INTRODUCTION TO CAPABILITY ANALYSIS

INTRODUCTION FOR INTRODUCTION TO CAPABILITY ANALYSIS

Introduction to capability analysis program basically introduces participants to process capability and stability concept and tools that is used in process control in manufacturing and process environment. The participants will be exposed to various capability analysis fundamental aspects and methodology used in process control. 

This overview course is designed to provide a broad understanding of various methods used in stability  and accessing process capability.

LEARNING OBJECTIVE

This program is designed to enable participants to learn process capability and stability fundamentals, and to use it in practical situations such as process control, understanding process capability and other possible applications. 

Here are the learning objectives for the two days training program; after completing this program, participants will be able to:

• Understand SPC and basic statistical concept related to process capability.
• Understanding different types of control chart and define control limits. 
• Understand the concept of process control and process capability. 
• To create control charts and compute process capability. 

WHO SHOULD  ATTEND

Process Engineers, R & D Engineers/Scientist, and other technical based individuals, working on process Improvement.

COURSE OUTLINE

UNDERSTANDING VARIATION 

1. Process and Product Flow 
2. Process Input and Output
3. Identifying type of variation
4. Source of variation

INTRODUCTION TO SPC/STABILITY CHART

1. What is Process Control? 
2. Why statistical Process Control? 
3.  SPC charts 
4. Objective of SPC chart. 
5. Use of SPC chart

DESCRIPTIVE STATISTICS IN PROCESS CONTROL 

1. Common descriptive statistics in Process Control
   
   1. Measure of Central Tendency
   2. Measure of Dispersion

CONTROL CHARTS 

1. Definition of a Control Chart 
2. Understanding control chart and control limits. 
3. Central Limit theorem.
4. Sampling Risk 
5. Reasoning Sampling risk in a process. 
6. ARL- Average Run Length 

CONTROL LIMITS

1. Control Limit Calculations. 
2. Control Limit vs Specification Limit. 
3. Setting up warning limits.

FUNDAMENTALS OF SPC CHART

1. Shewhart Control Charts Introduction.
2. Variable Control Charts.
3. Determining the sampling method.
4. Detecting drift sensitivity
5. Rational Subgroup 
6. General steps in SPC implementation

CREATING VARIABLE CONTROL CHART. 

1. Procedures to create control charts. 
2. Calculating control limits
3. Control Chart roadmap. 
   
   1. I-MR chart 
   2. X- Bar R chart 
   3. X- Bar S chart 

OUT OF CONTROL INDICATORS. 

1. Primary Indicators 
2. Secondary Indicators 
3. Western Electric Rules. 
4. Out of control test. 
5. Applying WE Rules in the process.

OUT OF CONTROL ACTION PLAN (OCAP) 

1. Creating OCAP 
2. Linking OOC with proper OCAP action. 

ATTRIBUTE CONTROL CHART 

1. Defective and Defect 
2. Control Chart 
   
   1. P chart and np chart
   2. U chart and C chart

INTERPRETING SPC CHART

1. Process capability and stability 
2. Variable charts and attribute charts

ACTIVITY:

1.  SPC chart creation using process simulation
2. Real experience and case study

VARIATION AND PROCESS CAPABILITY. 

1. 1. Process capability fundamentals
   2. Process capability and specification. 
   3. Types of Control Limit and Specification Limit.
   4. Process Capability vs Spec Limit. 
   5. Process Entitlement and process potential 
      
      1. Definition of process entitlement in process improvement. 
      2. Process Potential Indices Cp, Pp 
      3. Relating process potential with process improvement.
   6. Process capability. Cpk, Ppk 
   7. Process Potential vs Process Capability. 
   8. How much can I improve my process? 
   9. Improvement and limitation of current process capability. 

CAPABILITY ANALYSIS 

1. Process Stability. 
2. Within and overall capability.
3. Process Variation.
   
   1.  Variation within and Overall Capability 
   2. Quantifying variation 
      
      1. Z- score. 
      2. Z-score relationship with process capability.
4. Long term process capability six sigma definition.
5. Long term sigma estimation by six sigma definition. 

PROCESS CAPABILITY ANALYSIS WITH STATISTICA

1. Capability Analysis for Normal Data. 
2. Using Statistica to compute process capability for normal data. 
3. Understanding variation within and between subgroups. 
4. Calculating between and within subgroup capability. 
5. Choosing the right process capability measurement. 

PROCESS CAPABILITY ANALYSIS FOR DISCRETE DATA. 

1. Process capability for Reject Rate
2. Understanding Binomial Distribution. 
3. Using Binomial Distribution to compute reject rate process capability. 
4. Process Capability for Reject Rate. 
5. Understanding Poisson Distribution. 
6. Using Poisson Distribution to compute defect rate process capability. 

ACTIVITY 

1. Process capability calculation based on simulation activity

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