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Repeatability vs Reproducibility | Discussion of Key difference.

19/02/2024 by TECHIEQUALITY

What is the difference between Repeatability & Reproducibility?

Hello…Readers! Today here we will discuss the frequently used terms in an industry i.e. Repeatability vs Reproducibility. These two wards are more familiar with Measurement system analysis. So don’t waste your time and go through the below article and enhance your knowledge. If you are further looking for a similar type of article, then click on below links/ topic.

Reproducibility vs Repeatability :

Repeatability: Variation due to Gage.

As per the MSA Manual, The common cause, random variation resulting from successive trials under defined conditions of measurement. Often denoted to as equipment variation (EV), although this is misleading. The best term for repeatability is within-system variation when the conditions of measurement are fixed and defined the fixed part, instrument, standard, method, operator, environment, and assumptions. In addition to within equipment variation, repeatability will include all within variations from the conditions in the measurement error model.

It’s an Equipment variation.

Reproducibility: Variation due to Operators.

As per the MSA Manual, The variation in the average of measurements is caused by a normal condition(s) of change in the measurement process. Naturally, it has been defined as the variation in average measurements of the same part between different operators using the same measuring instrument & method in a stable environment. This is frequently true for manual instruments influenced by the skill of the operator. It is not true, however, for measurement processes (automated systems) where the operator is not a major source of variation. For this reason, reproducibility is mentioned as the average variation between systems or between conditions of measurement.

It’s a variation due to the operators, measuring the same part using the same measuring instrument and method in a stable environment.

Useful Articles:

5’S Concept | what are 5’S?

The Key difference between Corrective Action and Preventive Action.

Process Capability Analysis |Cp & Cpk Calculation Excel Sheet with Example.

How to calculate Cp and Cpk? |Practical Case Study | Process Capability Example

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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.

Verification vs Validation | What is difference between verification and validation?

19/02/2024 by TECHIEQUALITY

What is difference between verification and validation?

Hi readers! Today we will discuss an important topic i.e. What is difference between verification and validation.

Verification: Am I building the product right?

Evaluating the process and product in the developing stage.
It is performed to build a product in the right way.
The verification process generally comes first done before validation.
It is the process, to ensure whether we are manufacturing the product according to drawing/ Standard/ specification or not.
It is a low-level activity.
Example: Inspection, Document review, Checking, etc.

Example of Verification:

Let us say that you are producing the mobile case covers, and you are checking the dimension of 100% product at the molding section and ensuring that the product is manufactured according to the Drawing.

Validation: Am I building the right product?

A process of seeing whether the product satisfies the customers’ requirements or not.
It is performed to build the right product.
The validation process is generally followed after verification.
It is the process of validating whether the product which we have developed is right or not.
It is a high-level activity.
Example: In-process testing, final product testing.

Example of Validation:–

After verification of the Mobile case cover, now the Test Team member will do the appropriate test to validate such products that meet the customer needs like fitment, color testing, drop testing, etc.

I hope that the above example is useful to you and you understand well. And if are searching for a similar type of topic to enhance your knowledge then the below articles will help you to enrich and enlarge your ken.

Useful Articles:

5’S Concept | what are 5’S?

Kaizen vs Innovation, Differences between Kaizen and Innovation.

The Key difference between Corrective Action and Preventive Action.

Rework vs Repair |IATF Requirement for Control of Reworked/ Repaired Product.

Process Capability Analysis |Cp & Cpk Calculation Excel Sheet with Example.

How to calculate Cp and Cpk? |Practical Case Study | Process Capability Example

What is difference between verification and validation?

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5’S Concept | What are 5’S?

07/04/202619/02/2024 by TECHIEQUALITY

Hi readers! today we will discuss a popular and important topic that is widely used in the industry i.e. 5’S Concept

What is 5’S Concept

5’s are the techniques for organizing the work effectively and safely. It helps people to do their jobs without wasting time or injury. 5’S is the base pillar of TPM (Total productive maintenance) and TPS (Toyota Production System).

What are 5’S?

Five Japanese words	In English
1-S: Seiri	1-S: Sort
2-S: Seiton	2-S: Set in Order
3-S: Seiso	3-S: Shine
4-S: Seiketsu	4-S: Standardize
5-S: Shitsuke	5-S: Sustain

History:

The concept 5’S was initiated as part of the TPS [Toyota Production System] at the Toyota Motor Company in the early and mid-20th century. This system is often used in Lean manufacturing and TPM [Total Productive Maintenance].

Advantages of 5’S Concept:

Easy Accessing.
Better work environment.
Reduced costs
High quality
Increased productivity
A safer work environment

Illustration of 5’S:

1-S: Sort:

The first step of 5’S is the “Sort”, simply in this process, we have to remove the unwanted materials and to determine what needs to be present. If required for any situation to take the decision together with the lime manager at that situation we can use the Tag system (Red tag and yellow tag).

The below questions will help you to do the sorting in your work areas.

Q1: Does it really need to be here or not?

Q2: What is the tenacity of this item?

Q3: How often is it used?

Ask these questions during the sorting operation and make also a work layout.

2-S: Set in Order:

It means neatness. Always follow the golden rule of “Place for everything and everything in its place”

Follow the below steps to “set in order”:

Identify each and every item.
Lay down the Work layout of each workstation/zone.
Keep the items nearest to the point of use.
Ensure easy accessibility, and easy retrieval, Minimize the inventories.
Mark the gangway and foot stoppage on the shop floor for safe and easy movement of men and materials.

In this way, you can easily store the essential material in the appropriate location. You will get so many advantages after the effective implementation of 2-S as;

Improves workplace utilization.
Reduce the inventory level.
Create a safe work environment.
Helps reduce time consumed in searching for materials for use.

3-S: Shine:

Cleaning is not a job; it is a frame of mind.

In many places, cleaning is considered as a separate job. A workman feels that it is not his job to clean the machine. So to overcome their thinking, the culture has to come from top management to the bottom-most designation. First of all, we have to clean our table, and chairs without waiting for the sweeper or peon. We have to follow the three-step approach as Macro level, Individual Level, and Micro Level. During the 3-S operation, we can also put the tag, if we will find the Problems like electrical, mechanical, civil, etc. in the workplace.

4-S: Standardize:

The 4-S is the Standardization, this means ensuring whatever cleanliness and orderliness have been achieved through improvement in Sort, Set in Order, and Shine have to be standardized.

You can follow the below-mentioned methodology to achieve standardization:

Prepare a 5-S SOP or Manual.
Lay down the Work Layout of every work zone.
Standardize the cleaning kits.
Visual management.

5-S: Sustain:

This is the last step but not the least, it’s a Sustain.

Define the rules and responsibilities of each zone member and make them aware of the 5-S benefit. If some practices are not followed, analyze the root cause of failure. Carry out the 5-S audit on a periodic basis and appreciate the best zone.

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Rework vs Repair |IATF Requirement for Control of Reworked/ Repaired Product

13/02/2024 by TECHIEQUALITY

Rework vs Repair:

Hello Reader! Today we will discuss the Rework vs Repair of Parts and Control of Reworked/ Repaired Products.

If still, your process exists the Rework or Repair product, then what you need to do? What are the documents and records to be maintained? So don’t waste your time and read the below Article carefully.

Rework Definition:

ISO Definition: Action on a nonconforming product to make it conform to the requirements.”
NOTE Unlike rework, a repair can affect or change parts of the nonconforming product.

Explanation:

Fix the part to meet specifications.

To take action for correcting the defective or non-conforming parts to conforming parts that shall meet the specification/ requirement of the customer.

Example:

The Gearbox housing is rejected due to extra metal, which may probably cause the fouling issue. However the process engineer has taken action to remove the extra metal from the gearbox housing and finally, it meets as per the customer drawing. So here the “action taken by the process engineer” is the reworking process because by doing the temporary work/rework, it meets the customer’s requirement.

Repair Definition:

ISO Definition: Action on a nonconforming product to make it conform to the requirements.”
NOTE Unlike rework, a repair can affect or change parts of the nonconforming product.

Explanation:

Fix the part so it is usable, but does not meet the specification

To take action for correcting the defective or non-conforming parts to conforming parts, so that it is usable but it does not meet the specification/ requirement of the customer.

Example:

Fixing of a flat tire, fixing a leak in a tire by putting a plug in the tire, or a patch on the tire is called repairing the tire; it doesn’t look like it did when it was brand new. It means the product is ready for use but does not meet the specifications.

Control of Reworked Product: (As per IATF 16949):

What does the organization need to be maintained?

Ans.:- 1. The organization shall prepare the PFMEA w.r.t risks in the rework.

2. The unit shall obtain approval from the customer if required by the customer.

3. The unit shall lay down the rework procedure, control plan, or other relevant documents.

4. The organization shall maintain a record of reworked products/parts including quantity, disposition, date, and traceability information.

[Note: above four important requirements need to be established by the organization/unit if there is an existence of Rework product/ items.]

Control of Repaired Product: (As per IATF 16949):

What are the mandatory requirements that an organization needs to be maintained?

1. The organization shall prepare the PFMEA w.r.t risks in the repair.

2. The unit shall obtain approval from the customer.

3. The unit shall lay down the repair procedure, control plan, or other relevant documents.

4. The unit shall obtain documented customer authorization for a concession for the product to be repaired.

5. The organization shall maintain a record of repair products/parts including quantity, disposition, date, and traceability information.

The Basic difference between the controls of the reworked product and the Repaired product:

In the case of repaired products, the organization must have to obtain the approval and customer authorization for a concession from the customer

I hope the above article is useful to you. We have prudentially described the difference between the rework and repair product with examples.

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Corrective Action vs Preventive Action

13/02/2024 by TECHIEQUALITY

Corrective Action vs Preventive Action

Hi readers! Today we will discuss an important topic which is Corrective Action vs Preventive Action. The terms Corrective Action and Preventive Action are the most popular terminology in the manufacturing industry. But now in the new business system standard, the preventive action is expressed through the use of risk-based thinking. It means preventive action is replaced by Risk and opportunity. Here we will discuss the definition of Corrective action and preventive action with industrial examples.

CAPA Process/ CAPA Concept w.r.t ISO 9001 and IATF 16949.

CAPA Template/ Format

Corrective Action vs Preventive Action:

Correction: Action to eliminate the symptom of problems.

Corrective Action:

Action to eliminate the cause of non-conformity in order to prevent a recurrence.
Definition 2-Action to eliminate the Root cause of Problems.
Action taken in order to eliminate the root cause.

Preventive Action:

Action to eliminate the cause of potential nonconformities in order to prevent their occurrence.
Definition2.-Action to eliminate the potential cause of problems
Action taken in order to avoid root cause recurrence

Example1-

The XYZ Pvt Ltd Company manufactures Oil sump. But 2% of castings were rejected at the customer end due to shrinkage. So the purchasing department asked the supplier to submit the 8D report and CAPA Report. After getting the Customer Complaint. The Process Engineer of the Supplier started the Rejection investigation and finally prepared the CAPA Report;

Correction: Segregated the Casting and stopped the consignment of the same batch of products.

Corrective Action:

Problem- Shrinkage.

Why-why Shrinkage? Ans. Shrinkage was found at the In-gate of Casting so the process engineer thought that the wrong gating system may be a potential cause for in-gate shrinkage. And he started to recheck the in-gate system.

Why-why in-gate Shrinkage? Ans. The gating system was modified but validation was not done.

Why- Why gating system validation was not done?

Ans. – The production Manager has scheduled the same product for the Next day of modification without the validation of the tool.

Why- why validation is not done timely?

Ans. – There was no comprehensive Production planning.

Corrective Action: Comprehensive Production planning will be prepared considering with tools status.

Preventive Action: Tools Status will update periodically.

I hope this example is helpful to you to understand the difference between Corrective Action vs Preventive Action.

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Kaizen vs Innovation | Key Differences between Kaizen and Innovation

07/04/202613/02/2024 by TECHIEQUALITY

Kaizen vs Innovation | Key Differences between Kaizen and Innovation

Kaizen vs Innovation: Both kaizen and Innovation can be applied at every stage in Manufacturing. But in normal circumstances, these two are applied in two different stages.

In the aforesaid figure, its clearly indicates that the Innovation phase can be started from scientific development i.e. R&D, and leads to new technology and later to design in this order. But the Kaizen phase is giving more emphasis on Gemba Kaizen (Work Place Kaizen).

Diagrammatic Comparison Between Kaizen vs Innovation:

In the above Fig. 2, it clearly indicates that, if an organization starts both the innovation plus kaizen culture, then it will take very little time to achieve a high level of improvement in all aspects.

The organization has only innovation-oriented products that would cost more. Because the transformation of technology will cost high.

Only innovation-oriented organizations may often face the above situation (Decline) due to non-maintenance. So we have to sustain the new standard of innovation to prevent the declining situation.

Innovation without maintenance:

Key Differences Between Kaizen and Innovation:

KAIZEN:

Elements of Comparison	Kaizen
Approach	More often collective, team Effort, and System oriented.
Method	More often collective, Team Effort, and System oriented.
Idea Generation	Flow from experience and Knowledge.
Involvement	Through People
Maintenance Effort	Whether effort put into process improvement gives better results.
Impact	Long Term and Long Lasting.
Participation & Involvements	Everybody.
Evaluation	Whether effort put in process improvement gives better results.
Advantage	Very well suitable for a slow-growth economy.
Effect	Long term and continuous but undramatic
Speed	Small Steps
Timeframe	Continuous and Rising
Changes of success	Always on a high level.
Motto	Preservation & Improvement

INNOVATION:

Elements of Comparison	Innovation
Approach	An Aggressive individual likes efforts from an individual.
Method	Drastic Change of existing methods by discarding i.e. Creating a new process.
Idea Generation	New Investment, Technology Transformation, R&D.
Involvement	Investment in Equipment, Technology
Maintenance Effort	Through technology
Impact	Short -but dramatic change, yielding short-term gains.
Participation & Involvements	Select a few.
Evaluation	Whether Efforts put in results in profit.
Advantage	Fast-growing economic.
Effect	Short term but dramatic.
Speed	Big Steps
Timeframe	Interrupted and limited.
Changes of success	Unsettled
Motto	Reconstruction

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How to plot the Run Chart in Excel | Run Chart Excel Template:

10/02/2024 by TECHIEQUALITY

How to plot the Run Chart in Excel?

A run chart is also termed a Line Chart. You can use it on the shop floor to monitor the Process variation. In the run chart, you could able to set up the mean value, upper specification limit, lower specification limit, Median & mode. A Run chart will not be able to give an idea about the control limits. It represents the variation in summarizing data of Process, or Product characteristics. However, it can show you how the process is running. Today we will discuss on how to plot a run chart in Excel. Download the Run Chart Excel template from the below link.

Download Template.

Step by Step guide on How to plot Run Chart in Excel:

Step-1: Enter the reading in the Excel sheet.

Step-2: Calculate the Mean, Median, and Mode values in Excel

Step-3: Put the USL & LSL in an Excel sheet.

Step-4: Select the Excel data table and then follow the below step to select the line chart;

“Insert>>Line graph”

Illustration with Example:

Step-1:

We are going to plot the run chart of the Permeability Number of green sand. Hence we have observed the readings four times per day; these readings are given below;

Date	Permeability Number
xx/12/18	198
xx/12/18	199
xx/12/18	195
xx/12/18	198
pp/01/19	196
pp/01/19	198
pp/01/19	199
pp/01/19	197
ss/02/19	198
ss/02/19	197
ss/02/19	196
ss/02/19	198
pp/03/19	197
pp/03/19	195
pp/03/19	196
pp/03/19	200
nn/04/19	199
nn/04/19	200
nn/04/19	198
nn/04/19	200

Step-2:

Calculate the mean, median, and mode of observed value;

Mean: Use the Excel formula to calculate the average value automatically. Details are described in the below figure.

Median: Select the Excel Median formula to calculate the Median value automatically. For better understanding, kindly go through the highlighted portion of the below figure.

Mode: use the Excel formula to calculate the mode value for the details formula, kindly go through the below figure highlighted portion.

Step-3:

Put USL and LSL values in Excel, if you would like to draw the line in the run chart. So here specification of Permeability is 200±10. USL is 210 and LSL is 190.

Step-4: To draw the run chart, kindly follow the sequence from “1” to “4” as per the below figure.

Sequence-1: Select the data table.

Sequence-2: Select the “Insert” option in the Excel sheet.

Sequence-3: Select the “Run Chart/ Line Chart” in Excel sheet.

Step-5: Run Chart:

[Run Chart]

(Click-Here to learn about the interpretation of the Run Chart)

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How to plot the Run Chart in Minitab

10/02/2024 by TECHIEQUALITY

How to plot the Run Chart in Minitab

Hi Reader! Today we are going to learn how to plot a Run Chart in Minitab. A run chart is also a Line Chart. It is generally used on the shop floor to monitor the Process variation. In the run chart, you could able to set up the mean value, upper specification limit, lower specification limit, Median & mode. The Run chart will not be able to give an idea about the control limits. It represents the variation in summarizing data of Process, or Product characteristics. However, it can show you how the process is running. If you would like to download the Run Chart Excel template then click on the below link.

Download Quality Template.

Download Run Chart Excel Template.

Step by Step guide on How to plot Run Chart in Minitab:

Step-1: Open the Minitab Software and enter the Reading (Observed Value).

Step-2: Select the Run Chart from Minitab (Start>>Quality Tools>>Run Chart).

Step-3: Select the option “Subgroups across rows of”, next to click on “ok” to draw the Run Chart.

Illustration of Steps:

Step-1:

When you will open the Minitab software; the main screen will look like below. To execute the Minitab you have to enter the data in the input sheet. Please go through the below figure to understand better.

Step-2:

Select the Run Chart option in Minitab. Go to (Start>>Quality Tools>>Run Chart).

Step-3: After selecting the “Run Chart” option in Minitab, Such below type Dialog Box will appear on the screen. Next; you have to select the Option as “Subgroups across rows of” and then finally select the Column. Look into the below figure for a better understanding.

Run Chart: –

After following up the steps from Step-1 to step-3, The Run Chart will be ready to appear.

Interpretation of Result: A run chart will give you the approx. P-value of Clustering, Mixtures, Trends, and Oscillation. The Non-Random Variation is not available in the above Run Chart.

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**Run Chart Example | Interpretation of Result**

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How to calculate Cp and Cpk? | Practical Case Study | Process Capability Example

10/02/2024 by TECHIEQUALITY

How to calculate Cp and Cpk? | Process Capability Example

Hi readers! today we are going to discuss on Process Capability Example. The Process Capability (Cp) and Process Capability Index (Cpk) are very important tools to measure the process Capability of a Stable Process.

DOWNLOAD (Cp & Cpk Excel Template).

Process Capability Example is given below to understand better.

Process Capability (Cp):

Process Capability (Cp) is a statistical measurement of a process’s ability to produce parts within specified limits on a consistent basis
It gives us an idea of the width of the Bell curve.
The Process Capability for a stable process is typically defined as ((USL-LSL)/ (6 x Standard Deviation)).

Process Capability Index (Cpk):

It shows how closely a process is able to produce the output to its overall specifications.
More Value of Cpk means more process capable.
Cpk value <1 means the bell curve will be out of USL/LSL
Common Cpk vale=1,1.33,1.67 & 2
The Cpk value of a startup manufacturing organization is supposed to be 1.33.
The Process Capability Index for a stable process is typically defined as the minimum of CPU or CPL

Process Capability Example (Manufacturing Example):

The XYZ Pvt. Ltd, the organization manufactures oil sump. In their quality assurance plan, they have mentioned the Pouring Temperature (Process Parameter of the Melting Process) is a critical characteristic. So they have decided to monitor the Cp and Cpk trend.

The Specification of Pouring Temperature is 1400±10°C.

The Process Engineer has observed the Pouring Temperature and listed the same as below table;

Table (Readings):

Sl. No	SB1	SB2	SB3	SB4	SB5	RANGE
1	1403.0	1402.0	1402.0	1401.0	1401.0	2
2	1401.0	1401.0	1401.0	1400.0	1400.0	1
3	1402.0	1402.0	1402.0	1401.0	1401.0	1
4	1400.0	1400.0	1400.00	1399.00	1399.00	1
5	1402.0	1402.0	1401.0	1401.0	1400.0	2
6	1403.0	1403.0	1402.0	1402.0	1401.0	2
7	1400.0	1400.0	1399.0	1399.0	1398.0	2
8	1402.0	1402.0	1402.0	1401.0	1401.0	1
9	1401.0	1401.0	1400.0	1400.0	1399.0	2
10	1399.0	1399.0	1399.0	1398.0	1398.0	1
11	1400.0	1400.0	1400.0	1400.0	1399.0	1
12	1402.00	1402.00	1402.00	1401.0	1401.0	1
13	1402.0	1402.0	1402.0	1401.0	1401.0	1
14	1400.0	1400.0	1399.0	1399.0	1398.0	2
15	1400.0	1400.0	1400.0	1400.0	1399.0	1
16	1399.0	1399.0	1398.0	1398.0	1397.0	2
17	1401.0	1401.0	1401.0	1400.0	1400.0	1
18	1402.0	1402.0	1401.0	1401.0	1400.0	2
19	1400.0	1400.0	1400.0	1399.0	1399.0	1
20	1401.0	1401.0	1400.0	1400.0	1399.0	2

Range=Maximum Value-Minimum Value

Average of Range=1.45

Value of d2=2.326 (For Subgroup size 5)

USL = 1410°C, LSL = 1390°C.

Standard Deviation:

= Average of Range/d2

1.45/2.326

=0.623

Process Capability (Cp Formula):

= ((USL-LSL)/ (6 x Standard Deviation))

= (1410-1390)/ (6 x 0.623)

20/3.738

= 5.351

Process Capability Index (Cpk Formula):

CPU:

= ((USL-Average of Mean)/3 x Standard Deviation)

= (1410-1400.42)/ (3 x 0.623)

9.58/ 1.869

= 5.12

CPL:

= ((Average of Mean-LSL)/3 x Standard Deviation)

= (1400.42-1390)/ 1.869

10.42

=5.58

Cpk= 5.12 (minimum of CPU or CPL).

Process Capability Analysis | Cp & Cpk Calculation Excel Sheet with Example

07/04/202610/02/2024 by TECHIEQUALITY

Process Capability Analysis | Cp & Cpk Calculation Excel Sheet with Example

Process Capability Analysis: – The Process Capability (Cp) and Process Capability Index (Cpk) are the important tools, which give an Idea about the Process Capability of a Stable Process. Here we will discuss on Calculation of Cp and Cpk with Examples. We are offering here Process Capability Excel Template / Format for you, hence click on the below links to Download the Excel Format.

DOWNLOAD (Cp & Cpk Excel Template / Format-Sample copy)

Process Capability (Cp):

Process Capability (Cp) is a statistical measurement of a process’s ability to produce parts within specified limits on a consistent basis
It gives us an idea about the width of the Bell curve.
The Process Capability for a stable process is typically defined as ((USL-LSL)/ (6 x Standard Deviation)).

Cpk-Process Capability Index :

It shows how closely a process is able to produce the output to its overall specifications.
More Value of Cpk means more process capable.
The Process Capability Index for a stable process is typically defined as the minimum of CPU or CPL.

Process Capability Analysis:

Industrial Example:

As per the Quality Assurance Plan, The shift engineers of Core Shop have started collecting the readings of the scratch hardness of Core. Given below are the details of Product Characteristics;

Specification of Scratch hardness is 70±10.

The Upper Specification Limit is 80.

The Lower Specification Limit is 60.

Tolerance is 20.

Scratch hardness readings Table:

Table-1

Sl.No.	1	2	3	4	5	6	7	8	9	10
SG 1	72.00	71.00	72.00	71.00	72.00	71.00	73.00	71.00	72.00	73.00
SG2	71.00	72.00	72.00	72.00	72.00	72.00	72.00	73.00	73.00	71.00
SG 3	72.00	72.00	71.00	71.00	71.00	73.00	72.00	72.00	71.00	73.00
SG4	70.00	70.00	70.00	70.00	71.00	70.00	71.00	70.00	71.00	70.00
SG 5	72.00	72.00	72.00	72.00	72.00	72.00	72.00	71.00	72.00	71.00

Table-1 [Scratch hardness readings Table]

Table-2

Sl.No.	11	12	13	14	15	16	17	18	19	20
SG1	71.00	72.00	71.00	71.00	72.00	73.00	71.00	72.00	73.00	71.00
SG2	72.00	73.00	73.00	72.00	71.00	72.00	71.00	73.00	71.00	70.00
SG3	72.00	71.00	73.00	72.00	72.00	72.00	71.00	71.00	71.00	70.00
SG4	71.00	70.00	71.00	70.00	70.00	71.00	70.00	71.00	71.00	70.00
SG5	70.00	70.00	71.00	71.00	72.00	71.00	72.00	71.00	71.00	72.00

Table-2 [Scratch hardness readings Table]

In the above two tables (Table-1 &2), we have taken the 100 readings i.e. (20 times X 5 readings at a time).

Range=Maximum Value-Minimum Value

Average of Range=2.15

Value of d2=2.326 (For Subgroup size 5)

USL = 80, LSL = 60.

Standard Deviation:

= Average of Range/d2

2.15/2.326

=0.92

Process Capability (Cp):

= ((USL-LSL)/ (6 x Standard Deviation))

(80-60)/ (6 x 0.92)

20/5.52

= 3.61

Process Capability Index (Cpk):

CPU:

= ((USL-Average of Mean)/3 x Standard Deviation)

(80-71.43)/ (3 x 0.92)

8.57/ 2.76

= 3.10

CPL:

= ((Average of Mean-LSL)/3 x Standard Deviation)

(71.43-60)/ 2.76

10.4211.43/2.76

=4.14

Cpk= 3.10 (minimum of CPU or CPL).

After doing the Process Capability Analysis on Scratch hardness readings, we got the below result value:

Characteristics: Scratch Hardness

Cp (Process Capability) = 3.61

Cpk (Process Capability Index) = 3.10

[ Cp & CpK ]

Process Capability Analysis with Manufacturing Example

The process engineer has collected the 100 nos laddle temperature reading and the same is mentioned in the below table.

Laddle Temperature Specification= 600 ± 15°C

USL = 615

LSL = 585

Table-1

	1	2	3	4	5	6	7	8	9	10
S1	605	599	610	605	603	604	600	609	605	601
S2	603	601	612	599	601	598	603	610	603	598
S3	604	598	609	610	612	609	605	612	604	603
S4	600	603	605	598	599	610	598	609	600	610
S5	602	602	607	609	605	612	599	605	609	603
Max.	605	603	612	610	612	612	605	612	609	610
Min.	600	598	605	598	599	598	598	605	600	598
Range	5	5	7	12	13	14	7	7	9	12
Average of Range	9.85
Mean	602.8	600.6	608.6	604.2	604	606.6	601	609	604.2	603
Average of Mean	603.92

Table-2

	11	12	13	14	15	16	17	18	19	20
S1	599	601	602	604	598	598	609	598	600	598
S2	610	598	602	603	603	603	605	603	603	610
S3	598	603	607	598	610	607	612	607	605	598
S4	609	610	609	603	603	598	604	598	607	602
S5	600	603	605	607	598	610	603	610	598	603
Max.	610	610	609	607	610	610	612	610	607	610
Min.	598	598	602	598	598	598	603	598	598	598
Range	12	12	7	9	12	12	9	12	9	12
Mean	603.2	603	605	603	602.4	603.2	606.6	603.2	602.6	602.2

d2=2.326

Standard Deviation = Average of Range / d2 = 4.23

Cp = (USL-LSL)/6*Standard Deviation = 1.2

CPU = ((USL-Average of Mean)/3 x Standard Deviation) = 0.872

CPL = ((Average of Mean-LSL)/3 x Standard Deviation) = 1.489

CpK = 0.872(minimum of CPU or CPL).

Note: Download the Cp & Cpk excel template or format and deploy it in manufacturing process. downloading links are provided at top of this Article.

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FAQ:

What is the difference between Cp & Cpk?

Ans.: Cp & CpK are termed as process capability and process capability index. In both cases, we would like to verify whether the process can meet the customer’s requirements or not. Generally, it is used when the process is under stable & statically control.

What is the formula of Cp & Cpk?

Cp= ((USL-LSL)/ (6 x Standard Deviation)) , where USL=Upper Specification Limit & LSL=Lower Specification Limit.

Cpk= Minimum of CPU or CPL, where CPU= ((USL-Average of Mean)/3 x Standard Deviation) & CPL= ((Average of Mean-LSL)/3 x Standard Deviation)

What are the good values of Cpk?

Generally, the customers provide the Cpk value to their supplier to maintain it in their manufacturing process. but for your knowledge, a Cpk value of 2 or greater than 2 is an excellent one.

What is cpk?

The cpk is the process capability index which shows how closely a process is able to produce the output to its overall specifications.

What is the IATF 16949 requirement of Statistical Concepts or SPC?

Application of statistical concepts in the IATF 16949 standard has been mentioned in Clause no-9.1.1.3, both Control chart (variable and Attribute) and process capability are the mandatory requirements. The application of statistical concepts shall be understood and used by the employees involved. We have published a separate article on Control Charts for our readers and you can Download Control Chart Excel Template / Format.