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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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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.

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.

Related Post:

**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.

How to do Capability Analysis by Minitab 18? | Minitab Process Capability Tutorial

09/02/2024 by TECHIEQUALITY

Minitab Process Capability Free Tutorial |Capability Analysis by Minitab:

Hello! Readers, today we will guide you to learn a new topic as “how to do the Capability Analysis by Minitab18?” as you know that how process capability (Cp, Cpk) is important to know the Process consistency or Stability. To delight and enhance the customer requirement and to get the defect-free product, all critical process’s characteristics capability analysis is supposed to Monitor. Download the Minitab Process Capability free tutorial from below link.

Download Minitab Process Capability Tutorial.

The Customer has generally mentioned the value of Process capability and its index in CSR (Customer Specific requirement or Voice of Customer or Critical to Quality). Even after, Supplier can set their own level of Process capability index value considering with CSR and other requirements. Basically, startup company are set up the value as 1.33 at the initial stage and then to further improvement to 1.67, next 2 and onwards.

Minitab Process Capability Tutorial (Step by Step guide):

Step-1:

When you will open the Minitab 18, the main screen will appear like below.

Step-2:

let’s get started with an Example, A sheet metal manufacturing company was producing Brake pad. The length of the Brake pad was 150±1mm. After stabilizing the process at “Blanking operation”, Process QC Engineer starts to analysis the Process capability and calculates the Cp & Cpk by using Minitab-18.

We would like to help my all readers to know on How to do Capability Analysis by Minitab 18?

We are having 100 numbers of data readings w.r.t below specifications as;

Subgroup Size=5, Brake pad Length=150±1mm (LSL=149, µ=150, USL=151).

Date	Observations
12.03.2019	149.9
12.03.2019	149.3
12.03.2019	149.5
12.03.2019	149.8
12.03.2019	149.9
12.03.2019	149.8
12.03.2019	149.8
12.03.2019	149.8
12.03.2019	149.7
12.03.2019	150
12.03.2019	150.1

……

13.03.2019	149.5
13.03.2019	149.5
13.03.2019	149.8
13.03.2019	150.4
13.03.2019	150.4
13.03.2019	150.3
13.03.2019	150.4
13.03.2019	150.3
13.03.2019	150.3
13.03.2019	150.2

Now, you have to enter all readings in Minitab’s sheet.

Step-3:

Next, you have to select the capability analysis option from Minitab’s Icon. Just follow the serial number sequence from 1 to 4 as shown in the below fire for selecting the capability analysis option.

[Start>>Quality Tools>>Capability Analysis>>Normal].

Step-4:

After, selecting the Capability Analysis option, a Dialog Box will appear on the screen just like below. Now, you have to set up some value in a dialog box, just go through the below figure to understand better, here we have already filled up the value w.r.t Brake pad’s specs. (Length=150±1mm, subgroup size=5). Finally, after set-up the value you are expected to click on the “ok” option in the dialog box.

Step-5:

Finally, after selecting the “ok” option in the dialog box, your Process Capability value and the graph will be ready, just like below;

Process capability Report:

Process capability (within), Cp: 1.97

Cpk, Process capability index (within): 1.97

Process Performance (overall), Pp: 1.20

Ppk, Process performance index (overall): 1.20

You could also like to learn about:

How to Create Control Chart by Minitab-18?

What is SPC?

CAPA Process.

OEE Calculation.

Root Cause Analysis Methodology.

[If you would like to download the several quality Templates, then go to the Download section in below.]

Useful Links:

Control Chart in Minitab — **Create Control Chart by Minitab-18**

How to plot Histogram in Excel — **How to Create histogram in excel**

Corrective and Preventive Action Format — **CAPA Format**

Thank you for reading…………. Keep visiting Techiequality.Com

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Run Chart Example | Concept & Interpretation of Result with Case Study | Industrial Example:

05/10/202409/02/2024 by TECHIEQUALITY

Run Chart Example | Concept & Interpretation of Result with Case Study | Industrial Example:

Hi readers! today we are going to discuss on Run Chart Example. A run chart is also called a Line graph. It’s a live Chart that 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, and lower specification limit. 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.

Download the Run Chart Example Template in Excel.

Interpretation of Result with Case Study:

Interp.-1: Six or more consecutive points fall above or below the centre line (Median Line).

Interp.-2: Five or more successive points are going up or down.

Interp.-3: Too many or too few runs.

Interp.-4: An astronomical data point.

If any, one of the above interpretations has been identified in the run chart, it means variation (non-random variation) present in the process’s characteristics.

Industrial Practical Example of Run Chart (Run Chart Example):

We are going to take an example from the Iron manufacturing industry. Such a company is produced as an automobile part with the following specifications.

Pouring Temperature =1400°C±20°C.

The company has decided to maintain the variation trend of Pouring temperature. They have implemented a run chart on the shop floor to monitor and measure the variation of pouring temperature w.r.t time period. The process engineer promptly started to measure the temperature readings four times a day (three working shifts) for five days. Below are the readings for your reference as;

Temperature Reading Table:

Date	Observed Value
xx/yy/19	1397
xx/yy/19	1398
xx/yy/19	1401
xx/yy/19	1405
pp/qq/19	1407
pp/qq/19	1400
pp/qq/19	1398
pp/qq/19	1405
ss/gg/19	1398
ss/gg/19	1405
ss/gg/19	1398
ss/gg/19	1401
pp/ss/19	1425
pp/ss/19	1399
pp/ss/19	1402
pp/ss/19	1398
nn/gg/19	1403
nn/gg/19	1400
nn/gg/19	1398
nn/gg/19	1407

Now, we are supposed to calculate the mean, median, and mode values to plot the run chart.

Date	Observed Value	USL	LSL	Mean	Median	Mode
xx/yy/19	1397	1420	1380	1402.25	1400.5	1398
xx/yy/19	1398	1420	1380	1402.25	1400.5	1398
xx/yy/19	1401	1420	1380	1402.25	1400.5	1398
xx/yy/19	1405	1420	1380	1402.25	1400.5	1398
pp/qq/19	1407	1420	1380	1402.25	1400.5	1398
pp/qq/19	1400	1420	1380	1402.25	1400.5	1398
pp/qq/19	1398	1420	1380	1402.25	1400.5	1398
pp/qq/19	1405	1420	1380	1402.25	1400.5	1398
ss/gg/19	1398	1420	1380	1402.25	1400.5	1398
ss/gg/19	1405	1420	1380	1402.25	1400.5	1398
ss/gg/19	1398	1420	1380	1402.25	1400.5	1398
ss/gg/19	1401	1420	1380	1402.25	1400.5	1398
pp/ss/19	1425	1420	1380	1402.25	1400.5	1398
pp/ss/19	1399	1420	1380	1402.25	1400.5	1398
pp/ss/19	1402	1420	1380	1402.25	1400.5	1398
pp/ss/19	1398	1420	1380	1402.25	1400.5	1398
nn/gg/19	1403	1420	1380	1402.25	1400.5	1398
nn/gg/19	1400	1420	1380	1402.25	1400.5	1398
nn/gg/19	1398	1420	1380	1402.25	1400.5	1398
nn/gg/19	1407	1420	1380	1402.25	1400.5	1398

By using the aforesaid data table, we have plotted a run chart/line chart with the help of Excel. But you can also plot the run chart by Minitab such a process we will discuss later in separate articles.

[Run Chart Plot by Excel]

Interpretation of the above run chart:

Before, we discuss the result of the above run chart. I would like to request you kindly go through the above chart prudently.

In the above chart, one reading (red highlighted point) suddenly goes up and the chart represents an astronomical data point interpretation. It means there is the existence of variation in the process and it is a non-random variation. In such a way you can plot the run chart to know how the process is running and according you could able to act on it.

Useful Links: (Download Template)

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Risk Register | Download Risk Register Template:

05/10/202406/02/2024 by TECHIEQUALITY

Download Risk Register Template:

Hi Reader! Today we are going to discuss an important topic, which is called Risk-based thinking and Risk management. The organization uses different types of tools to identify the Risks but here, we will be discussing one of the popular tools, i.e. Risk Register. As we know most probably business standards like QMS, EMS, OH&SMS, etc. are now risk-based thinking approaches. So we will only concentrate on learning how to use the Risk register with Examples.

DOWNLOAD–the Risk Identification Template in Excel.

DOWNLOAD–the Risk Record Template in Word.

Risk Identification Template in Pdf.–DOWNLOAD

If you are interested to know about Risk Management, then Click here.

How to Use Risk Register Template:

Step-1: Download the Above Template by simply clicking on the Download link.

Step-2: Read carefully the terminology.

Step-3: The severity Table is given in the Excel Template in a Separate Sheet, So don’t forget to download the Excel Template.

Step-4: Read carefully the sample example written in red colour in Template.

Example: Before I describe the Template, Please go through the below figure.

Terminology:

[1] Risk No.: Unique identification of each and every identified risk.

[2] Risk: Details about the Risk.

[3] Mitigating Action: Action to eliminate the Impact of Risk.

[4] Contingent Action: Action to eliminate the re-occurrence of Risk.

Here, in the above Figure, I have taken an Example of Customer complaints. So let’s get started with details about the above complaint.

High Line rejection at the Customer end was the Risk which has the score value 6 and severity is coming under the High Level. The criteria of probability and impact depend upon the organization’s decision. For a sample basis, I have taken the severity ranking according to the below data;

A Mitigation plan has taken w.r.t the Root Cause Analysis, so here Increasing the core curing time was the corrective action and contingent action is the Preventive action. Which is “Core curing time is being maintained shift-wise”.

FAQ:

Q1: Where can we use this template?

A1: You can use this template in Project management, Risk Management, to identify the QMS, EMS OHSAS, and Business-related risks.

Q2: Who will decide the Criteria of Probability, Impact, and Severity?

A2: The organization itself will decide the criteria as to what it would be.

Download Free Templates/Format:

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