1st Edition

Six Sigma and Beyond Statistical Process Control, Volume IV

By D.H. Stamatis Copyright 2002
    520 Pages 211 B/W Illustrations
    by CRC Press

    In this volume of the Six Sigma and Beyond series, quality engineering expert D.H. Stamatis focuses on how Statistical Process Control (SPC) relates to Six Sigma. He emphasizes the "why we do" and "how to do" SPC in many different environments. The book provides readers with an overview of SPC in easy-to-follow, easy-to-understand terms. The author reviews and explains traditional SPC tools and how they relate to Six Sigma and goes on to cover the use of advanced techniques. In addition, he addresses issues that concern service SPC and short run processes, explores the issue of capability for both the short run and the long run, and discusses topics in measurement.


    Introduction
    What is statistical process control (SPC)?
    The need for improvement
    Overview
    How to effectively direct the SPC effort?
    What is ideal process control?
    How to pull it off
    Problem solving techniques
    Overview
    Team concept
    Tools and techniques
    Problem solving difficulties
    Selected bibliography
    Summarizing dada
    Overview
    Summarizing data
    Graphical presentation
    Selected bibliography
    Descriptive statistics
    Overview
    Measures of central tendencies
    Measures of dispersion
    Normal distribution
    Overview
    Characteristics of the normal distribution
    Standardized values(Z)
    Underlying distribution analysis
    Methods of testing for underlying distributions
    Process variation and control charts
    Overview
    Common variation
    Special variation
    Process control and process capability
    Parts of control chart
    Control chart goals
    The relationship of variation to mean to normal distribution and to control chart
    References
    Selected bibliography
    Preparing for control charts
    Overview
    The data orientation
    Sampling consideration
    The frequency of the sample
    Control charts - preliminary issues
    Overview of control chart development
    Control chart form
    References
    Selected bibliography
    Variable Charts
    Overview
    Xbar and R chart
    X and MR chart
    Xbar and s chart
    Control chart with slopping center line
    CuSum chart
    References
    Selected bibliography
    Attribute charts
    Overview
    p chart
    np chart
    c chart
    u chart
    The weighted number of defects (D) chart
    References
    Selected bibliography
    Other charts
    Overview
    Median chart
    Standardized charts for attribute data
    Difference control chart
    The lot plot method
    Modified control charts
    Tool wear and trend analysis
    Control charts based on weighted average
    Miscellaneous control charts
    Methods for controlling several related quality characteristics
    Statistical alternatives to control charts
    Evolutionary operation
    References
    Control chart signals
    Overview
    Common variation
    Special variation
    Out of control points
    The runs test
    Control charts and hypothesis testing
    Other out of control indications
    Statistical analysis of control conditions
    Statistical analysis of runs
    Statistical analysis of trends
    References
    Selected bibliography
    Capability
    Overview
    Capability analysis
    Process and machine capability
    Steps for studying process capability
    Interpreting capability results
    Capability indices
    Motorola's 6 sigma
    Comments on traditional and 6 sigma capability
    References
    Selected bibliography
    Short run SPC
    Overview
    Definition of short run
    Coded data
    Target values
    Sampling considerations
    Short run variable charts
    Short Run Attribute control charts
    Interpretation of short run charts
    Recalculating targets, not control limits
    Recalculating target values
    Measuring capability
    References
    Selected bibliography
    Distribution shape and stability
    Overview
    Capability analysis and non normal distribution
    Trending processes and control charts
    Trending processes and capability
    Selected bibliography
    Measurement system analysis
    Overview
    Measurement error vocabulary and concepts
    Basic measurement error analysis (MEA)
    Control charts measurement stability
    Measurement error analysis and advanced statistical methods
    Load the computer software
    References
    Selected bibliography
    Machine acceptance
    Overview
    Phase I: Preliminary investigating machine warm-up and supplier's previous studies
    Phase I example
    Phase II: Preliminary study investigating process stability and capability description
    Phase II example
    Phase III: Recommended yes/no acceptance. A study predicting long term capability
    Phase IIII example
    Final step
    Using the computer. A full description of how to use MINITAB and SPC with machine acceptance type data
    Typical Phase II computer session
    Selected bibliography
    SPC for non manufacturing
    Overview
    Criteria for success
    Reaction versus Planning
    Implementation strategy
    Tools
    Process improvement
    References
    Selected bibliography
    Appendix A: General Statistics
    How do you compute average
    Control limits for Xbar and Rcharts
    Control limits for p charts
    Common SPC formulae
    Formulae for calculating control chart limits
    Capability
    Control chart construction guide - variable data
    Control chart construction guide - attribute data
    Testing for normality and exponentiality
    Appendix B: Production Part Approval Process (PPAP)
    Appendix C: Deming's Management Principles
    Appendix D. Quality needs and overall strategic plan
    Appendix E. Statistical tables
    Appendix F. Forms
    Flow process chart
    Variable control chart form
    Attribute control chart form
    Control chart - process log sheet
    Data collection sheet for capability analysis
    Capability analysis sheet
    Capability analysis - normal distribution
    Capability analysis - skew distribution

    Biography

    D.H. Stamatis