-effect diagrams
- Stratification
- Check sheets
- Histograms
- Scatter diagrams
- Run charts and control charts
- Flowcharts
- Design of experiments
Role of Total Quality Tools


- Resetting of machines
- Errors in measurements
- Operator errors
Causes of Variability
- Analysis on treated water

- Quality control on 30 chemical parameters

- 3 most important parameters:
1. Turbidity
2. Residual chlorine
3. Aluminum
Athens Water Supply & Sewerage Company


- Drinking water
- Similar case :
Athens Water Supply and Sewerage Company

 - Process out of statistical control

- Natural log transformation
Control Chart Turbidity

- Normally distributed
- Not autocorrelated


 Adaptations needed to control charts
Control Charts Applicable?
Case Study : Albert Canal
Natural Variability
- Humidity fluctuations
- Temperature changes
Special Cause Variability
Data Have to Be
Chlorine & Aluminum: Autocorrelation
Condition of Normality Violated
Determination UCL, CL and LCL
- Based on empirical data
Outliers
- 2σ Warning Limits
- 3σ Action Limits
Advantage Control Charts

Removal of special causes

Operators exercise greater care
Variability Decreases
QUESTIONS ?
Planning
Preparation
Execution
Commitment to SPC
- Top management involvement
Form an SPC Committee
Train the SPC Committee
- Cross-functional team
- Basic training by experts in
Statistics
Set SPC Objectives

Identify Target Processes

Train Appropriate Operators and Teams

Ensure Repeatability and Reproducibility
(R&R) of Gauges and Methods


Delegate Responsibility for Operators
to Play a Key Role
Flowchart the Process

Eliminate the Special Causes of Variation

Develop Control Charts

Collect and Plot SPC Data; Monitor

Determine Process Capability
Respond to Trends and Out-of-limits Data

Track SPC Data

Eliminate the Root Causes of Any new Special
Causes of Variation

Narrow the Limits for Continual Improvement
What's on
the Menu
TODAY ?
Implementation
&
Deployment
Control Chart
Development
SPC Applied
on
Water Quality
SPC
Defined
Factors Which Inhibit SPC
Implementation
- Capability in Statistics
- Misdirected Responsibility for SPC
- Failure to Understand the Target Process
- Failure to Have Processes under Control
- Inadequate Training and Discipline
- Measurement Repeatability and Reproducibility
- Low Production Rates
- Statistical Process Control Defined

- Rationale for SPC
3 Phases for Implementation
Inhibitors
- Control Chart
Development

- Role TQ Tools
SPC applied
on
Water Quality
TQM
Total Quality Management
P-chart
- Fraction defective
C-chart
( Detailed explanation chapter 15 )
Implementation
&
Deployment
Phase 1
Phase 2
Phase 3
- Important to measure the correct data
- Main Inhibitor = Lack of Resources
Full transcript