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Materials
www.elsevier.com/locate/matdes
Materials and Design 27 (2006) 364–372
&Design
Statistical process control in machining, a case study for machinetool capability and process capability
Ali Rıza Motorcu, Abdulkadir Gullu *
Department of Mechanical Education, Technical Education Faculty, Gazi University, 06500 Teknikokullar/Ankara, Turkey
Received 12 July 2004; accepted 9 November 2004
Available online 10 December 2004
Abstract
In this experimental study some statistical calculations have been made to eliminate quality problems such as undesirable toler-
ance limits and out of circularity of spherodial cast iron parts during machining. X–R control charts have been constructed on the
data obtained from this manufacturing to discover and correct assignable causes, so that the machine capability (Cp) and the pro-
cess capability (Cpk) can be determined.
In order to compare design tolerance on working drawings and attained tolerances on workpieces after machining five mass pro-
duction lines were set up in a medium sized company. The results obtained from five X–R control charts and the data gathered from
all production lines were processed and evaluated. At this stage of the study, it was observed that some parts were oval and out of
tolerance limits, machines and processes were insufficient and production was instable. Through machining data and follow up stud-
ies some assignable causes for faulty workpieces were discovered, and ovalness and out of tolerance limits problems were eliminated.
In addition to these developments, surface roughness of machined workpieces was improved.
All these activities show that in small or medium sized companies statistical quality control can be useful component of produc-
tion provided that sufficient finance and qualified personal are utilized.
� 2004 Elsevier Ltd. All rights reserved.
Keywords: Statistical quality control; Machine tool capability and process capability; Machinability; Cutting parameters
1. Introduction
High quality production provides some advantages
such as reduced scrap or remachining and increased
market share. For this purpose there are some require-
ments to be met. First of all the organization shouldbe cooperative and the quality should come first. On
the other hand, in order to meet quality requirements
of final product, quality should be achieved at every
stage of production [1].
Another way of achieving good quality during pro-
duction is to use the statistical period techniques at
0261-3069/$ - see front matter � 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2004.11.003
* Corresponding author.
E-mail addresses: [email protected] (A.R. Motorcu), agullu@
gazi.edu.tr (A. Gullu).
every stage of production. If the production is statisti-
cally under control the process can continue and there
is no need for a change in the process. However, if it
is not statistically under control, the assignable causes
should be discovered and removed from the process.
Statistical quality control methods apply statistical prin-ciples and techniques at every stage of design, manufac-
turing, and servicing. Statistical quality control methods
are quite different from traditional methods and they
have made great contribution to improvements in com-
panies dealing with mass production. In traditional
methods, the product is manufactured first and then it
is checked to determine whether it meets the quality
requirements. The product that does not meet the qual-ity requirements is rejected and sent back to the ma-
chines for remachining or correction otherwise it is
A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372 365
thrown away as scrap. If faulty products are too much,
in order to eliminate the assignable causes or the prob-
lem necessary corrections are made by examining pro-
duction period (Fig. 1a). However, statistical quality
control is the vital part of production. Instead of check-
ing the finished product after production, it is applied at
every period of production. If this period is under con-
trol, the next period is considered, otherwise the assign-able causes are discovered and corrected (Fig. 1b).
Today, in order to preserve and improve quality com-
panies perform their work in three phases: firm organi-
zation phase, process phase and application/
performance phase [2]. The priority orders of informa-
tion and data in these phases are control, diagnosis,
and planning respectively. Determination of how this
information is distributed and equalized on organiza-tional level is of vital importance for the success of com-
pany [2].
Quality improvement processes and calculations are
generally carried out at design stage or at work stages.
At these stages the standards for the product are quality
oriented and customer requirements are taken into
account.
But at organizational level, the tasks and the proce-dures at process level should also be organized together.
The standards desired for the product may have some
criteria such as exact size, material composition, and
production time. All employees should understand the
necessity of quality and employ required techniques at
their daily works [2].
Even tough quality is a must in almost every com-
pany, it receives limited attention by managements.Some firms use traditional methods and some of them
prefer statistical quality control methods. There are
plenty of research work concerning quality improve-
ment. Control process and quality management philoso-
phy was defined according to quality requirements by
Jabnoun [3] and it was pointed out that not enough
No
Yes
Does it meet thespecifications?
Scrap or remachining
Adjust the period
Customer
Product
Production Period
(a) (b
Fig. 1. Quality control methods: (a) traditional quality co
attention for quality was paid by managements. For
accepting the manufactured parts as identical in mass
production, it is enough to try to manufacture parts
according to working drawings and tolerances. Because
sizes and tolerances obtained after manufacturing make
them identical rather than the dimensions and tolerances
on working drawings. For this reason, when unbiased
decisions about a production period is needed statisticaltechniques based on unbiased information obtained
from product or process are used. Control charts, pro-
cess capability definitions and design of experiments
have been used for years.
There is considerable theoretical and experimental re-
search work for improving product quality and pro-
cesses using statistical techniques. Xie and Goh [4]
discussed statistical techniques and their roles for pro-cess development considering recent research works
and they summarized design techniques by giving some
examples. They focused on statistical techniques used
for improving quality continuously. In another work,
the application of statistical process control in a firm
manufacturing chemical and plastic products and its
usage was discussed. Focusing on outer necessary fac-
tors, statistical process control application was realized.Optimization of processes which is one of the important
part of statistical process control was discussed in man-
ufacturing activities and the success of statistical process
control was evaluated [5].
2. Process control definitions: machine tool capability
(Cp) and process capability (Cpk)
Definitions of process control are used to establish
qualified measurements for potential and performance
of process in industry which are elements of capacity
[6]. Capacity analysis is made by using a data set in sta-
tistical calculations for defining the system�s capability.
Yes
Eliminate causes
No
Is it undercontrol?
Scrap or remachining
Discover causes
SPC applications
First period step
)
ntrol method; (b) statistical quality control method.
366 A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372
In order to define the system capability, the values are
compared. If the product is approximately 100% in tol-
erance limits, it can be said that the system is ‘‘capable’’.
The tolerance limits are determined by customers, engi-
neers and management and they are classified as require-
ments, aims, specifications and standards. There should
be lower and upper limits of specification restrictions for
the definition of the system.It is accepted that the data should distribute normally
for making capacity analysis calculations. A histogram
is plotted to see if the data distribute normally or not.
Before making capacity analysis, control charts are plot-
ted on the data gathered from the system to see the sys-
tem stability. Traditional applications of control charts
are used to discover the points exceeding the tolerance
limits of the part. In modern production systems, sinceproducts are generally inspected automatically, data ob-
tained during the use of traditional charts is not suitable
for a specific dimension of sample parts. Alongside this
the sample size should be selected larger. To make a
clear decision about the capability of a production line,
enough number of sample parts should be manufactured
and inspected [7].
Capability analysis helps to determine the ability formanufacturing parts in the tolerance limits and engi-
neering values. Capability analysis can be applied not
only to a manufacturing period but also to a machine
tool [1]. Capability analysis gives the information about
the system development during the period.
Machine tool capability (Cp) and process capability
(Cpk) are used to determine the efficiency. Cp is used
to determine the system�s location in tolerance limits.The size of deviations from the average value of process
dimensions will indicate how well the production is. If
the system is not at the center of specification values,
the trend of Cp is progressing faultily.
Cpk is used to determine the average so that the sys-
tem will works better in the specification limits. If the
value of Cpk is 1 it shows that the manufacturing is
going on in the system specification limits staying at99.73% level (±3r limits). If the system centralized at
the target value, Cp and Cpk values will be aqual. When
the values of Cp and Cpk is 1, this is considered, as the
minimum requirement of the system for some compa-
nies. Alongside this, larger Cp and Cpk values, for in-
stance 2, are accepted by many companies. Cp and
Cpk are defined by the following equations [8]:
SD1 ¼Range
d2
ð1Þ
SD2 ¼
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiPX � X aveð Þ2
n� 1
sð2Þ
Cp ¼ UTL� LTL
6:SD1
ð3Þ
Cpk ¼ UTL� LTL
6:SD2
ð4Þ
where
SD1 guessed standard deviation
Range tolerance, the difference between upper and
lower tolerance limits
d2 center line factor used for calculation of 3r con-
trol limitsSD2 experimental standard deviation
X measured size
Xave average of measured sizes
n number of measurements
UTL upper tolerance limit
LTL lower tolerance limit
The value of d2 was taken as 3.472 for n = 15 [9].Capability helps to reach the target values which are
important for customers. If a product deviates from the
target values, it means the product specifications do not
meet the requirements. This causes increase in costs and
decrease in sales. An experienced team is required for
capability analysis and this team tries to improve it.
They collect necessary information and data, and they
develop theories and do necessary calculations [10].Small and medium sized companies must make cor-
rect decisions and develop more efficient processes in or-
der to survive in the competitive market. Thereby,
correct understanding of the components of variables,
definition of factors causing variations and keeping
them under control are all important for small sized
companies [10,11]. Develeyd et al., presented two papers
on application of statistical methods. First paper is onthe capability analysis in Swedish industry and the sec-
ond one is on statistical quality control in two small
companies of ceramics industry which do not have large
production capacities. These cases shown that efficien-
cies of some medium sized companies may be increased
by applying the statistical methods developed [11].
3. Statistical process control in machining the cast parts, a
case study on Cp and Cpk analysis
With this study, eliminating the quality problems of
work pieces during machining in a medium sized com-
pany comprising a casting and machining work shop
was aimed. The process was required to reevaluate be-
cause of some problems accrued during assembly andafter quality control of products in the company where
the assembly of the products was carried out. Obtaining
the permission and support of the management a team
was gathered, the data was collected and analyzed and
the reason for problems investigated [12].
The workpiece is the part of a construction machine.
It was cast as spheroidal cast iron and machined using
various chip removing operations namely rough and
A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372 367
finish turning and drilling operations. First turning
operations are applied on the sizes of 62.500–62.250,
56.410–56.490 and 63.512–63.550 must be machined
within the specification limits and must be under con-
trol. The size, tolerance values and surface roughness
values of the sample part are shown in Fig. 2.
After having examined the faulty parts, it was discov-
ered that there were some problems with the sizes of62.500–62.250, 56.410–56.490 and 63.512–63.550; some
problems with geometric tolerances and some problems
with the surface finish. In other words, there were some
parts out of tolerance limits, some parts out of circular-
ity (ovalness), some parts with poor surface finish.
First the process in the foundry where the parts were
cast was examined. Then, in the machining work shop
where the quality problem had not been able to solved,the machining problems were identified by doing statis-
tical process control during production.
Using the lot acceptance sampling plan, a single-sam-
pling plan in statistical study, it was accepted that 10%
of Plot size of 600–750 parts sent to the partner com-
pany which represents the whole lot. 75 sample parts
were taken from each lot and the accepted quality level
was determined as 5%. Samples were taken from five
5˚
A
A
0.05 D
0.08 FN8
N8
D
0.80x45
Fig. 2. Technical drawing
production lines where the same amount of products
were manufactured in every hour. In order to plot X–
R control graphics and to do process capability analysis,
statistical parameters were calculated using the measure-
ments values taken from the samples that represent the
whole process [9,11].
For one size, dimension distribution of the products
manufactured in each production line affects the averageof the whole process in a different way. Thereby, carry-
ing out statistical work for each production line, normal
distribution diagrams and histograms were prepared
and how these affect the whole process was investigated.
In Table 1, for the production line 1 statistical study
results of 62.500–62.250, 56.410–56.490 and 63.512–
63.550 sizes are given.
In Fig. 3, for the production line 1 histograms for62.500–62.250, 56.410–56.490 and 63.512–63.550 sizes
are presented. In the production line 1, 62.500–62.250
size the average was calculated as 62.270 and it was
determined that normal distribution curve was located
in the middle (Table 1, Fig. 3). Staying of the average
value within the tolerance limits indicates that no faulty
product is manufactured. However, for this production
line it can not be said that the manufacturing is
0.05 D
0.08 F
N7
N9
F
Ø59.5
Ø66.7
DE TA Y C
DETAIL J
DETAIL C
DETAIL J
DETAIL C
of the sample part.
Table 1
For the production line 1, statistical calculation results for 62.500–62.250, 56.410–56.490 and 63.512–63.550 sizes
Sample no. 62.500–62.250 56.410–56.490 63.512–63.550 62.500–62.250 56.410–56.490 63.512–63.550
S1 62.270 56.450 63.540 Average 62.270 56.444 63.538
S2 62.280 56.450 63.540 SD1 0.0072 0.0057 0.0028
S3 62.255 56.430 63.540 SD2 0.0085 0.0071 0.0036
S4 62.255 56.450 63.530 Range 0.0250 0.0200 0.0100
S5 62.275 56.440 63.540 Cp 5.7870 2.3148 2.1990
S6 62.265 56.445 63.530 Cpk 4.8735 1.8549 1.7191
S7 62.280 56.435 63.540
S8 62.280 56.450 63.535
S9 62.265 56.435 63.540
S10 62.265 56.450 63.540
S11 62.275 56.445 63.540
S12 62.265 56.450 63.535
S13 62.280 56.440 63.540
S14 62.265 56.450 63.540
S15 62.270 56.435 63.540
6
5
4
3
2
1
0
8
6
4
2
0
12
10
8
6
4
2
0
Freq
uenc
y
Freq
uenc
y
Freq
uenc
y
63.530 63.535 63.540 56.430 56.435 56.440 56.445 56.450 62.255 62.265 62.270 62.275 62.280
Fig. 3. For the production line 1, histograms of 62.500–62.250, 56.410–56.490 and 63.512–63.550 sizes.
368 A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372
continuing normally. The averages of 56.410–56.490 and
63.512–63.550 sizes stays within the tolerance limits andit can be said that there is no faulty production for these
sizes.
The results of statistical calculations of the process
with data obtained from all production lines and process
capability values are listed in Table 2. Since the gap be-
Table 2
Statistical results of the process
Statistical
parameters
62.500–62.250 56.410–56.490 63.512–63.550
Average 62.2470 56.4367 63.5390
SD1 0.00576 0.00748 0.00403
SD2 0.01998 0.00924 0.00569
Range 0.0200 0.0260 0.0140
LSL 62.500 56.490 63.550
USL 62.250 56.410 63.512
Cp 7.2337 1.7825 1.5710
Cpk 2.0851 1.4422 1.1124
LCL (average) 62.2517 56.4425 63.5421
UCL (average) 62.2427 56.4309 63.5359
LCL (range) 0.0330 0.0430 0.0231
UCL (range) 0.0070 0.0090 0.0049
tween the upper tolerance values and lower tolerance
values in three sizes is large, the values of machine tooland process capability were desired to be larger than 2
(Cp, Cpk > 2) [12].
Since in the production line 1, for 62.500–62.250
Cp = 5.7870 > 2 and Cpk = 4.8732 > 2 the machine tool
and process is sufficient (Table 1). In the same produc-
tion line during machining of 56.410–56.490 and
63.512–63.550 sizes while the machine capability was
accomplished since Cp was greater than 2, it was deter-mined that the process capability was not achieved be-
cause Cpk was less than 2.
The process stability was observed in this production
line after evaluated of capability data obtained from
statistical calculations of production line 1. These ob-
tained values showed that having reevaluated the pro-
cess, process parameters were required to be
redetermined. When examining of Table 2 for othertwo sizes, except for 62.500–62.250 size, both machine
tool and process capability were accomplished. On
the other hand for two sizes of 62.500–62.250, process
capability value Cpk approached to the limit value.
When compared the Cp and Cpk values of production
A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372 369
line 1 in Table 1 and the Cp and Cpk values of the pro-
cess in Table 2 while the machine tool capability of all
sized in production line 1 was achieved, in the whole
process, accept for 62.500–62.250 size, any machine
tool and process capability was not achieved. It can
be seen that at least one or more production lines affect
the machine and process capability badly. It was ob-
served that the production deviated from the aimed val-ues and the production was not continued stably after
doing machine and process capability work.
In Fig. 4, the histograms and normal distribution
curves of 62.500–62.250, 56.410–56.490 and 63.512–
Fig. 5. The X–R graphics and normal distrib
12
10
8
6
4
2
0
20
18
16
14
20
18
16
14
12
10
8
6
4
2
0
56.4
10
56.4
20
56.4
15
56.4
25
62.2
20
62.2
25
62.2
30
62.2
35
62.2
40
62.2
45
62.2
50
62.2
55
62.2
60
62.2
65
62.2
70
62.2
75
62.2
80
62.2
85
62.2
90
62.2
95
62.3
00
62.3
05
62.3
10
62.3
15
62.3
20
62.3
25
62.3
30
Freq
uenc
y
Freq
uenc
y
Fig. 4. The histograms of 62.500–62. 250, 56.410–56.49
63.550 for the whole process were presented. In Fig. 3
for 62.500–62.250 sizes, while size dimensions were accu-
mulated near to the lower tolerance value and no pro-
duction was made out of tolerance in production line
1, Fig. 4 for the same size the normal distribution curve
was concentrated near to the lower tolerance value and
it can be seen that the production was made in high fre-
quency out of lower tolerance.Being high of size frequency manufactured out of tol-
erance shows that there is a problem at least in one or
more production lines. When examining Fig. 4, it can
be seen that no production was made out of tolerance
ution curve for the 62.500–62.250 size.
40
35
30
25
20
15
10
5
0
56.4
30
56.4
35
56.4
40
56.4
45
56.4
50
63.5
20
Freq
uenc
y
63.5
25
63.5
30
63.5
35
63.5
40
63.5
50
0 and 63.512–63.550 sizes for the whole process.
370 A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372
for 56.410–56.490 and 63.512–63.550 sizes. The normal
distribution curves and the frequency were concentrated
near average values for both sizes.
Using the data obtained from the statistical calcula-
tions in Table 2, X–R graphics charts were prepared
for each size and normal distribution curves were plot-
ted. In the X–R control graphic shown in Fig. 5 while
the averages study near the control limits in the produc-tion line 2 and 3 of the sample groups, the averages stay
out of the control limits in the production lines 1, 4 and
5. Due to making production out of the control limits it
was necessary to stop the production and rearrange the
manufacturing and machine tool parameters by evaluat-
ing the process completely. As it can be seen from the
normal distribution curve in Fig. 5 the average of aver-
ages Xave is smaller than the lower value (Xave =62.247 < 62.500). Thereby it can be said that most of
the products manufactured are faulty.
When examining the X–R charts of 56.410–56.490
size in Fig. 6, it is clearly seen that the averages of the
production line 1 and 3 are out of the control limits
and the average of the production line 2 approached
to the control limits. Whereas in the production line 4
and 5 since the averages came close to the average ofaverages, the production continuous normally. The pro-
duction line 1, 2 and 3 must be stopped, examined and
the necessary arrangements must be made.
In Fig. 7 for 63.512–63.550 size while the production
is made out of the control limits in the production line 1,
2 and 3, the production is carried out normally in the
Fig. 6. The X–R graphics and normal distrib
production line 4 and 5 according to the X control gra-
phic. Since the production is made out of the control
limits, the production lines must be stopped, machine
tool and machining parameters reexamined and the nec-
essary arrangements must be made.
Since the values of the average of averages for
56.410–56.490 and 63.512–63.550 sizes accumulated be-
tween the tolerance values of the two sizes faulty prod-ucts were not manufactured however, it can be said
that there is a tendency that these sizes can be manufac-
tured faulty in some production lines.
4. Machinability parameters and rearranging the process
As a result of the statistical studies, it was necessaryto stop the process, reexamine the process parameters
and rearrange the process in order to reassure machine
tool and process stability. Workpiece material, machine
tool and cutting parameters which are three important
components of machinability were reevaluated.
� First of all the structure of the workpiece material
were examined. Since the casting and machining ofthe part are carried out in different work shops in
the firm, having done arrangements in the casting
work shop, it was determined that there existed shell
hardening of the outer surface of the part because of
dismantling of casting dies before the necessary wait-
ing time. Casting die sets were dismantled after the
ution curve for the 56.410–56.490 size.
Fig. 7. The X–R graphics and normal distribution curve for the 63.512–63.550 size.
A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372 371
required time in order not to reduce the tool life and
therefore not to increase the tool costs because of this
excessive shell hardening.
� After the statistical studies carried out during manu-
facturing in the production workshop, the parameters
of two main components of machinability were inves-
tigated in order to prevent manufacturing out of tol-
erances and ovality and to obtain the ideal surfaceroughness. In order to prevent the ovality, the set-
tings of the center line of the chuck and tail stock
of the CNC machine tool and chuck jaws were exam-
ined. Having redetermined the work piece reference
points on the CNC machine tool, the center setting
of the machine tool were readjusted.
� It was determined that inappropriate cutting speeds
and feed rate values, hard shell and sandy areas onthe outer surface of the part reduced the cutting tool
life. It was also determined that early fractures of cut-
ting tools were occurred during machining and differ-
ent from the sizes programmed in CNC part
programs were obtained because of the insert corner
wear. Since tool wear was not determined dynami-
cally, size dimensions were determined as larger than
they should be after a number of parts manufactured.Since the tool wear was not measured and the tool life
was not determined correctly, the production out of
tolerance values were occurred. In order to prevent
this, the cutting parameters in the CNC part program
namely cutting speed, feed rate and cutting depth
were examined [13].
� Taking into account of insert nose radius values of
CCGT09T304, HC2DNGA 443TN and CCGT-
09T304 used for machining 62.500–62.250, 56.410–
56.490 and 63.512–63.550 sizes, (0.4 mm, 1.2 mm
and 0.4 mm respectively) and the desired surfaceroughness values (N8 = 0.16 lm, N7 = 0.8 lm and
N8 = 0.16 lm respectively), the feed rate values were
redetermined as 0.130 mm/rev, 0.163 mm/rev and
0.130 mm/rev respectively [13].
� When machining the spheroidal cast part, 100mm/
min cutting speed were selected and spindle speeds
were entered to the CNC part program as 505 rev/
min, 568 rev/min and 497 rev/min for machining62.500–62.250, 56.410–56.490 and 63.512–63.550
sizes respectively [13].
� In order to prevent excessive tool wear, cracks and
fractures when machining the outer shell of the part,
the rough cutting depth of the first pass was increased
and the damages generated by intermittent impacts
and sandy areas to the tool nose and cutting edge
minimized.� After entering the new calculated parameters into the
CNC program, it was determined that how much the
cutting tool wore and the tool life expired after how
372 A.R. Motorcu, A. Gullu / Materials and Design 27 (2006) 364–372
many parts. According to the criteria determined, the
operator was told to change the insert before it�s toollife.
After rearranging the machining parameters, the pro-
duction was resumed, it was investigated that how thenew values had affected the process and the statistical
studies were accomplished. As a result of the studies
the parts were manufactured within the tolerance limits
and ovality and surface roughness problems were elimi-
nated. These results were observed by measuring and
controlling the parts manufactured.
5. Results and discussion
Statistical quality control is applying statistical rules
and techniques to each phase of design, manufacturing
and service. One of the techniques for assuring the qual-
ity during production is to apply the statistical period
control techniques to each phase of production during
or after manufacturing. Statistical quality control havehad great deal of improvements in companies using
mass production. Capability analysis helps to determine
the ability for manufacturing between tolerance limits
and engineering specifications. Capability analysis can
be applied not only to production period but also to a
machine or machine tool. Capability analysis gives the
information about changes and tendencies of the system
during production. It is used to determine the systemtendencies between tolerance limits. Deviations and
faults of the average of process dimensions can be seen.
Cp and Cpk are used to determine capability.
In this study, statistical calculations for a product
manufactured using mass production in a medium sized
company were carried out. An X–R chart was con-
structed for each production line using the manufactur-
ing data obtained from each line respectively and themachine tool – process capability was determined.
The X–R graphics of the data obtained from the pro-
duction line 1 and whole production lines and capability
values were compared in order to determine the differ-
ences in sizes having tolerances of the part manufac-
tured by five different production lines.
It was determined that the production had not car-
ried on normally before the statistical work. After thestatistical study, during the machining the sizes having
quality problems the production lines where parts were
manufactured out of tolerance were determined. It was
detected that the machine tool and process capability
for the whole process was inadequate and the mass pro-
duction was unstable. Ovality, faults regarding manu-
facturing out of tolerance limits were eliminated and
surface roughness was improved.
As a result of this study, the employee understood the
quality requirement, the cost due to unquality produc-
tion was reduced and the production was enabled to car-
ry on normally with the help of problem solving desire
of them. Since this study reduced the unquality costs
during production, the company management sup-ported the study. However, because of economic prob-
lems, the necessary financial support was not given
and therefore the statistical quality control studies could
not pursued efficiently.
As can be seen from the study accomplished, the sta-
tistical quality control and capability method is effective
for determining the quality problems and solving them
in small and medium sized companies that manufactureparts by machining. In today�s competitive market, one
of the problems of small companies is insufficient invest-
ments and lacking sufficient qualified employee having
practical and theoretical knowledge for the job.
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