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Chapter 5. Methods and Philosophy of Statistical Process Control

This document discusses statistical process control (SPC) tools and methods. It explains that control charts contain a center line, upper control limit, and lower control limit to determine if a process is in or out of statistical control. Control charts can be used to monitor both continuous variables and discrete attributes. The document also discusses rational subgroups, patterns that indicate non-random variation, rules for determining when a process is out of control, and Phase I and Phase II applications of control charts.

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50 views36 pages

Chapter 5. Methods and Philosophy of Statistical Process Control

This document discusses statistical process control (SPC) tools and methods. It explains that control charts contain a center line, upper control limit, and lower control limit to determine if a process is in or out of statistical control. Control charts can be used to monitor both continuous variables and discrete attributes. The document also discusses rational subgroups, patterns that indicate non-random variation, rules for determining when a process is out of control, and Phase I and Phase II applications of control charts.

Uploaded by

BouslaDI Projects Team
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Chapter 5.

Methods and Philosophy of


Statistical Process Control
Basic SPC Tools
• In statistical control: a process operating with only chance
causes of variation
• Out of control: a process operating in the presence of
assignable causes
• A control chart contains
– A center line
– An upper control limit
– A lower control limit
• A point that plots within the
control limits indicates the
process is in control
• A point that plots outside
the control limits is
evidence that the process is
out of control
• There is a close connection
between control charts and
hypothesis testing
Photolithography Example
• Important quality
characteristic in hard bake
is resist flow width
• Process is monitored by
average flow width
– Sample of 5 wafers
– Process mean is 1.5 microns
– Process standard deviation
is 0.15 microns
• Note that all plotted points
fall inside the control limits
– Process is considered to be
in statistical control
Shewhart Control Chart Model
w: sample variable
μw: mean of w
δw: standard deviation of w
L: distance in terms of δw
Improving Quality
Out of
range (R) chart
Control
Action
x -chart
Plan
(OCAP)
More Basic Principles
• Charts may be used to estimate process
parameters, which are used to determine capability
• Two general types of control charts
– Variables (Chapter 5)
• Continuous scale of measurement
• Quality characteristic described by central tendency and a
measure of variability
– Attributes (Chapter 6)
• Conforming/nonconforming
• Counts
• Control chart design encompasses selection of
sample size, control limits, and sampling frequency
Types of Process Variability
• Stationary and uncorrelated  data vary around a fixed mean in a
stable or predictable manner
• Stationary and autocorrelated  successive observations are
dependent with tendency to move in long runs on either side of
mean
• Nonstationary  process drifts without any sense of a stable or
fixed mean
Reasons for Popularity
of Control Charts
1. Control charts are a proven technique for
improving productivity.
2. Control charts are effective in defect
prevention.
3. Control charts prevent unnecessary process
adjustment.
4. Control charts provide diagnostic information.
5. Control charts provide information about
process capability.
• 3-Sigma Control Limits
– Probability of type I error is 0.0027
• Probability Limits
– Type I error probability is chosen directly
– For example, 0.001 gives 3.09-sigma control limits
• Warning Limits
– Typically selected as 2-sigma limits
Sample Size and Sampling Frequency

Average Run Length (ARL): Average number of


points plotted before a point indicates an out of
control condition
p: probability any point exceeds control limits

Average time to signal (ATS)


h: in hours
Rational Subgroups
• Rational subgroup: subgroups or samples should be
selected so that if assignable causes are present,
chance for differences between subgroups will be
maximized, while chance for difference due to
assignable causes within a subgroup will be minimized.

• Two general approaches


1. Sample produced at the same time  consecutive units
2. Sample representing all units produced since last sample
– Often used to make decisions about acceptance of product
– Effective at detecting shifts to out-of-control state and back into in-
control state between samples
– Care must be taken because we can often make any process
appear to be in statistical control just by stretching out the interval
between observations in the sample.
Analysis of Patterns on Control Charts

• Pattern is very nonrandom in appearance


• 19 of 25 points plot below the center line, while only 6 plot above
• Following 4th point, 5 points in a row increase in magnitude, a run
up
• There is also an unusually long run down beginning with 18th point
Western Electric Rule for Out of Control
Additional Rules (Sensitizing Rules)
Assume k decision rules.
αi = probability of type I error under rule i

α = overall type I error probability when k


decision rules are independent.
Phase I and Phase II of Control Chart Application

• Phase I: Retrospective analysis of process data


to construct trial control limits
– Effective at detecting large, sustained shifts in
process parameters, outliers, measurement errors,
data entry errors, etc.
– Facilitates identification and removal of assignable
causes
• In phase II: Process monitoring
– Process assumed to be reasonably stable
– Emphasis on process monitoring, not on bringing an
unruly process into control
THE “MAGNIFICENT SEVEN”

1. Histogram or stem-and-leaf plot


2. Check sheet
3. Pareto chart
4. Cause-and-effect diagram
5. Defect concentration diagram
6. Scatter diagram
7. Control chart
Check
Sheet
Pareto
Chart
Cause-and-Effect Diagram
causes

effects
Defect Concentration Diagram
Scatter Diagram
Implementing SPC
Nonmanufacturing Application of SPC

• Nonmanufacturing applications do not differ


substantially from industrial applications, but
sometimes require ingenuity
1. Most nonmanufacturing operations do not have a
natural measurement system
2. The observability of the process may be fairly low
• Flow charts and operation process charts are
particularly useful in developing process
definition and process understanding.
– Used to identify value-added versus nonvalue-
added activity

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