The first club session of the
year was held by Opera on 24-Jan-2011. The session introduced SPC -
“Statistical Process Control” Tool to the SOM students. It was a knowledge
sharing session in which the concept and the application of the tool were
discussed along with training on Excel for conducting Cp, Cpk Study.
Swethadri B, a SoM’12 student presented the concept and the excel tool to
conduct the study followed by application of SPC by Meghna Tyagi, a SoM’11
student. In his presentation Swethadri shared his experience in Bosch Limited
and Wipro e Peripherals related to the application of the tool. Meghna
presented her summer internship project “Process Capability Roll-out in Mulund
Plant of Johnson and Johnson” to explain the application of the SPC tool.
Concept
Summary-
Statistical Process Control or
SPC is a tool which helps in identifying the variation in the output from the
desired level. Ideally, the variation should be within the tolerance limit from
the desired level. But that seldom happens in a manufacturing industry
resulting in losses. This tool assists in –
· Improving
product Quality.
· Increasing
product consistency.
· Decreases
scrap and rework of products.
· Increases
production output.
The variation in the data can be
measured easily by collecting sample data of 100-125 nos (as per industry
standards) in a periodic sequence. This data is then fed into the excel tool
which calculates the variation in the data w.r.t desired value. Two indices
which are of particular importance are Cp and CpK.
Cp is the Process Capability
which tells you how capable the process is to give consistent output. It is a
measure of the p. Higher the value of Cp, the more capable your process is. As
per industry standard, the Cp value should be above 1.33.
CpK is the Process Capability
Index which tells you how accurate the process is in giving the output. Again,
higher the value of CpK, the better is the process. As per industry standard,
the CpK value should be above 1.67.
Cp gives the measurement of
process distribution while CpK gives the process cantering.
Summer
Experience Sharing-
It was interesting to see how the
concept of SPC could be used during our summer projects. The summer project of
Meghna in J&J was entirely based on SPC and it was used to determine the
process capability of the manufacturing lines for Bandaids, Sanpro and Baby
Powder. In case of baby powder, this tool was used to identify the following
parameters –
1) Variation in
weights of the powder bottles.
2) Quantity of
perfume used, labelling, cap fitment and sleeve.
Data for finished weights of the
bottle was collected from the manufacturing line on an hourly basis for the
entire day. The variation in the weight was studied and based on the Cp,
Cpk values a fishbone analysis was conducted to identify the probable reason
for the variation.
By understanding the application
of Statistical process control tool in this summer project, we realised that
though this tool is very easy to use, it can be highly effective in
indentifying the variation in your manufacturing processes. The statistical
process control tool is very easy to use.
In the end Madhavan Pillai,
Opera11 Club Co-ordinator emphasised on the importance of the club activities
and also shared his summer internship experience providing valuable tips to the
first year students.
Opera plans to keep many more
sessions in future to provide inputs on relevant industry tools and topics like
Value Stream Mapping, Value Stream Designing, Six Sigma, PPAP(Production
Part Approval Process), Lean Manufacturing, TRIZ(Theory of inventive
problem Solving) and others.
written by,
Puneet Shah, Member of Opera Club,
SJMSoM’12.
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