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DPMO Calculation, Formula, Template & Manufacturing Example

07/04/202609/04/2024 by TECHIEQUALITY

DPMO Calculation, Formula, Manufacturing Example & DPMO Excel Template

Hello readers! Today we will be discussing on DPMO calculation with manufacturing examples. The full form of DPMO is defects per million opportunities. Similarly, dpmo there are 3 more popular terms used in quality for the calculation of defect level and these are [1] DPPM, [2] DPO, [3] DPU. These terms are also frequently used in six sigma project work. If you would like to download the sample template of all 4 calculations in a single sheet then download it from below given link.

DPMO Calculation Excel Template–DOWNLOAD

Formula of DPMO, DPPM, DPO, DPU:

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

First of all, below example-1 is one of the scenarios that are given for calculating the DPMO, DPPM, DPO, and DPU for all my article readers. So, this is the task for you my readers for your better understanding. Similarly, we are also going to solve one of the scenario-based questions for calculating the DPMO, DPPM, DPU, and DPO.

Example-1 (Task for the reader):

Suppose a sheet metal automobile manufacturing company, produces an automobile part. In the press shop, we found that 4 parts had been rejected at press machine-1 & 9 parts at press machine-2. When a QA engineer had analyzed, he found that the total defective product has 16 defects. And defects opportunity per parts is 5 and total 1100 parts had been produced. Calculate the DPMO, DPPM, DPU and DPO?

Have you completed the calculation of above example-1 or not? If not yet then, we are going to help to calculate the same. First of all, note down the data, i.e. Total defects, Total defective parts, defects opportunity per part, total parts produced and total defects opportunity. I know that it will take more time for manual calculation of all calculations, that is why we are recommending you to download our excel automatic calculation template for easy and time-saving calculation. Downloading link is given at top of the articles just try to download the format or template. I would request you all my readers, you just calculate the DPMO and DPPM manually and try to match your value with Excel calculation, which is given below;

I hope you have completed the matching of the value calculated by the automatic excel template and your manual calculation. Now we will be discussing the different types of examples and will calculate the value by both manually and by using an automatic excel format. So, let’s get started.

Example-2:

Lets a company manufacturing a toy product and below are the data given in several processes. so, calculate the DPMO, DPPM, DPO and DPU of individual processes and overall process by manually and by using the excel template. And also try to compare both solutions.

Process-1 Data Table:

Total Defects	30 nos
Total Defective parts	20 nos
Defects opportunity per part	3
Total parts produced	840 nos

Process-2 Data Table:

Total Defects	102 nos
Total Defective parts	80 nos
Defects opportunity per part	4
Total parts produced	987 nos

Process-3 Data Table:

Total Defects	17 nos
Total Defective parts	16 nos
Defects opportunity per part	3
Total parts produced	1003 nos

Calculate the DPMO, DPPM, DPO and DPU of individual processes and overall processes by manually and by using the excel template?

Solution of Process-1:

DPU Formula = Total number of Defects / Total units

= 30/840

=0.0357

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 30/(840×3)

= 0.0119

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [30/(840×3)]x1000000

=11904.7

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= (20/840) x1000000

=23809.5

Similarly, Excel template calculation is given below as;

Solution of Process-2:

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

= 102/987

= 0.1033

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 102/(987×4)

= 0.0258

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [102/(987×4)]x1000000

= 25835.86

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= (80/987) x1000000

= 81053.69

You can compare the answer with the below given Excel calculated value.

Solution of Process-3:

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

= 17/1003

= 0.0169

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 17/1003×3

=0.0056

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [17/1003×3]x1000000

= 5649.7

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= [16/1003]x1000000

= 15952.14

Below are the excel calculation of the above value, you can match the value;

Overall Process DPMO Calculation:

For doing so we need a combined data table, so we have clubbed all the data of process-1,2 & 3 and given in below; the same part is produced in all 3 processes.

Total Defects	149 nos
Total Defective parts	116 nos
Defects opportunity per part	8
Total parts produced	2830 nos

DPU (Defects per unit):

DPU Formula = Total number of Defects / Total units

= 149/2830

= 0.0526

DPO (Defects Per Opportunity):

DPO Formula = Total number of defects/ (number of units x defects opportunity per unit)

= 149/2830×8

=0.00658

DPMO (Defects per million opportunities):

DPMO Formula = {Total number of defects/ (number of units x defects opportunity per unit)} x 1000000

= [149/8×2830]x1000000

= 6581.27

DPPM (Defective Parts Per Million):

DPPM Formula = (Total Defective parts / Total parts) x 1000000

= (116/2830) x1000000

= 40989.39

[Excel Calculation of DPMO]

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Shanti Gopal Pradhan is an experienced professional in Quality Management Systems, QA, Operations, Business Excellence, and Process Improvement. He has strong expertise in international standards including IATF 16949, ISO 9001, ISO 14001, ISO 45001, and ISO 17025, along with methodologies such as TQM, TPM, and Six Sigma.

He holds a degree in Mechanical Engineering along with an MBA, combining strong technical acumen with strategic business insight, he is a Certified Internal Auditor, Lead Auditor, and Six Sigma Black Belt, with a proven track record in driving quality transformation and operational excellence.

Process Flow Diagram Template | Examples |Symbols |PFD

07/04/202603/04/2024 by TECHIEQUALITY

Process Flow Diagram Template | Examples |Symbols |PFD

Hi Readers! Here, today we will be discussing the process flow diagram, its symbols, and practical examples. We have prepared a PFD template for sample and example basis, if you would like to download the free template or format of the PFD-process flow diagram then, go through the below-given link.

The process flow diagram template or format in excel-DOWNLOAD-PFD in Excel template or format.

What is a Process Flow Diagram- PFD?

The PFD or process flow diagram is a flow chart or process flow diagram or process mapping of a process. The PFD represents the process sequence and details (like a machine, activities, process sequence, relevant document, process control, decision, etc).

Symbols of Process flow diagram – PFD:

PFD/PFC has many symbols but we will discuss only common symbols. Details are given below;

Symbol Name	Function
Flowline	To show the process direction
Terminal symbol	It indicates the beginning or end of the Process flowchart
Process	Represent Process steps
Decision Symbol	Which shows the decision step of a process
Input / Output	Inputting or outputting data
Predefined process	Which indicates the predefined process
On-page connector	Pairs of on-page connectors are used to replace long lines on a flowchart page
Off-page connector	It is used when the target is on another page.
Delay	Which represents the delay period that is part of a process
Document	Document requirement
Multi-document	Multi-document requirement
Display	Machine display
Manual input	Data or information in the system
Manual Operation	It indicates the manual process

Process Flow Chart symbols / PFD

4 Steps to create a PFD-Process flow Diagram:

Step-1:

CFT team formation including the process owner.

Step-2:

List out the process, activities, decision, machine, control mechanism, etc

Step-3:

Sequentially write down the process, activities, and decisions of the process

Step-4:

Plot the diagram by using the PFD symbols.

Process Flow Diagram Example:

We have created two process flow diagrams, i.e. [1] without repetition of the process after the decision and [2] with repetition of the process after the decision. Both two types of PDF are given below;

Industrial Example:

Here we have taken the process flow diagram example of Training, which is one of the most powerful things to competent the workforce and enhance the skill of employees. So that optimum knowledge can be utilized for effective output from operation by employees at an organization. Hence if you would like to create a process flow chart of education and training operations then the below example will be helpful to prepare the same. This is only for reference and learning purposes.

We have prepared the PFD followed by the above steps:

Step-1:

We have formed a team including the HRD member.

Step-2:

Identified the activities below

Training needs identification
Prepare the training plan and schedule
Conduct the training as per schedule
Training feedback and effectiveness monitoring
Skill evaluation.

Step-3:

We have arranged the activities sequentially as given below of education and training operations.

Activities-1	Training needs identification
Activities-2	Prepare the training plan and schedule
Activities-3	Conduct the training as per schedule
Activities-4	Training feedback and effectiveness monitoring
Activities-5	Skill evaluation

Step-4:

We have prepared the PFD – process flow chart for education and training operations and details are given below;

FAQ:

What is the process flow?

The process flow is the flow chart that represents the process sequences or process mapping including machine details, control data, document reference, etc.

What is the difference between SIPOC and PFD?

The SIPOC diagram consists of 5 elements i.e. Supplier, Input, Process, Output, and Customer. the PDF is the process mapping that represents the process sequences.

What is flowchart?

The FC is a flow diagram or mapping of activities.

What are the 3 types of PFD?

[1] System PFD, [2] General PFD, [3] Detailed PFD

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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What is Visual Management? | Visual Management Board Examples

03/04/2024 by TECHIEQUALITY

What is Visual Management?| Visual Management Board Examples

Hi Readers! Here, today we are going to discuss on what is visual management. Its examples and tools. The Visual management is a method to visualize the performance, standards, and signs in operation or any activities. This visual standard is widely used in a manufacturing operation to enhance operation excellence, performance and optimize the output from the operation or activities. The main purpose of the visual management is to communicate the important criteria to the shop floor workforce in visual forms.

Benefits of Visual Management

Cost reduction
Easy understanding of performance
Quick reference of critical parameters and one-step process.
Waste reduction
Reduced dependency for understanding the critical operation standard
Status of objectives
Information sharing
Improve productivity, rate of quality, cost, delivery, morale, and product & operator safety.
Promote values
Raise awareness
Improve accountability, etc.

What are the common tools used in industries to implement visual management? As we all know that we can easily understand and remember the visual sign rather than information in other forms. So it’s an effective method to control your operation process and optimize the output. The common tools and methods used in industries are given below;

FIFO (First in First Out): This is a very helpful tool that you can control your material flows in systematic ways. In this process, you can easily manage your material storage and movement.
5’S: the 5’S stand for Sort, set in Order, Shine, Standardize, and Sustain.
Display: Display board, Sign, labels, and marking.
OPL, OK and Not OK process sample display, colour code, level, Visual poka yoke, do & don’t, and Andon system.
Digital display

Example of visual management

FIFO:

Visual management is one of the best techniques in an organization by which very easily and quickly, you can understand critical information in visual ways. I think visual information is very easy to understand and helps to enhance the optimize the output and minimize the waste/ errors. FIFO is the one of the visual management systems which means First-In-First-Out. For inventory management, FIFO is the one of the best techniques to help for systematic storage and handling of materials/products/elements, etc. Some common FIFO systems are –colour code systems, numbering, bin cards, digital FIFO systems, IOT-based FIFO, etc.

Example: suppose an organization is being planned to implement the FIFO visual management system at raw material store room. So the store manager decided to store the material in month-wise material received in the different racks with month-wise colour codes. So that the first incoming raw material can be used first in the production area. Accordingly, to the colour code, the store manager issued the material to the user department. In the below image, you can easily understand that how the material is stored with month-wise colour code. As you can see in the below image, production is for the month of April, and the store manager issuing the material available in the month of January instead of month April. This is the material issuing and handling followed by the FIFO system.

5’S:

The 5’S is the base pillar of visual management or visual control. The terms 5’S are the [1] Sort, [2] Set in order [3] Shine, [4] Standardize and [5] Sustain. From the office to the manufacturing shop floor, you can easily implement the 5’S concept. We have taken an example as a tool board for a better understanding of the 5’S concept for easy implementation in the manufacturing industry. As you can see in the tool board image below that how the different sizes and types of tools are placed in a systematic manner followed by the5’S concept.

Match Marking:

Match marking refers to the process in which a pictorial view is provided to place the pieces in the position of the marked point by identifying the final output image. E.g. In the image attached below an object is placed between the nut and the bolt. Now by looking at the final image, we can understand that the nut has to be rotated in such a way that the object placed in between the nut and bolt gets tightened or fixed. To do this one will need to rotate the nut to an extent that it matches with the yellow mark as shown in the output image.

Pipeline colour code on shop floor:

Pipeline colour coding is done to help one identify the contents flowing through the pipe. Also, additional details would be required to be provided if any hazardous material is flowing through the pipe to avoid any mishap. Thus pipeline colour coding helps in obtaining crucial information about the pipes contents. E.g. Now in the image provided below we can see the Pipeline visual display has been provided in four colours:-

The yellow coloured pipeline represents gas.

The green coloured pipeline represents water.

The red coloured pipeline represents components required for fire services.

The Light blue coloured pipeline represents air element present.

Tag System:

The Tag system helps in the easy identification of the segment of a product with the help of just the tag. Now let’s understand how? When any kind of production takes place in a factory it’s quite understood that on production you do get some wastage or rejections. Suppose a factory does the production of garments. Now in the process of production, there are certain items that get rejected for several reasons. Again there are several garments that need to be recertified before being sent out to the market.

Through the below presented image, we can easily understand that the garments which are tagged in Red are the rejected ones and cannot be sent out to the market. Green Tags represent the ones that are perfect to be sent out to the buyers. White tags are the ones that have been kept on hold for further verification due to the possibility of thread cutting or needs stitching before it’s sent out to the market.

Visual Management Board:

Shop floor display helps in streamline the process of work. The visual display helps in improving the workplace functioning by ensuring that the important information is clearly presented in a professional manner. Shop floor display works as a fundamental to any well communicated working environment. It helps in managing the operations of the manufacturing unit for effective planning and productivity. In the image provided below following information is provided for better understanding:-

Quality is presented with the help of a graph which helps one in identifying and comparing whether the quality is improving or deteriorating by merely looking at the graph. Similarly, different charts are displayed related to production performance to know the status, and understand the present position. In the shop-floor visual management board, you can display the critical information related documents, OPL, master sample, instruction, etc.

Andon System:

The Andon system is one of the strong visual management tools or visual control systems which promptly alerts about the status or problem of the operation line. In the below image, we have considered three colours Andon alert system as an example. Where different colours indicate different meanings. [1] Green colour light –There is no problem in the operation line. [2] yellow colour light- problem detected in line, [3] red colour light- problem exists, production stopped / operation stopped.

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ABC Analysis of Inventory with Industrial Example

01/04/2024 by TECHIEQUALITY

ABC Analysis of Inventory with Industrial Example:

Hi Readers! Here, we are going to discuss one of the popular inventory management systems, which is nothing namely called ABC Analysis of Inventory. As you know that in the industry managing stock of raw materials, bop, WIP, semi-finished products, and the finished product is a matter, if you don’t have any control over inventory then a huge amount of product or material stock, Space consumption, and money consumption for a certain period will be there. That-why proper inventory control or management should be there in place so that you can get the benefit from low inventory costs.

Free Download of Quality Template / Format

Benefits of Inventory management or control:

Low Inventory Cots
Preventing stock issues
Better space control
Eliminates duplication in ordering
Better utilization of stocks
Reduces stock holding costs

To achieve maximum benefits with minimum efforts, it is essential to manage inventory control, so here, we are going to discuss the step-by-step process of abc analysis of inventory control.

ABC Analysis of Inventory with Industrial Example:

ABC analysis classifies a large number of items in inventory into three categories- A-class, B-class, and C-class items. The classification is based on annual usage in value. ABC analysis aims to reduce the cost of managing inventory by controlling the inventory of a few high-value items. The abc analysis technique is based on the Pareto chart law. A higher contribution of annual usage is because of low items. These high annual usage inventory values should be paid more attention.

Class or Category	Annual Usage (Not limited to)
A-Category	70-80%
B-Category	15-25%
C-Category	5%

ABC Analysis Example:

For example, the Maintenance department of ABC Limited has recorded the annual usage unit of machine maintenance parts as below for doing the ABC analysis and categorizes the items into A, B & C for better inventory control and minimizing the inventory carrying costs.

Item	Annual Usage Unit	Unit Cost in $
MCP-1	5000	200
MCP-2	800	25
MCP-3	1500	150
MCP-4	2500	60
MCP-5	3000	30
MCP-6	900	18
MCP-7	2000	20
MCP-8	1200	50
MCP-9	1000	40
MCP-10	1300	19
MCP-11	600	100
MCP-12	2000	40

ABC Analysis of Inventory Steps by Steps Calculation:

Step-1: Calculate the annual usage cost by multiplying the quantity of each item with their respective price.

Item	Annual Usage Unit	Unit Cost in $	Annual Usage Cost ($)
MCP-1	5000	200	1000000
MCP-2	800	25	20000
MCP-3	1500	150	225000
MCP-4	2500	60	150000
MCP-5	3000	30	90000
MCP-6	900	18	16200
MCP-7	2000	20	40000
MCP-8	1200	50	60000
MCP-9	1000	40	40000
MCP-10	1300	19	24700
MCP-11	600	100	60000
MCP-12	2000	40	80000

Step-2: Rearrange the above items in descending order (largest to smallest).

Item	Annual Usage Unit	Unit Cost in $	Annual Usage Cost (xK$)
MCP-1	5000	200	1000
MCP-3	1500	150	225
MCP-4	2500	60	150
MCP-5	3000	30	90
MCP-12	2000	40	80
MCP-8	1200	50	60
MCP-11	600	100	60
MCP-7	2000	20	40
MCP-9	1000	40	40
MCP-10	1300	19	24.7
MCP-2	800	25	20
MCP-6	900	18	16.2

Step-3: Calculate the cumulative annual usage cost:

Item	Annual Usage Unit	Unit Cost in $	Annual Usage Cost (xK$)	Cum. Annual Usage Cost (xK$)
MCP-1	5000	200	1000	1000
MCP-3	1500	150	225	1225
MCP-4	2500	60	150	1375
MCP-5	3000	30	90	1465
MCP-12	2000	40	80	1545
MCP-8	1200	50	60	1605
MCP-11	600	100	60	1665
MCP-7	2000	20	40	1705
MCP-9	1000	40	40	1745
MCP-10	1300	19	24.7	1769.7
MCP-2	800	25	20	1789.7
MCP-6	900	18	16.2	1805.9

Step-4: Calculate the cumulative percentage

Item	Annual Usage Unit	Unit Cost in $	Annual Usage Cost (xK$)	Cum. Annual Usage Cost (xK$)	Cum. Percentage %
MCP-1	5000	200	1000	1000	55.37
MCP-3	1500	150	225	1225	67.83
MCP-4	2500	60	150	1375	76.14
MCP-5	3000	30	90	1465	81.12
MCP-12	2000	40	80	1545	85.55
MCP-8	1200	50	60	1605	88.88
MCP-11	600	100	60	1665	92.20
MCP-7	2000	20	40	1705	94.41
MCP-9	1000	40	40	1745	96.63
MCP-10	1300	19	24.7	1769.7	98.00
MCP-2	800	25	20	1789.7	99.10
MCP-6	900	18	16.2	1805.9	100.00

Step-5: Select the category by “A” by max. 80% contribution, “B” by 25% and “C” by 5%

Item	Annual Usage Unit	Unit Cost in $	Annual Usage Cost (xK$)	Cum. Annual Usage Cost (xK$)	Cum. Percentage %	Class/Category
MCP-1	5000	200	1000	1000	55.37	A
MCP-3	1500	150	225	1225	67.83	A
MCP-4	2500	60	150	1375	76.14	A
MCP-5	3000	30	90	1465	81.12	B
MCP-12	2000	40	80	1545	85.55	B
MCP-8	1200	50	60	1605	88.88	B
MCP-11	600	100	60	1665	92.20	B
MCP-7	2000	20	40	1705	94.41	B
MCP-9	1000	40	40	1745	96.63	C
MCP-10	1300	19	24.7	1769.7	98.00	C
MCP-2	800	25	20	1789.7	99.10	C
MCP-6	900	18	16.2	1805.9	100.00	C

Note: Based in Cumulative percentage we have selected “A” category up to 80% contribution, “B” category from 80% to 95%, and “C” category from 95% to 100% contribution.

Class / Category	Item
A	MCP-1, MCP-3, MCP-4
B	MCP-5, MCP-12, MCP-8, MCP-11, MCP-7
C	MCP-9, MCP-10, MCP-2, MCP-6

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P Chart Excel Template | Formula |Example | Control Chart | Calculation

28/03/202601/04/2024 by TECHIEQUALITY

P Chart Excel Template | Formula | Example | Control Chart | Calculation

Hi Readers! Here, we are going to discuss on attribute type control chart, especially on the P chart. Also, you can learn the formula, and calculation part with industrial or manufacturing examples. You can download the P chart excel template from below given link.

Sample P chart excel template with industrial example-Download Here

Attribute type Control chart (P Chart):

The P chart, attribute type control chart, or proportion nonconforming chart is generally used to identify the common or special causes present in the process and also used for monitoring and detecting process variation over time. It helps to determine whether the process is in a state of statistical stable or not. Overall, it indicates that special causes are present in the process or not, whether the process is under control or not, and process variability.

How to select proportion nonconforming (P chart):

Step-1: Data Types?

Ans.:- Discrete type data (Attribute type data)

Step-2: Is the interest in nonconforming units or one defect per unit?

Ans.:- yes, one defect per unit

Step-3.:- Is the sample size constant?

Ans.:- Yes or No, then use P chart.

Note; for both the cases, if the sample size is constant or if not, in this scenario you can select p chart.

Data Type:——	Discrete type data (Attribute type data)
Is the interest in nonconforming units or one defect per unit?—-	Yes
Is the sample size constant?	Yes or No
Select Chart type:	P Chart

P Chart Formula:

For plotting the P chart in excel we have to calculate the three important things i.e. [1] Center line, [2] Upper control limit, & [3] lower control limit.

P chart example & Calculation for constant sample size:

In a manufacturing unit producing the auto part products, a process quality engineer would like to monitor the process control, so he started to collect the data for 30 days and daily inspected 250 products & recorded the defectives or nonconforming parts (Defects-blow hole, shrinkage, pinhole, etc.). 30 days data is given in below table.

Date	Constant sample size (n)	Defective/ Nonconforming
1	250	1
2	250	2
3	250	2
4	250	1
5	250	2
6	250	1
7	250	0
8	250	1
9	250	4
10	250	2
11	250	3
12	250	1
13	250	0
14	250	3
15	250	10
16	250	1
17	250	4
18	250	3
19	250	2
20	250	1
21	250	3
22	250	2
23	250	1
24	250	3
25	250	2
26	250	2
27	250	1
28	250	2
29	250	3
30	250	1

With the help of the above data, we are going to calculate and plot the P chart. As we know that we have to calculate the 3 important things, Center line, upper control limit & lower control limit.

Center Line (CL)-P bar: – Total Defectives/ Total sample Inspected

= 64/ (30*250)

= 0.0085

=0.009

Upper Control limit (UCL):-

= P bar+3*square root of (p bar*(1-p bar)/sample size)

= 0.009+3* square root of (0.009*(1-0.009)/250)

=0.009+3*0.005972

=0.026

Lower Control Limit (LCL):-

= P bar-3*square root of (p bar*(1-p bar)/sample size)

= 0.009-3* square root of (0.009*(1-0.009)/250)

=0.009-3*0.005972

= -0.0089

= -0.009

0 (Note: The LCL value is negative, so the final value of LCL is zero)

Now, you have to calculate the proportion defective or nonconforming

Proportion defective:

Here, I’m calculating the proportion defective of day-1, so similarly you can calculate for next day onwards

= Day-2 Defects/Sample size

= 1/250 = 0.004

Now, Based on the above data i.e. proportion defects, center line, upper control limit, and lower control limit, we have plotted the P chart in Excel. If you would like to download the p chart excel template with the same calculation then, download it from the above given link and similarly you can download the other template or format by Click Here

Interpretation of P Chart:

In the above p chart, we have seen that one proportion defect value is beyond the upper control limit. It means on day-15 special cause is present so, we have to take the action on it to control the process.

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C Chart Excel Template | Formula | Example | Calculation

07/04/202601/04/2024 by TECHIEQUALITY

C Chart Excel Template| Formula |Example |Calculation:

Hi Readers! Today, we will be discussing here on attribute type SPC chart i.e. C chart. Its formula, calculation, and industrial example. The C chart is also called the number of nonconformities chart. Where the sample size is constant. Read the below description to learn about its selection and application in industries. If you are interested in downloading the sample C Chart Excel Template then, click on the given below link.

Sample C Chart Excel Template with industrial example-Download.

Number of nonconformities chart (C Chart):

The C chart, attribute type SPC control chart, or the number of nonconformities chart is generally used to identify the common or special causes present in the process and is also used for monitoring and detecting process variation over time. It helps to determine whether the process is in a state of statistical stable or not. Overall, it indicates that special causes are present in the process or not, whether the process is under control or not, and process variability. This C chart is selected when there is a constant sample size and multiple defects per unit are present.

Selection of Attribute type SPC Control chart (C Chart):

Step-1: Data Types?

Condition: – Discrete type data (Attribute type data)

Step-2: Is the interest in nonconformities or multiple defects per unit?

Condition: – yes, multiple defects per unit

Step-3.:- Is the sample size constant?

Condition: – Yes, then use the C chart.

Description	Condition
Data Type:	Discrete type data (Attribute type data)
Is the interest in nonconformities or multiple defects per unit?	Yes, Multiple defects per unit present
Is the sample size constant?	Yes
Chart type:	C Chart

C Chart Formula:

The three important things need to be calculated before plotting the C chart i.e. [1] Centerline, [2] Upper control limit, & [3] lower control limit.

Centerline (CL) or C bar = Total number of nonconformities or defects / Number of samples

Upper control limit (UCL) = C-bar + 3 x Square root of C-bar

Lower control limit (LCL) = C-bar – 3 x Square root of C-bar

	The formula of C chart
CL or C- bar =	Total number of nonconformities or defects / Number of samples
UCL =	C-bar + 3 x Square root of C-bar
LCL =	C-bar – 3 x Square root of C-bar

How to plot a c chart in excel?

Here, I’m going to share my own industrial experience regarding the application and usage of a c chart in the manufacturing industry by providing a sample example for your quick learning and implementation in your organization. I have considered 50 sample sizes, and three different defects and collected the data for 30 days. Details of data are given below table.

Date	Constant sample size (n)	Defect-1	Defect-2	Defect-3	Total Defects
1	50	1	1		2
2	50	1	1	2	4
3	50	2	2	1	5
4	50	1	1		2
5	50	1	1	2	4
6	50	1	1		2
7	50	1	1	1	3
8	50	2	2	2	6
9	50	2	2	3	7
10	50	1	1	2	4
11	50	1	1	3	5
12	50	1	1	1	3
13	50	5	5	7	17
14	50	1	1		2
15	50	1	1	1	3
16	50	2	2	1	5
17	50	1	1		2
18	50	1	1	1	3
19	50	1	1	3	5
20	50	1	1		2
21	50	2	2		4
22	50	1	1		2
23	50	2	2	2	6
24	50	1	1	3	5
25	50	1	1	1	3
26	50	2	2		4
27	50	1	1	1	3
28	50	1	1		2
29	50	1	1	1	3
30	50	1	1	1	3

All the above three defects are attribute type defects. Before plotting the c chart in excel we have to calculate the three important things first, one is CL, UCL & LCL.

Calculation:

Centerline (CL) or C-bar:

Formula = Total number of nonconformities or defects / Number of samples

CL = 121 / 30 =4.033

UCL (Upper control limit):

Formula = C-bar + 3 x Square root of C-bar

UCL = 4.033 + 3* Square root of 4.033

UCL = 4.033+3*2.008

UCL = 10.0577

UCL = 10.058

LCL (Lower control limit):

LCL = C-bar – 3 x Square root of C-bar

LCL = 4.033 – 3* Square root of 4.033

LCL = 4.033-3*2.008

LCL = 4.033-6.024

LCL = -1.991 (the value is negative so LCL is Zero)

LCL = 0.00

	Calculation value
CL =	4.033
UCL =	10.058
LCL =	0

Follow the below step to plot the c chart in excel:

Step-1: open the excel sheet.

Step-2: Do the data entry on the Excel sheet.

Step-3: Select the data and then go to the insert option in the main menu and next to select line chart. The detail is mentioned in the below image.

C Chart:

With the help of the above data, we have plotted the c chart, which is given below. if you would like to download the C Chart Excel Template then, click here.

Interpretation of the above C Chart:

In the above C chart, we have seen that one defect value is beyond the upper control limit. It means on day-13 special cause was present in the process, so we have to take the action on it to control the process.

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4M Change Management | How to implement in Manufacturing unit | Template | Format

16/11/202401/04/2024 by TECHIEQUALITY

4M Change Management| How to implement in Manufacturing unit |Template | Format

Hi Readers! Today here, we are going to discuss 4M Change management related to manufacturing industries with an illustration. You can learn many more things from this article like 4M change concepts, planned and unplanned changes, implementation of concepts in your organization, etc. The concept of 4M change management is generally used to record 4M (man, machine, method & material) related to planned and unplanned changes. This can apply to all internal process changes.

Download the 4M checklist for gap analysis.-4M Checklist-DOWNLOAD

As we already discussed 4M changes i.e. Man, Machine, Method & Material related planned and unplanned changes. so here, first of all, we have to understand, what planned and unplanned changes are. The plan changes that occur with the advanced information to the pertinent personnel. Similarly, the un-plan change that occurs without prior information to the pertinent person. If once the planned and unplanned changes occurred then a defined action which is mentioned in SOP/Procedure is required to control the occurrence of nonconformity at the shop floor change area.

Illustration / Example (How to implement 4M change management in manufacturing Unit?):

Example of plan change:

Let’s say an organization has planned for preventive maintenance of machine-1 in shift –A, dated xx/1/20xx, and executed the same as per plan. If so then how to record the same 4M change and control the process after PM.

Before implementing 4M change management, personally, I would recommend that try to prepare the procedure /SOP as per your organization’s nature of production, like the 4M procedure, change tracking record, list of trained operators, list of machines, material list, etc.

According to the above example scenario, we are going to record the 4M change in the below template (this template is only for reference)

Date	Machine	Shift	Type of change	Details of change	Action taken
xx/1/20xx	machine-1	A	Planned / machine	Preventive maintenance	Set up approval checking

In this way, you can maintain the change record. For your better understanding and more clarification, we have given below another example related to the unplanned 4M change.

Example of un-plan change:

For example, an operator on leave without prior information to the pertinent supervisor and you as a supervisor planned for running the machine-1 with the help of other operators. In that scenario, how to record the 4M change, and what action is to be taken?

Similarly, we are going to record the un-plan change as per the above 4M change template or format.

Date	Machine	Shift	Type of change	Details of change	Action taken
xx/1/20xx	machine-1	A	Un-planned /Man	The operator is on leave without intimation	A similar skilled operator will run the machine/machine setup approval to be done

The 4M change record can be helpful for analysis in the future if there will be any issues with the product. And the action you have taken at the time of the 4M change can control the process as proactively.

I hope the above example is meaningful for your better learning and understanding related to 4m change management implementation in your organization.

Example of Abnormality ( Abnormal situation handling):

It is very important to understand all three situations/changes i.e. [1] plan change, [2] un-plan change, [3] abnormality. now here we are going to discuss the 4M change management of abnormal situation handling (abnormality). Suppose in a production line, a machine-1 on a sudden breakdown, for this situation we are going to record the 4M change, and the same is given below.

Date	Machine	Shift	Type of change	Details of change	Action taken
dd/mm/yy	machine-1	B-shift	Abnormality /Machine	Machine-1 on sudden breakdown	1) Run a backup machine, if available. 2) Do the setup approval & Retroactive inspection 3) Containment action.

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SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

07/04/202601/04/2024 by TECHIEQUALITY

SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

Hi Readers! Today here, we will be discussing on SIPOC template and examples of sipoc diagrams of manufacturing and service industries. As you know that SIPOC is one of the most useful diagrams which is generally used for a better understanding of the process. In both the manufacturing and service industries are commonly used the two types of process mapping diagrams are. I.e. [1] PFD- Process flow diagram and another [2] SIPOC diagram. If you would like to download the free SIPOC excel template then, click on the given below download link.

Download the SIPOC template in excel format-SIPOC Excel format-DOWNLOAD Link

What is SIPOC Diagram?

The SIPOC diagram consists of 5 elements i.e. [1] Suppliers, [2] Inputs, [3] Processes, [4] Outputs, [5] Customers. The diagram is generally used for process mapping. It helps to understand the overview of the process in detail.

5 Steps to create a SIPOC Diagram:

Step-1:

Create a CFT team including the process owner of a particular process, which you are trying to draw.

Step-2:

Define the process, for example, let’s consider a process namely called Process-A and you are trying to draw an SIPOC diagram, so first of all you are supposed to list out the details activities of process-A in sequence with the help of the CFT team.

Step-3:

After listing out the details process sequence, find out the internal and external suppliers. Details are mentioned below example.

Step-4:

List out and identify the inputs, process, process output and then customers

Step-5:

Draw the Diagram by entering the above points in the appropriate places.

[SIPOC Template / Format]

SIPOC Diagram vs PFD – process flow diagram:

Both the SIPOC diagram and process flow diagram are used to represent the process mapping but the difference between the two is the elements that are used to represent the process details. In SIPOC, we use the 4 elements like supplier, input, process, output, and customer but in PFD, we use flow chart symbols, like the terminator, process, flow line (arrow connector), decision, document, connector, data, preparation, off-page connector, etc.

SIPOC Diagram Example of Manufacturing & Service Industry:

Manufacturing Industry Example:

Suppose a company manufactures automobile parts through foundry technology and they have planned to prepare a SIPOC diagram of one of the processes called green sand mould preparation.

Supplier	Input	Process	Output	Customer
Sand plant	Green sand	Filling green sand into drag pattern cavity	Drag mould	Mould making dept.
Sand plant	Green sand	Filling green sand into cope pattern cavity	Cope mould	Mould making dept.
Mould making dept.	Cope and drag mould	Core fitting	Mould with core fitted	Mould making dept.
Mould making dept	Mould with core fitted	Fitting of cope and drag mould	Final mould	Pouring dept.

Service Industry Example:

Let’s consider one of the service sectors of finance as an example bank, and we are going to draw a SIPOC diagram of an offline saving bank account opening process, which is given below;

Supplier	Input	Process	Output	Customer
…..	Application filled-up form	Offline checking and verification of documents deposited by the customer	Verified document	Document verification document
Document verification dept.	Verified document	Account creation	New saving bank account number	Account creation dept
Account creation dept	New saving account	Passbook issuing	New passbook	Mr. XYZ

FAQ:

What does sipoc stand for in Six Sigma?

Ans.: The SIPOC stands for Supplier, Input, Process, Output and Customer.

What is a SIPOC template?

The SIPOC template is a diagram which consists of suppliers, inputs, processes, outputs and customers. With the help of the SIPOC diagram, you can prepare the details process flow from start to end.

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Equipment Ranking Process | A B C Ranking of Machine with Manufacturing Example

30/03/2024 by TECHIEQUALITY

Equipment Ranking Process | A B C Ranking of Machine with Manufacturing Example:

Hi readers! Today we are going to discuss on equipment ranking process, it is an important part of the maintenance process, where machines/equipment/ parts will be ranked and based on the rank category, and you can easily set up the maintenance principle. The organization will get benefits in terms of productivity, quality, cost, safety, etc., and also it will help you to select the type of maintenance applicable / applied on which machine.

Equipment Ranking Process:

If first time, you are going to implement it in your organization then you have to formalize many more things like SOP, Check-sheet, list of equipment/ machine, machine /equipment ranking criteria, data, etc. so here, we will help you for easy implementation of this process.

Step by step process has been defined below to implement the machine /equipment ranking process in your manufacturing organization;

Step-1: Prepare the SOP, List of equipment, and equipment/machine ranking criteria procedure.

In the ranking criteria, you can consider the PQCDS means Production, Quality, Cost, delivery, and safety as weightage for factors in categorization, but some industry also considers other factors like Maintenance / Maintainability, Operability, etc.

All the above factors are not equally important and they vary from industry to industry based on the application, material used, quality, safety, etc. For example, equipment is being used for chemical handling, safety factors get a high weightage for rating calculation. And similarly, imported machines may come under high weightage on maintainability if spare parts are mostly imported procurement may take more time and the cost of repair could be high.

Step-2: Form a CF-Team, including Production, quality, maintenance, and safety personnel for best weightage consideration.

For example, let’s say we are having total of 16 machines, and according to their criticality w.r.t PQCDSM and consultation with CF-Team, finally, we have broadly done the weightage of factors of individual machines or similar types of machines.

Machine-1

P-Production	100
Q-Quality	100
C-Cost	50
D-Delivery	50
S-Safety	20
M-Maintainability	20
Total =	340

[M/C-1 Data Table-1]

Machine-2

P-Production	100
Q-Quality	90
C-Cost	50
D-Delivery	40
S-Safety	40
M-Maintainability	40
Total =	360

[M/C-2 Data Table-2]

Machine-16

Production-P	100
Quality-Q	80
Cost-C	50
Delivery-D	40
Safety-S	40
Maintainability-M	40
Total =	350

[M/C-16 Data Table-3]

Similarly, you can do the weightage of factors of all machines or you can prepare the common criteria sheet for similar types of Machines.

Step-3: Prepare the final ranking criteria sheet.

For example, we have prepared the below-ranking criteria sheet for reference only, you can prepare according to your organization’s decision and machine’s factors, operations, etc. but here we have made the generic criteria rules is given below.

Let’s say “Quality” factors have 100 marks and we have divided them into four degrees of factors.

Mark=100	80	60	40
Always being required to work to a very fine tolerance or Equipment failure mode has a major effect on quality, the product produced out of Specification.	Produce quality variations, some of the products may get rejected but the operator’s intervention requires less time to correct it.	The Product can be reworked and used, meets the specification and drawing, machine is sufficiently accurate for required tolerance.	No quality problems, no effect on quality, and no product defects.

[Ranking Criteria Matrix]

Accordingly, you can prepare the ranking criteria matrix for Production, cost, safety, delivery, and maintainability, etc.

Let’s consider the machine-1, factors given in above i.e.

P-Production	100
Q-Quality	100
C-Cost	50
D-Delivery	50
S-Safety	20
M-Maintainability	20
Total =	340

The total mark of the entire above factor (PQCDSM) is 340. Based on the organization’s decision and degree of factors mark, an organization can decide the range for the category of machine, e.g.

Up to 130 marks ——-C Rank / Category

131 to 190 marks ——-B Rank / Category

191 to 340 marks ——- A Rank / Category

As you know that we have considered 16 machines, so our CF-team members have collected and gathered the machine history records, data and with the help of the ranking criteria matrix, they have evaluated the entire machine, and the same is mentioned below the table.

Machine	Rank / Category
M/C-1	A
M/C-2	B
Machine-3	C
M/C-4	C
M/C-5	A
Machine-6	B
M/C-7	A
Machine-8	B
M/C-9	B
Machine-10	B
M/C-11	A
Machine-12	B
M/C-13	B
Machine-14	A
M/C-15	C
Machine-16	C

[A B C Ranking Table]

According to the machine’s rank, you have to prepare the maintenance plan, e.g. our maintenance engineer has decided that M/C-1 will be covered under preventive and predictive maintenance twice a month and similarly M/C-8 will be covered under preventive maintenance twice a month. And M/C-16 may be covered under preventive maintenance once a month or only BM. So, in this way, you can prioritize the machine maintenance period w.r.t m/c or equipment category or ranking.

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Variation Calculation in Excel | Types of Variation | Manufacturing Example

30/03/2024 by TECHIEQUALITY

Variation Calculation by Excel | Types of Variation | Manufacturing Example:

Hi readers! Today we are going to calculate the different types of Variation with the help of Excel. Here we will learn the complete calculation of variation with industrial examples. All the calculations related to variation are done here with the help of the excel-2007 version, the positioning and terminology may be varied w.r.t other versions of Excel. But anyway variation calculation in excel-2007 version will give you a complete idea so you can easily apply the concept in any version of Excel as well.

This topic will help you to enhance your knowledge so that you can easily solve the problem related to variation calculation and the important things that, if you are working in the manufacturing industry and if you would like to know the data variation of process or product characteristics then by using of excel sheet easily you can calculate the variation of the data set.

Variation Calculation in Excel:

First of all, we are supposed to know that what is Variation. I mean to say that Variation is nothing but a way to show how the data is spread out, which means how the data are spread over a wide area.

Types of Variation:

There are so many ways to measures the variation but some common measures of variation used in statistics are;

Range.
Variance (Population, Sample).
Standard Deviation (σ, s).
Coefficient of Variation ((Population, Sample).
Mean Absolute Deviation.
Z-score
Quartiles.
5-Number Summary

We will be calculating all the above measures of variation with the manufacturing example so that you can easily understand and implement the concept in your manufacturing process to know the variation of the data set.

Manufacturing Example to Calculate the Different Measures of Variation:

Let’s a company m/s PQR manufacturing the product “X”. A Quality Engineer Mr. P monitoring the process parameter as per the QA plan, but one day during the shop floor visit, the QA head observed that the process parameter of temperature reading was on the higher side, so he immediately called to process QA engineer and asked to calculate the different measurement of the variation of last period data set. Accordingly, the Process QA engineer had started the calculation, details are given below;

Data: Specification of Temperature: 1400±10°C

Time/Shift	Temperature in °C
8AM/A	1402
8.30AM/A	1405
9AM/A	1401
9.30AM/A	1400
10.0AM/A	1405
10.30AM/A	1403
11.0AM/A	1406
11.30AM/A	1401
12.00Noon/A	1404
12.30AM/A	1400

[Temperature reading table]

Here, we are going to calculate the first Range of all the above data sets.

Range = (Maximum Value – Minimum Value)

How to Calculate Range in Excel?

Step-1: Open the Excel Sheet

Step-2: Type the Data.

Step-3: Use the “MAX” function to find out the maximum value, see the below picture to learn more

The Maximum value, we found from the above data set is 1406°C and similarly calculated the minimum value as per the below process as.

Found, the minimum value is 1400°C.

Range = (Maximum Value – Minimum Value)

=1406-1400=6°C

VARIANCE:

Excel-2007 function of Variance for population = VARP(data range)

The Variance of the above population data is 4.41, enter the same data in your excel sheet and calculate & check whether you are getting the same value or not.

Standard Deviation (σ):

Standard Deviation (σ)excel-2007 function=STDEVP(Data range)

(σ) The standard Deviation of the above data set is 2.1, check whether you found the same value in your excel sheet or not using the above data set.

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