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SPC Case Study
Part 1
A team has been assigned the problem of reducing the process variation in one of
the reactor towers in a large chemical manufacturing nt. It has been estimated that if
the process can be consistently operated within the process specification limits with a
Cpk ‡ 2.0, the annual savings or reduction ost Of Poor Quality (COPQ) will be
$3 million. This is because the variation introduces slow-downs or upsets downstream in
the nt.
In assessing the current situation (step 3 of the 9-step process improvement /
problem-solving model), the team studied the product strengths taken every two hours
over a recent month. The data were taken from a computerized data system; see the
individuals or run chart in Figure 1. Along with this run chart is a check sheet on root
causes related to every point falling outside the process control limits determined from
earlier data (Week 1 through Week 5 charts make it easier to match the data to the check
sheet). The product strength P is controlled by the flow rates of feed streams A and B,
and by temperature T.
To compare the current performance with how well the process performed a year
ago, the team got a run chart printed out for that period. See Figure 2. For this historical
period, the average of X = 12.70 and the average moving range R = 0.227.
Suppose you are members of the team and are determined to act on fact before
proceeding. You ask yourselves the following questions and develop the answers.
1. Is our current process under control? Yes No
2. Is it capable? Yes No
3. What are the more frequent causes of out of control operation? Show as Pareto Chart.
4. Was the process under control a year ago? Yes No
5. If so, calculate the control limits (UCL
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