Process Capability Analysis from Udemy

Capability analysis is a computational method for comparing the output of a manufacturing process to its engineered specification limits. It's also an essential set of tools for new process development, 6-sigma projects, Statistical Process Control, and process monitoring. This set of tools can be applied to product characteristics such as its size, weight and hardness, or to process characteristics such as temperature, voltage or flow.

This class, "Process Capability Analysis" starts at the beginning of how manufacturing processes are developed and analyzed. It moves on to the basic concepts of capability analysis along with it applications and math (both "on paper" and in Excel). You will learn how to analyze capability data for a population, for a sample drawn from a population, and from the data found on control charts. At the end, you will also learn more advanced topics such as dealing with one-sided tolerances and an alternate capability index call Cpm. Plus, you'll receive all the Excel templates and "cheat sheets" you'll need to apply this to your manufacturing projects.

By the end of this course, you will have a thorough understanding of capability analysis, and be able to apply these tools broadly across a wide range of production problems.

Also, if you are studying for your ASQ CQE, CQT or CQIA exams, this is essential material. I carefully explained the difference between Cpk and Ppk, between analyzing a population and a sample, and how to interpret your capability analysis results; all critical elements on these exams.

Hear what you're colleagues are saying about Process Capability Analysis:

“This Process Capability Analysis class is awesome. ” - Lawrence M.

“Clarity on the confusing Process Capability concepts and how to apply them was well explained. Lecture very good and passionate about the subject. Thank you very much, really enjoyed the course from start to finish.” - Kemsley J.

“I'm a quality manager, consultant and project manager in the food industry. This course was a great way to for me to gain experience with process capability analysis. The explanations were thorough and the examples made the math and statistics come to life. I recommend this to anyone who wants to better understand the measures of process capability.” - Chris F.

“A comprehensive knowledge of utilizing Pp and Cp Indices. Also the instructor have good knowledge and understanding of the topic.” - Nasir M.

“I work in manufacturing and appreciated this courses focus on Cpk and Ppk . it gave me a better understanding of what I was looking at when i analyzed process capability data. it is definitely worth taking if you use process capability charts. Easy to follow and made a dry topic easy to follow and complete. ” - Robin S.

“Great course. If you work in a manufacturing environment, you will find that the lessons are very applicable to your everyday dealings with quality. The instructor (Ray) mentions that even many quality professionals are 'fuzzy' with some of these concepts. I have found that to be true in my experience. I much appreciate Ray Harkins for delivering this great content. ” - Charles S.

“Great refresher course. ” - Wallace Y.

If you want to excel as a quality or manufacturing professional, you must understand and be able to apply Sign up today.

What's inside

Learning objectives

Learn to build histograms and compute the capability statistics in microsoft excel
Calculate and interpret process capability indices like cp, cpk, pp, ppk and cpm.
Understand the exact differences between cpk and ppk

How to apply process capability analysis to manufacturing improvement projects or new parts
Interpret the results of a capability study to drive process improvement
Advanced topics such as one-sided targets, estimating % defective using capability indices, skew, and kurtosis

Learn to build histograms and compute the capability statistics in microsoft excel
Calculate and interpret process capability indices like cp, cpk, pp, ppk and cpm.
Understand the exact differences between cpk and ppk
How to apply process capability analysis to manufacturing improvement projects or new parts
Interpret the results of a capability study to drive process improvement
Advanced topics such as one-sided targets, estimating % defective using capability indices, skew, and kurtosis

Syllabus

Introduction

An introduction to this course, "Process Capability Analysis"

By having an overview of the manufacturing development process, it's much easier to see where Process Capability Analysis is best applied. Excel spreadsheets and additional info attached to this lecture.

A continuation of the Manufacturing Development Process.

The Manufacturing Development Process., Pt 3

This video shows you a real manufacturing process in action: Donut-making!! The it ideas a few of the key process and product parameters.

A discussion of the available measurement systems and their accuracies.

Measurement Systems, Pt 2

Should you measure 100% of the parts you produce or just a sample of them? It depends on the application.

Picking the correct sampling option for your application.

Why a 30 piece sample size matters.

Understanding the arithmetic mean as a cornerstone to Process Capability Analysis

Quiz on Arithmetic Mean

How to measure the spread, or dispersion of data.

Quiz on Standard Deviation

The histogram is one of the seven quality tools. It is effective is visualizing your capability data, and estimating its underlying probability distribution.

Excel's Data Analysis Add-in

The most common underlying statistical distribution and a key input to process capability analysis.

A continued exploration of this very important probability distribution.

Modality

Skew

Kurtosis

Plotting the Distribution Curve

The first pair of capability indices, used to examine a "population" of process data.

A continuation of this first pair of capability indices.

Wrap up of Pp and Ppk to measure the capability of a population.

A slight twist when applying Pp and Ppk to a "sample" of data.

Quiz on Pp and Ppk

Another of the seven quality tools, the run chart is the foundation for the second pair of capability indices: Cp and Cpk.

The math behind these critical indices.

Using Excel to calculate Cp and Cpk.

What does it all mean? Interpreting your process capability results.

One of the most commonly misunderstood aspects or capability analysis: What's the difference between Cpk and Ppk?

A graphical look at the differences between Cpk and Ppk.

Closing thoughts on interpreting your results.

The introduction to a few "advanced" topics in capability analysis.

A simple review quiz of the previous material

One of the most commonly asked questions ... how to deal with one-sided tolerances.

A model showing the effect of targeting your process on financial loss.

Calculating Cpm to determine a process's capability relative to its target.

Calculating Cpm in Excel.

Applications of Cpm.

Closing thought on the course.

"Real Life" example exercises that you can complete to practice you're newly learned skills. Solution provides within.

Once you calculate the estimated x-bar and sigma for a population, and determine that it has an underlying normal population distribution, you can plug your parameters into Excel to easily calculate the percent of the population above and/or below values you choose. This method is an excellent way to estimate the percent of a population outside your specification limits.

Continued in Excel.

A slightly more complicated, yet more realistic version of the above scenario. This version has values both above the USL and below the LSL.

Continue in Excel.

Calculating the cost of quality defects through a process requires some simple data modeling and formulas that may not be intuitive. This video shows how to model quality defect costs through a series of processes.

Combining what we learned about estimating the percent defective in a process using our capability data with costing defects through a series of processes is powerful. This video shows you how to build a data model that will show the value of improvement opportunities.

Coefficient of Variation

SPC versus PCA

Sturges' Rule

Quiz on Sturges' Rule

Z Score

Applying Z Score

Norm Functions in Excel

Calculating Equivalent Cpk

Bonus Lecture

Good to know

Know what's good

, what to watch for

, and possible dealbreakers

Focuses on understanding process variability and its impact on product quality, a foundational skill for quality control personnel

Taught by Ray Harkins, a renowned expert in manufacturing and quality control

Emphasizes practical applications of process capability analysis in manufacturing, making it highly relevant for industry professionals

Provides step-by-step guidance on conducting capability studies and interpreting results, catering to both beginners and experienced practitioners

Covers advanced topics such as one-sided tolerances and Cpm, equipping learners with comprehensive knowledge

Course completion prepares learners for ASQ CQE, CQT, or CQIA exams, demonstrating its alignment with industry standards

Reviews summary

Process analysis help

According to students, these lectures help them understand process analysis and introduce process capability analysis to business process analysis.

Helps you understand the meaning of process capability analysis.

"Ability to understand the concept of process capability analysis..."

Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Process Capability Analysis with these activities:

Practice Calculating Cp, Cpk, and Pp

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Reinforce your understanding of these critical indices by solving practice problems.

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Find a set of practice problems online or in a textbook.
Work through the problems, step-by-step, ensuring you understand the process.
Check your answers against provided solutions or consult with an expert if needed.

Develop a Process Capability Analysis Report

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Apply your knowledge by creating a comprehensive report that demonstrates your understanding of process capability analysis.

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Gather data from a manufacturing process.
Calculate the necessary capability indices (Cp, Cpk, Pp, Ppk).
Interpret the results and draw conclusions about the process.
Write a clear and concise report summarizing your findings.

Explore Advanced Topics in Process Capability Analysis

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Expand your knowledge by delving into advanced concepts such as one-sided tolerances and Cpm.

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Identify reputable online tutorials or articles covering advanced process capability analysis topics.
Follow the tutorials, taking notes and working through any examples provided.
Experiment with applying these advanced concepts to real-world scenarios.

Show all three activities

Career center

Learners who complete Process Capability Analysis will develop knowledge and skills that may be useful to these careers:

Quality Engineer

Quality Engineers have a strong understanding of manufacturing processes, and analytics. As such, a deep understanding of Process Capability Analysis can help them to better manage processes and improve product quality. Furthermore, this course could prove helpful when applied to interpreting the implications of data analysis for senior management.

See salaries and explore the career path for Quality Engineer

Statistical Process Control Engineer

Statistical Process Control Engineers oversee the implementation of statistical techniques for the purposes of improving the quality of the manufacturing process. Understanding Process Capability Analysis is a core skill in this role, as it is used to ensure that the manufacturing process is producing products within acceptable limits.

See salaries and explore the career path for Statistical Process Control Engineer

Process Engineer

Process Engineers design and improve manufacturing processes to increase efficiency and quality. In this role, Process Capability Analysis is used to assess whether a process is producing consistent results. Accordingly, this course could also serve as a helpful study resource for candidates preparing to take the ASQ CQE exam.

See salaries and explore the career path for Process Engineer

Manufacturing Engineer

Manufacturing Engineers manage the manufacturing process from start to finish, including designing and improving processes. Process Capability Analysis is an essential tool for these engineers as it provides crucial insights into the production process. This course may be particularly relevant for those in the automotive industry where understanding process capability is essential for meeting quality standards.

See salaries and explore the career path for Manufacturing Engineer

Quality Control Inspector

Quality Control Inspectors are responsible for monitoring and inspecting products, processes, and equipment. They use Process Capability Analysis tools to ensure that products meet specifications. This course provides these inspectors with a strong foundation in the fundamentals of Process Capability Analysis.

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Six Sigma Black Belt

Six Sigma Black Belts leverage a wide range of quality improvement methodologies, including Process Capability Analysis, to implement quality improvements across an organization. This course is particularly well-suited for these professionals, as it delves into advanced topics such as one-sided targets and alternate capability indices.

See salaries and explore the career path for Six Sigma Black Belt

Data Analyst

Data Analysts utilize statistical methods to analyze and interpret data, often for the purpose of making business decisions. In manufacturing, Process Capability Analysis can be used by Data Analysts to identify areas for improvement in the production process. This course could be helpful for those interested in working as a Data Analyst in the manufacturing industry.

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Industrial Engineer

Industrial Engineers are responsible for improving the efficiency and effectiveness of manufacturing processes. Process Capability Analysis is a fundamental tool for these engineers, as it provides insights into the performance of manufacturing processes. This course would be especially helpful for those working in the automotive or aerospace industries.

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Project Manager

Project Managers oversee projects from start to finish, including developing plans, managing resources, and tracking progress. In manufacturing, Project Managers may be involved in implementing process improvements based on Process Capability Analysis. This course provides a strong foundation for Project Managers who need to understand the technical aspects of process improvement.

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Operations Manager

Operations Managers oversee the day-to-day operations of a manufacturing facility. This includes managing production schedules, inventory, and quality control. Process Capability Analysis is a valuable tool for Operations Managers as it provides data-driven insights into the performance of manufacturing processes. This course can be helpful for those seeking to advance into Operations Management roles within manufacturing.

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Reliability Engineer

Reliability Engineers are responsible for ensuring the reliability of products and systems. Process Capability Analysis can be used by Reliability Engineers to assess the reliability of manufacturing processes. This course would be helpful for those interested in working as a Reliability Engineer in the manufacturing industry.

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Quality Assurance Manager

Quality Assurance Managers are responsible for developing and implementing quality assurance programs. Process Capability Analysis is a cornerstone of these programs, as it provides data-driven evidence of the effectiveness of manufacturing processes. This course can be useful for those seeking to advance into Quality Assurance Management roles within manufacturing.

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Production Planner

Production Planners are responsible for planning and scheduling production activities. Process Capability Analysis can be used by Production Planners to identify and address bottlenecks in the production process. This course can be helpful for those seeking to advance into Production Planner roles within the manufacturing industry.

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Manufacturing Supervisor

Manufacturing Supervisors oversee the production process and ensure that products meet quality standards. Process Capability Analysis can be used by Manufacturing Supervisors to identify and address process problems. This course can be helpful for those seeking to advance into Manufacturing Supervisor roles within the manufacturing industry.

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Quality Technician

Quality Technicians perform quality control tests on products and materials. Process Capability Analysis can be used by Quality Technicians to assess the quality of manufacturing processes. This course can be helpful for those seeking to advance into Quality Technician roles within the manufacturing industry.

See salaries and explore the career path for Quality Technician