Innovative Control Charting

Douglas C. Fair, Stephen A. Wise

Description

Designed for the quality professional with a basic understanding of traditional SPC, this book presents solutions for the problems encountered when trying to apply traditional control charting techniques in a complex manufacturing environment.
Anyone using SPC who has felt limited by its traditional methods will find this book timely and beneficial. Along with basic SPC topics such as, control chart theories, process capability studies, data collection strategies, and sampling, this book concentrates on describing tools which solve the limitations of traditional SPC techniques. Specifically designed for those who face the challenges of limited data collection opportunities, small production runs, multiple characteristics, and demanding manufacturing situations, Innovative Control Charting will become a favorite, modern SPC reference.
Benefits:
Discover how SPC can be effectively applied even with complex parts, numerous part dimensions, similar but different characteristics, and small lot sizes.
Learn how to overcome the three main limitations of traditional SPC techniques.
Explore new SPC techniques in a step-by-step analysis approach using real-life examples.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Sciences & Techniques
• Statistiques
• Statistiques
• Probabilités et statistiques
• Quality Control
• Sciences et techniques
• Quality control (disambiguation)
• Statistical process control
• Manufacturing
• Statistics
• Probability
• Measurement
• Mathematics
• Leadership
• Maîtrise statistique des procédés

Informations

• Publié par: ASQ Quality Press
• Date de parution: 30 juin 2006
• Nombre de lectures: 0
• EAN13: 9781636940809
• Langue: English
• Poids de l'ouvrage: 4 Mo

Extrait

CONTROL
CHARTING
Practical SPC Solutions
for Today's Manufacturing
Environment
Stephen A. Wise
Douglas C. Fair Innovative
Control Charting Also available from ASQ Quality Press
Glossary and Tables for Statistical Quality Control, Third Edition
ASQC Statistics Division
Statistical Process Control Methods for Long and Short Runs,
Second Edition
Gary K. Griffith
SPC Essentials and Productivity Improvement: A Manufacturing Approach
William A. Levinson and Frank Tumbclty
Managing the Metrology System, Second Edition
C. Robert Pennella
Practical Product Assurance Management
John Bicda
To request a compli1nentary catalog of publications, call 800-248-1946. Innovative
Control Charting
Practical SPC Solutions for Today's
Manufacturing Environment
Stephen A. Wise
Douglas C. Fair
ASQ Quality Press
Milwaukee, Wisconsin Innovative Control Charting
Practical SPC Solutions.for Today's Manufacturing Environment
Stephen A. Wise and Douglas C. Fair
Library of Congress Cataloging-in-Publication Data
Wise, Stephen A.,
1960Jnnovative control charting: pnictical SPC solutions for today's
manufcturing environment/ Stephen A. Wise, Douglas C. Pair.
cm.p.
Includes bibliographical references and index.
ISBN 0-87389-385-9 (alk. paper)
l. Process control-Statistical methods. 2. Production
management. 3. Charts, diagrams, ere. I. Fair, Douglas C.,
1964II. Title.
TS156.8.\.58 1997
658.5'62'015195-dc21 97- 21281
CIP
©1998 by ASQ
All rights reserved. No part of this book may be reproduced in any form or by any means,
electronic, mechanical, photocopying, recording, or ot herwise, without the rior written p
permission of the publisher.
Trademark Acknowledg1nent
Trademarks owned by International Qualit Institute, Inc. Used with permission.
10 9 8 7 6 5 4
ISBN 0-87389-385-9
Acqui,itions Editor: Roger Holloway
Project Editor: Jeanne W. Bohn
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E-mail: [e-mail] To my darling wife, Joanna, and
action-packed daughter, Aubrey Sue.
Steve Wise
To the memory of my very special mother and friend,
Shirley Chism Fair.
Doug Fair Contents
IX Preface
XI Acknowledgments
1 1. Introduction
7 2. SPC Basics
15 3. Control Chart Overview
27 4. Process Capability and Performance Studies
39 5. Data Collection Strategics
49 6. Selecting the Right Chart
55 7. Traditional Control Charts for Single Characteristics
65 8. Individual X and Moving Range Chart
75 9. X and Range Chart
83 IO. X ands Chart
11. Control Charts for Similar Characteristics­
91 The Target Charts
97 12. Individual X and Moving Range Chart
107 13. Target X and Range'" Chart
115 14. X ands Chart
vii v111 Contents
15. Control Charts for Small Lot Production Runs­
The Short Run Charts 125
16. Run Individual X and Moving Range Chart 145
17. Short Run X and Range"' Chart 153
18. Run X and s Chart 163
19. Charts for Multiple Characteristics-The Group Charts 175
20. Group Individual X and Moving Range Chart 183
21 . X and Range Chart 191
22. Group X ands Chart 199
23. Charts for Multiple Characteristics with
Different Targets-The Group Target Charts 207
24. Group Target Individual X and Moving Range Chart 209
25. X and Range Chart 219
26. Group Target X ands Chart 229
27. Charts for Short Runs and Multiple Characteristics­
The Group Run Charts 239
28. Short Run Individual X and Moving Range Chart 241
29. Group Run X and Range"' Chart 253
30. Short Run X and s Chart 263
31. Conclusion 273
Appendix: Factors for Variables Data Control Charts 275
Bibliography 281
Index 283 Preface
"It's a great idea in theory, but n1y process is different. SPC just
won't work in my situation." Again and again, this was the response
fro1n Boeing Company engineers, managers, and machine operators.
As degreed statisticians, it was frustrating for us to learn that, in many
cases, they ,vere right. Fresh out of college and idealistic about ap­
plying statistical process control (SPC), we visited shop floors and
found, to our dismay, that the Boeing manufacturing operations were
the equivalent of an enorn1ous, complex job shop.
Huge numbers of different parts, configurations, and jobs seemed
to co1ne across each manufacturing area. Repeat jobs seemed to never
come back to the same machine. Machining centers or processes that
continuously manufactured a single product or part number were
rare indeed. In other words, it was difficult to find an area where
traditional control charts could be used to benefit those who would
be using them. Briefly, we thought that maybe the Boeing employees
were right. Maybe their situations were too different. In the begin­
ning, it seemed so.
But as we searched for alternative SPC methods, we uncovered
many different techniques that could allow us to apply control charts
in Boeing's job shop atn1osphere. However, our approach to apply­
ing SPC would have to be creative and flexible. Above all else, the
control charts would have to be useful to the manufacturing man­
agers, engineers, operators, statisticians, and quality assurance profes­
sionals who would be using SPC on a daily basis.
ix x Preface
In keeping with our early work at Boeing, this book has been
specifically written for the SPC users just identified. Our primary au­
dience is those people who have the daunting task of understanding
and implementing SPC in today's complex manufacturing situations.
The purpose of this book is to provide solutions for using control
charts in almost any manufacturing process. This book is intended
for people who face the challenges of small production runs, multiple
characteristics, limited data collection opportunities, sophisticated cus­
tomers, and demanding manufacturing situations.
Even though this was our primary focus, Innovative Control Chart­
ing has also been written for those who need to apply SPC in tradi­
tional, long production run environments as well. Also, those people
who have had no exposure to SPC should find this to be a useful
text. For the uninitiated, we have concentrated on making the word­
ing clear, concise, and easily understandable. So you need not have
a degree in statistics to understand the information contained \Vithin.
For those unfamiliar with SPC, the first few chapters deal with the
essentials. Chapters 2 through 10 cover the basics of SPC, control
chart theories, process capability studies, sampling and data collec­
tion strategies, and the three traditional control charts. These chap­
ters form the foundation upon which the rest of the book has been
written. Chapters 11 through 30 concentrate on charts that describe
creative ways of dealing with the limitations posed by traditional con­
trol charts.
In addition, this book has been written with manufacturing in
mind. Specifically, it deals only with applications and control charts
for variables (measurements) data. In turn, there will be no discus­
sion of service industries or attributes data applications.
Finally, Innovative Control Charting has been written with prac­
ticality in mind. The text has been minin1ized, and there appear only
short descriptions and examples of traditional and nontraditional con­
trol charts. Our intent was to provide a handbook of control chart­
ing tools that people could use to quickly identify and understand
the chart needed to solve their SPC challenge. Given this intent, the
reader will find the text de-emphasizes theory, probability, distribu­
tions, and formula derivations. A large number of excellent texts al­
ready exist that include this information and, therefore, will not be
covered in this book. Instead, we wanted to make this the kind of
book that would get dog-eared and dirty from an overabundance of
use by the quality professionals whose task it is to successfully imple­
ment SPC. Acknowledgments
We would like to acknowledge and thank the many people who have
contributed both directly and indirectly to the writing and comple­
tion of this book. First we would like to thank Joanna and Jody ( our
spouses) and Aubrey Sue; Douglas, Jr.; and Connor (our children)
who have been so extraordinarily patient and supportive of us during
the exciting, yet time-consuming process of writing this book. A spe­
cial thank you to Jody, for giving me the time needed to write, for
making the coffee, for taking care of the kids, and for providing to me
her incredibly supportive and positive attitude over the approximately
four and a half years it has required to bring this work to completion.
We \vould also like to thank Jerry Sprague and Harvey Hailer of
the Boeing Con1pany for their leadership and encouragement and
for giving us a chance. Jerry and Harvey gave us the original oppor­
tunity to work together, research, and prove many of the techniques
contained in this book. Many thanks go to Harvey for his idea to
write a book in the first place. We would also like to thank the Boeing
Company and