Process Capability Analysis
Process Capability
• Used to assess the degree to which the output of a
process conforms to specifications
• Natural spread of a process is defined as 6 sigma
• Determined w.r.t Specification limits (LSL, USL)
Process Capability Index
A measure of the process capability which indicates
how the process is behaving relative to specifications.
However, it is a a valid measure only for in-control
processes.
Process Capability
(a) (b)
specification specification
natural variation natural variation
(c) (d)
specification specification
natural variation natural variation
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Process Capability Index (PCI)
Allowable process variability
PCI =
Actual process variability
Many U.S. companies use PCI = 1.33 as a minimum acceptable
target and PCI = 1.66 as a minimum target for strength, safety, or
critical characteristics.
However, Some companies require that internal processes and
those at suppliers achieve a PCI = 2.0.
A process with PCI = 2.0 is referred to as a six-sigma process
because the distance from the process mean to the nearest
specification is six standard deviations.
Specification Terminology
Allowable process variability
USL = the Upper Specification Limit,
and
LSL = the Lower Specification Limit.
Actual process variability
Process spread 6σ
where, σ is the process standard
deviation
Process Capability Index, Cp
Cp= USL - LSL
6σ
– Suppose the process shown is
• in statistical control (i.e., stable and common cause
variations only)
• process mean is at 2000
• process standard deviation (std. dev.)= 500
• USL = 2750, LSL = 1250, Target = 2000
•Cp = (2750 - 1250)/(6x 500) = 0.5
– How about process std. dev. = 250, Cp =?
– How about process std. dev. = 125, Cp =?
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Process Capability Index, Cp
Cp= USL - LSL
6σ
Cp < 1
8
Process Capability Index, Cp
Cp= USL - LSL
6σ
Cp = 1
Process Capability Index, Cp
Cp= USL - LSL
6σ
Cp > 2
Cp
Limitations of the Cp Index
• Does not take into account the value (location) of the
process mean (where process is centered).
• If the process mean is not located at the mid-point
between USL and LSL, then Cp has little meaning.
Cp is same for both the cases
µ µ
LSL Target USL
Process Capability Index, Cpk
USL – µ
Cpu =
3σ
µ- LSL
Cpl =
3σ
Cpk = min{ C pl, C pu }
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Comparison of Cp and Cpk In Off-Center Process
Example
Target = 50, LSL = 30, USL = 70
Process 1 : Avg = 40, std dev = 1.66
Process 2 : Avg = 60, std dev = 1.66
Determine Cp and Cpk
The Cpm Index
An improved capability ratio to measure process centering
is Cpm.
USL - LSL
Cpm =
6τ
where τ is the square root of expected squared deviation
from target:
τ 2 = E [ (x – T) 2 ] = σ 2 + ( µ - T) 2
T = ½ (USL+LSL)
USL − LSL
C pm =
6 σ 2 + (µ − T ) 2
More About Process Centering
To simplify calculations, Cpm can be rewritten another way
USL − µ
C pmu =
3 σ 2 + (µ − T ) 2
µ − LSL
C pml =
3 σ 2 + (µ − T ) 2
Cpmk = min { C pml, C pmu }
Estimating population standard deviation
Since population µ and σ are not known most of the time,
they must be estimated from data.
USL − LSL
cˆP =
6σˆ
Case 1 : Using sample standard deviation values
m
E(s) = s = ( ∑ s i ) / m σ = s / c4
i=1
Case 2 : Using sample range values
m
R=(∑
i=1
Ri)/m σ = R / d2
Relation between PCI and DPMO
DPMO
500000
400000
300000
DPMO
200000
100000
0
0 0.5 1 1.5 2 2.5
PCI
Relation between PCI and DPMO
DPMO DPMO
500000 3000
400000 2500
2000
300000
DPMO
DPMO
1500
200000
1000
100000 500
0 0
0 0.5 1 1.5 2 2.5 0 0.5 1 1.5 2 2.5
PCI PCI
Relation between PCI and DPMO
DPMO DPMO
500000 3000
400000 2500
2000
300000
DPMO
DPMO
1500
200000
1000
100000 500
0 0
0 0.5 1 1.5 2 2.5 0 0.5 1 1.5 2 2.5
PCI PCI
DPMO
8
7
6
5
DPMO
4
3
2
1
0
0 0.5 1 1.5 2 2.5
PCI
Relation between PCI and DPMO
DPMO DPMO
500000 3000
400000 2500
2000
300000
DPMO
DPMO
1500
200000
1000
100000 500
0 0
0 0.5 1 1.5 2 2.5 0 0.5 1 1.5 2 2.5
PCI PCI
DPMO Chart Title
8 0.4
7 0.35
6 0.3
5 0.25
DPMO
DPMO
4 0.2
3 0.15
2 0.1
1 0.05
0 0
0 0.5 1 1.5 2 2.5 1.6 1.7 1.8 1.9 2 2.1
PCI PCI
1.5 sigma shift in the process average
2700 PPM 66800 PPM
1.5 σ shift
-3σ +3 σ
LSL USL
A Six Sigma Process
Assuming a normally distributed process, the fallout of the
shifted process is 3.4 parts per million.
0.002 PPM 3.4 PPM
Non-Normality and the PCI
• A capability Index based on the distribution of the
process is given by
USL - LSL
Cp (d)=
X 0.99865 – X 0.00135
m + 3s m - 3s
• In the case of the normal distribution Cp(d) reduces to
Cp
