LSL USL
Req
Requir ements – “V
ire “Vooice
Data - VOP of th
the Cu
Customer”
10.16
10.11 9.87 10.16
LSL = 9.
9.96
96 USL = 10.
10.44
44
10.05 9.99 10.11
10.33 10.12 10.05
10.44 10.43 10.33
9.86 10.21 10.44
10.07 10.01 9.86
10.29 10.15 10.07
10.36 10.44 10.29
10.03 10.36
10.33
10.15
Defects Defects
Capability Analysis -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 +6
9.70 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 10.6
Percent Com
Compositio
itionn
Capability Analysis
The X’s The Y’s
(Inputs)
Y = f(X) (Process Function) Variation – “Voice of
(Outputs)
the Process”
Frequency
Op i Verified Op i + 1
? Data for
Y1…Yn
X1
Y1 10.16
10.11
10.16 9.87
X2 Off-Line 10.05
10.11 9.99
10.16
9.87 10.11
Analysis Scrap 10.33
10.05 10.12
9.99 10.05
Correction 10.44
10.33 10.43
10.12 10.33
X3 Y2 9.86
10.44 10.21
10.43 10.44
10.01
10.21 9.86
9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5
10.07
9.86
10.29
10.07 10.15
10.01 10.07
10.36
10.29 10.44
10.15 10.29
10.03
10.44 10.36
X4 10.36
10.33
10.03
10.15
10.33
Yes No Y3 10.15
X5 Correctable
?
Requirements – “Voice
Critical X(s): Data - VOP of the Customer”
Any variable(s) 10.16
10.11 9.87 10.16
LSL = 9.96 USL = 10.44
10.05 9.99 10.11
which exerts an 10.33
10.44
10.12
10.43
10.21
10.05
10.33
9.86 10.44
undue influence on 10.07
10.29
10.01
10.15
9.86
10.07
the important 10.36 10.44
10.03
10.29
10.36
outputs (CTQ’s) of a
10.33
10.15
Defects
process Defects
Capability Analysis Numerically -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 +6
9.70 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 10.6
Compares the VOP to the VOC Percent Composition
3 © Open Source Six Sigma, LLC
Capability as a Statistical Problem
Our Statistical Problem: What is the probability of our process
producing a defect?
Define a Practical
Problem
Create a
Statistical Problem
Correct the
Statistical Problem
Apply the Correction
to the Practical
Problem
4 © Open Source Six Sigma, LLC
Understanding Process Capability
Process Capability:
• The inherent ability of a process to meet the expectations of the customer without
any additional efforts*.
• Provides insight as to whether the process has a:
– Centering Issue (relative to specification limits)
– Variation Issue
– A combination of Centering and Variation
– Inappropriate specification limits
• Allows for a baseline metric for improvement.
*Efforts: Time, Money, Manpower, Technology and Manipulation
5 © Open Source Six Sigma, LLC
Process Output Categories
Incapable Off target
LSL
Average
USL LSL Average
USL
Target Target
Capable and
on target
Average
LSL USL
Target
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Problem Solving Options – Shift the Mean
This involves finding the variables that will shift the process to the
target. This is usually the easiest option.
USL
LSL
Shift
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Problem Solving Options – Reduce Variation
Reducing Variation is typically not so easy to accomplish and occurs
often in Six Sigma projects.
LSL USL
8 © Open Source Six Sigma, LLC
Problem Solving Options – Shift Mean & Reduce Variation
This occurs often in Six Sigma projects.
USL
LSL Shift & Reduce
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Problem Solving Options
Obviously this implies making them wider, not narrower. Customers
usually do not go for this option but if they do…it is the easiest!
LSL USL USL
Move Spec
10 © Open Source Six Sigma, LLC
Capability Studies
Capability Studies:
• Are intended to be regular, periodic, estimations of a process’s ability to
meet its requirements.
• Can be conducted on both Discrete and Continuous Data.
• Are most meaningful when conducted on stable, predictable processes.
• Are commonly reported as Sigma Level which is optimal (short term)
performance.
• Require a thorough understanding of the following:
– Customer’s or business’s specification limits
– Nature of long-term versus short-term data
– Mean and Standard Deviation of the process
– Assessment of the Normality of the data (Continuous Data only)
– Procedure for determining Sigma level
11 © Open Source Six Sigma, LLC
Steps to Capability
Select Output for
Improvement
#1 Verify Customer
Requirements
#2 Validate
Specification
Limits
#3 Collect Sample
Data
#4 Determine
Data Type
(LT or ST)
#5 Check data
For Normality
#6 Calculate
Z-Score, PPM,
Yield, Capability
Cp, Cpk, Pp, Ppk
#7
12 © Open Source Six Sigma, LLC
Verifying the Specifications
Questions to consider:
• What is the source of the specifications?
– Customer requirements (VOC)
– Business requirements (target, benchmark)
– Compliance requirements (regulations)
– Design requirements (blueprint, system)
• Are they current? Likely to change?
• Are they understood and agreed upon?
– Operational definitions
– Deployed to the work force
13 © Open Source Six Sigma, LLC
Data Collection
Capability Studies should include “all” observations (100% sampling) for a specified period.
Short-term data: Long-term data:
• Collected across a narrow inference • Is collected across a broader inference
space. space.
• Daily, weekly; for one shift, • Monthly, quarterly; across multiple
machine, operator, etc. shifts, machines, operators, etc
• Is potentially free of Special Cause • Subject to both Common and Special
variation. Causes of variation.
• Often reflects the optimal • More representative of process
performance level. performance over a period of time.
• Typically consists of 30 – 50 data • Typically consists of at least 100 – 200 data
points. points.
Lot 1 Lot 5
Fill Quantity
Lot 3
Lot 2
Lot 4
Short-term studies
Long-term study
14 © Open Source Six Sigma, LLC
Baseline Performance
Process Baseline: The average,
long-term performance level of a
process when all input variables are
unconstrained. Long-term
baseline
Short-term
4
Performance
` 3
2
1
LSL TARGET USL
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Stability
A Stable Process is consistent over time. Time Series Plots and Control Charts
are the typical graphs used to determine Stability.
Time Series Plot of PC Data
70
60
PC Data
50
Tic toc… tic 40
toc…
30
1 48 96 144 192 240 288 336 384 432 480
Index
16 © Open Source Six Sigma, LLC
Measures of Capability
Hope Cp and Pp
• What is Possible if your process is perfectly
Centered
• The Best your process can be
• Process Potential (Entitlement)
Reality Cpk and Ppk
• The Reality of your process performance
• How the process is actually running
• Process Capability relative to specification limits
17 © Open Source Six Sigma, LLC
Capability Formulas
Six times the sample
Standard Deviation
Sample Mean
LSL – Lower specification limit Three times the sample Standard
Deviation
USL – Upper specification limit
s – long-term Standard Deviation
18 © Open Source Six Sigma, LLC
