Process Capability Training and Software
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Process Capability Training Program


This fully narrated training program is available online for delivery via the internet within your internet browser. Includes a user evaluation quiz to test retention of the key learning points

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On-line training program
The on-line training program delivers a fully narrated study course in flash via the internet. Study at your own pace and retake the training as many times as you would like. System Requirements: Windows 98 or later (with service pack updates), 512 MB RAM, Internet Exlorer 6.0 or later


>>Launch Application<<  (Adobe Flash format)

 


Case Studies


Cast Study 1 (Process) - Investment Casting Slurry Viscosity
An investment casting foundry recently noticed a decrease in the amount of fine detail in several of their casting runs. Analysis of the process variables caused the quality engineers to suspect that the viscosity of the slurry tanks in the shell department was consistently too high and was a potential root cause of the problem.

A foundry engineer was asked to determine:

  • Is the process within control?
  • Is the process capable of meeting the upper and lower specification limits for viscosity?
  • Is the process properly centered?
    • >Download Case Study 1<  (.pdf format)

    Case Study 2 (Casting) - Customer Tooling Change Request
    A foundry has received an engineering change notice from their customer. The customer has requested a change in the overall width requirement of their product and a new measurement tolerance, from the previous requirement of 2.475” (+/- 0.015”) to 2.480” (+0.030 and – 0.000). The customer has also requested that the foundry hold the process output (castings) to the minimum side of the tolerance range as much as feasible while maintaining a process capability score of at least 1.33 Cp and 1.33  Cpk. 

    A foundry engineer was asked to determine:

    • Is the process presently within control?
    • What is the current process capability index score for Cp and Cpk?
    • What target dimension should the foundry request of the pattern maker for the tooling dimension to satisfy the customer requirements?
     >Download Case Study 2<  (.pdf format)

     

    Process Capability Failure Resolution Paths


    Process capability failures are usually linked to chronic problems in the basic process either in raw materials, process or equipment.  Since raising equipment capability usually requires the expenditure of funds, it is prudent to extract all the improvements possible from raw materials and methods first. These guideance documents are designed to help the foundry professional with identification of potential causes of process capability failures within the following broad categories

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    Chemistry
    Poor chemistry process capability will result in an inability to control hardness, tensile, elongation and yield. It will also result in variable machinability and porosity. 
    >Download<  (.pdf format)


    Dimensional
    Dimensional capability in the foundry is often the result of many different process inputs and controls. Identification of the cause of dimensional variation can be quite complicated. Often times, a multitude of different potential causes can be considered, including raw materials, process variables and equipment capability. 
    >Download<  (.pdf format)

    Physical Properties
    Physical properties typically are tensile, yield, elongation and hardness. While metallurical properties are most strongly influenced by chemistry, processing is also crucial. The chemistry must be in reasonable control before the process capability of prcesses are considered. 
    >Download<  (.pdf format)

    Internal Defects
    Internal devects consist of casting flaws that are exposed either by maching or non-destructive testing such as x-ray, fluoroscope, or ultrasonic. They include slag, dross, shrinkage and gas holes. Frequently, internal defects are mirrored with external defects of the same type, especially when the problem is gross. 
    >Download< (.pdf format)


    Corrective Action Procedure and Form


    The corrective action procedure is designed to provide to most basic and user friendly method of managing change within the foundry. Most facilities have some type of existing process to manage change within their organizations. It is recommended to use your existing change management programs if available. The following procedure is intended for those company's who have no formal method of managing change in their plants

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    Corrective Action Procedure Template
    A sample corrective action procedure that may be used as-is or may be edited to reflect your own company's corrective action procedure.
    >Download<  (MS Word format)


    Corrective Action Form Template
    A sample corrective action form that can be used as-is or may be modified to suit your own company requirements.
    >Download< (MS Word format)

     

    On-Line Calculator and Charting Assistant


    The online calculator will allow you to input your own data, and provide you with all the necessary data including the process average, standard deviation, average range, Upper and Lower Control Chart Limits, and your process capability index score for both Cp and Cpk. Save and print the results right from your browser window.

     

    >>LAUNCH APPLICATION<<

     

    Additional Process Capability Resources


    The following links are valuable resources to additional information regarding process capability, control chart development and other related topics

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    Control Chart Table of Constants
    A table of the constants needs for control chart development based upon many different values of 'n'.
    >Download<  (.pdf format)


    Normality Tests for Data
    The following statistical tests can be used to verify the normal distribution or 'normality' of a data set. Helpful if you do not have enough data for a histogram, or the histogram is ambiguous.

    Anderson-Darling Test (URL Link)
    Lin-Mudholkar Test (URL Link)
    Shapiro-Wilk Test (URL Link)
    Chi-square Test (URL Link)

     

    Frequently Asked Questions (FAQ)


    Answers to some of the most common questions submitted regarding process capability studies.   >Download<  (.pdf format)


    Acknowledgement:


    Project was sponsored by the US Army Contracting Command Joint Munitions & Lethality Contracting Center, Picatinny, NJ on behalf of Benet Laboratories, and was accomplished under Cooperative Agreement Number W15QKN-10-2-0001.
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