Tools for Managers经理人工具-Statistical Process Control SPC.ppt

Process Control Tools Process Control Tools Process tools assess conditions in existing processes to detect problems that require intervention in order to regain lost control. Run Charts Example:Rogue River Adventures Process Variation Deming’s Theory of Variance Variation causes many problems for most processes Causes of variation are either “common” or “special” Variation can be either “controlled” or “uncontrolled” Management is responsible for most variation Causes of Variation Exogenous to process Not random Controllable Preventable Examples tool wear “Monday” effect poor maintenance Specification vs. Variation Product specification desired range of product attribute part of product design length, weight, thickness, color, ... nominal specification upper and lower specification limits Process variability inherent variation in processes limits what can actually be achieved defines and limits process capability Process may not be capable of meeting specification! Process Capability Process Capability Process Capability Variation -- RazorBlade Process Capability Ratio If Cp 1.0, process is... capable If Cp 1.0, process is... not capable Process Capability -- Example Process Centering Process Centering -- Example Process Capability Index Cpk Cpk Example 1 Cpk Example 2 Process Control Charts Process Control Charts Establish capability of process under normal conditions Use normal process as benchmark to statistically identify abnormal process behavior Correct process when signs of abnormal performance first begin to appear Control the process rather than inspect the product! Process Control Charts Process Control Charts When to Take Action A single point goes beyond control limits (above or below) Two consecutive points are near the same limit (above or below) A run of 5 points above or below the process mean Five or more points trending toward either limit A sharp change in level Other erratic behavior Samples vs. Population Types of Control Charts Attrib