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self. The cause of this variation can be corrected only by a management decision to change the basic process.

• Special cause variability or variation: This variation can be controlled at the local or operational level. Special causes are indicated by a point on the control chart that is beyond the control limit or by a persistent trend approaching the control limit.

To use process control measurement data effectively, it is important to understand the concept of variation. No two product or process characteristics are exactly alike, because any process contains many sources of variability. The differences between products may be large, or they may be almost immeasurably small, but they are always present. Some sources of variation in the process can cause immediate differences in the product, such as a change in suppliers or the accuracy of an individual's work. Other sources of variation, such as tool wear, environmental changes, or increased administrative control, tend to cause changes in the product or service only over a longer period of time.

To control and improve a process, we must trace the total variation back to its sources: common cause and special cause variability. Common causes are the many sources of variation that always exist within a process that is in a state of statistical control. Special causes (often called assignable causes) are any factors causing variation that cannot be adequately explained by any single distribution of the process output, as would be the case if the process were in statistical control. Unless all the special causes of variation are identified and corrected, they will continue to affect the process output in unpredictable ways.

The factors that cause the most variability in the process are the main factors found on cause-and-effect analysis charts: people, machines, methodology, materials, measurement, and environment. These causes can either result from special causes or be common causes inherent in the process.

• The theory of control charts suggests that if the source of variation is from chance alone, the process will remain within the three-sigma limits.

• When the process goes out of control, special causes exist. These need to be investigated, and corrective action must be taken.

Control Chart Types Just as there are two types of data, continuous and discrete, there are two types of control charts: variable charts for use with continuous data and attribute charts for use with discrete data. Each type of control chart can be used with specific types of data. Table 20-5 provides a brief overview of the types of control charts and their applications.

Variables charts. Control charts for variables are powerful tools that we can use when measurements from a process are variable. Examples of variable data are the diameter of a bearing, electrical output, orjhe torque on a fastener.

As shown in Table 20-5, X and R charts are used to measure control processes whose characteristics are continuous variables such as weight, length, ohms, time, or volume. The p and np charts are used to measure and control processes displaying attribute characteristics in a sample. We use p charts when the number of failures is expressed as a fraction, or np charts when the failures are expressed as a number. The c and u charts are used to mea-

Project Management Made Easy

Project Management Made Easy

What you need to know about… Project Management Made Easy! Project management consists of more than just a large building project and can encompass small projects as well. No matter what the size of your project, you need to have some sort of project management. How you manage your project has everything to do with its outcome.

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