Process Capability
Process capability of a machine/process/system is
index of capability of Machine/Process/System
to do the assigned job. It is a measure of its
capability in quantitative terms to manufacture
item to customer's satisfaction.
Process Capability
When to undertake process capability studies
1. Periodically as a measure of quality control
2. Mandatory when new product started
3. Mandatory when process altered
4. Mandatory when specs changed
5. When vendor rating is to be done
6. Shortlisting the vendors
Process Capability-terms used
• LSL-Lower Specified Limit
• USL-Upper Specified Limit
• LCL-Lower Control Limit
• UCL-Upper Control Limit
• Mean-Average of Data
Process Capability-terms used
• Central tendency
• Standard Deviation
Process Capability
• Mathematically Process Capability is
defined as
USL-LSL USL-LSL
CP = ---------- = -----------
UCL-LCL 6σ
Upper and Lower Process
Capability
Mean-LSL USL-LSL
CPL = ---------- = -----------
Mean-LCL 3σ
USL-Mean USL-Mean
CPU =---------- = ----------
USL-Mean 3σ
Critical Process Capability
Smaller of two values, that is, of lower and
upper Capability is termed as critical
process capability and is denoted by CP K
Process Capability
Process capability Defectives
1.00 0.27%
1.33 64 ppm
1.66 5 ppm
2.00 <0.1 ppm
Process Capability
Some home truths about process capability
1. If Cp is high, >1.5, you can reduce inspection
2. If Cp is too high, >2, you probably have purchased
too costly a m/c. Your product cost will go up
3. Cp of 1.33 to 1.50 is optimum for most industrial
applications
Process Capability
Some home truths about process capability
1. If Cp is high, >1.5, you can reduce inspection
2. If Cp is too high, >2, you probably have purchased
too costly a m/c. Your product cost will go up
3. Cp of 1.33 to 1.50 is optimum for most industrial
applications
Note: When you accept a m/c after overhaul or tool
change check central tendency.
CP and CPK
• If CP > 1.0, it is considered barely satisfactory but
regular rejections likely as CPK will almost
always be lower than 1.
• If CP is >1.33 but CPK very low (<1.0), the
machine is capable but process not under control.
This happens when central tendency of data is far
away from middle of specified range.
CP and CPK…contd
• In practical terms it means that initial setting of
tools, zigs & fixtures is not correct. With trial &
error, central tendency should be brought very
close to mean value of USL & LSL.
• A low CP is more difficult problem. You may
have to overhaul machine or buy new one. Or
change specification if it does not hurt customer.
Though CPK is called critical process capability
index, it is CP which is more critical problem to
handle. If CP is OK but CPK is low, you have to do
trial error or make adjustments to bring CPk
preferably more than 1.33