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PROCESS CAPABILITY AND STATISTICAL PROCESS CONTROL
Process capability is the performance of a process functioning under statistical process control or a process
where in variability’s are because of only system constrains like machine tolerances or natural variation but
within acceptable levels. It can also be defined as ability of a process to meet customer requirements through
its internal capability of material, machine, people and production methods. SPC control charts are used to
locate and eliminate the unnatural causes of variation. The study is completed when a state of statistical
control is reached and we can establish the natural variability of the process also known as its tolerance level.
So all causes of variability in a process, that are beyond acceptable tolerance levels are eliminated through
Process capability study.
In the present case SPC has to be established to do the process capability study. Process capability and SPC has
to be done in EMC for meeting customer requirements. The growing customer complaints further reiterate the
fact. EMC should first establish the acceptable limits for customer satisfaction for various products. Next the
sample’s at each stage of production should find the causes of variability in the product. The capability study
should first be established for plastic moulding and plasti-brack press machine group. Once the causes of
variability leading to scrapping of these items is established then these causes should be eliminated by
checklist , material specification, staff training and machine calibration. The Upper and lower control limits
should be decided based on tolerance levels meeting customer requirements. It is also important to establish
the percentage of defective or products falling beyond specification limits. The control limit of 6 sigma would
mean that the product with mean deviating up to 6 times of standard deviation will also conform to product
specification.
SIX SIGMA AT PLAST- BRACK
Six sigma processes basically brings greater predictability in the process thereby reducing waste and saving
cost. It also increase the life the product and leads to customer delight. Six sigma program can be utilized in
Plast-Brack to reduce waste of brackets as scrap and re-work of moulds. In implementing Six sigma process we
have five steps:
1. Define the project
 Define the projects purpose and scope especially which products to target.
 Collect background information about the process especially customer need. Machine tolerances,
process flow etc.
2. Measure the current situation
 Collect baseline data on defects and possible causes.
 Plot defect over time & analyse for special causes.
 Create frequency plots and pareto analysis.
 Calculate process sigma
 Crete detailed process maps.
3. Analyse to identify causes
...