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CIMPLICITY SPC Operation Manual

1. For CIMPLICITY SPC a document is a collection of products for which you are going to collect and analyze variable quality characteristics and defect data Mean See Average Median The middle value of a group of measurements when they are arranged in order from lowest to highest The median is not an average Observation An observation is a single instance of data Pareto Chart A chart that ranks all potential problem areas according to their contribution to the total variation Typically a few causes account for most of the variation In CIMPLICITY SPC the contents of a Defects folder contain the data displayed in a Pareto chart Process Capability The total range of a stable process s inherent variation For variable data The process s inherent capability is defined as 60 E 2 The capability index for a stable process is Cp CIMPLICITY SPC Operation Manual April 2000 GFK 1413D 1 GFK 1413D 1 Process Spread The extent to which the distribution of individual values of the process characteristic vary This is often shown as the process average plus or minus some number of standard deviations For example X 30 Product For CIMPLICITY SPC a product is the entity for which you want to collect Variable quality characteristics or Defect data for analysis Range The difference between the lowest and highest values in a subgroup Run A consecutive number of points consistently increasing or decreasing
2. 144 To define Document properties 1 Click File on the menu bar of the document window 2 Select Properties to display the Document Properties dialog box see figure 3 The Active box is checked by default to activate data collection for the document clear to disable option Note that the Database Logger must be configured for the project to enable the SPC Data Collector 3 Checked by default to activate data collection for every included product l a Clear box to deactivate 4 Designate the ODBC 1 Click File on data source using the the menu bar drop down list retrieve raw data when using logged data General 2 Select Properties Properties 7 Active Log update interval in seconds a0 ODBC data source CIMPLICITY SPC CIMPLICITY Alarm Logging Sand EIMPLICITY Logana SPE jogging 7 Type a password CIMPLICITY Logging Tracker for logging into the Password CIMPLICITY Point Lagging database CIMPLICITY SPC Cancel Help Database user 6 Type a user name for logging into the database GFK 1413E Configuring SPC Data 4 7 4 8 4 In the Log update interval in seconds field type an integer to define the frequency in seconds raw data will be retrieved from the database when using logged data as input 5 Use the default ODBC data source or select a different data source from the drop down list 6 Inthe Database user field type a name for logging into
3. Bar M Show tithe Font M Show legend M Exclusion Mode Cancel Amply Help Exclusion Mode Application Engineering Note By using the ExclusionMode property an applications engineer can create different ways to let an operator toggle exclusion mode on and off Excluding Returning Samples in Control Chart Calculation During runtime when SPC is in Exclusion Mode an operator can exclude one or more samples from calculation An operator can also re include samples As soon as you toggle the exclusion state of a sample SPC immediately recalculates the control limits displayed on the chart The following symbols allow you to view exclusion status X Inthe upper left hand corner of the SPC control chart Exclusion mode is on O Representing a sample Sample is included in the calculation X Representing a sample Sample is excluded from calculation To exclude samples from a control chart when SPC is in Exclusion Mode Method I Click on a dot that represents the sample to toggle its exclusion state Result The dot will change to an X indicating that the sample is excluded see figure Method 2 1 Click on a corner of the group of sample to be excluded Configuring SPC Data 4 37 2 Drag the cursor over the entire groups of samples Note that a box will appear around the selected samples 3 Release the mouse button Result Each dot that represented an included sample changes to an X indica
4. Yarnable Dually Cha eclenciass Properties YAH General Colection Limiz Ais QTE C Pons C Auto recalculson Ea UCL 100 Ras ua fio Bac Ei mgo fs Popup H Browse Force Auto Recale fw FORCE_BOO El E Note Whenever the Force Auto Recalc Point is set to either TRUE or FALSE the data collector will drop the current sample and start fresh CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di Points Control Limits In order to use Points to set control limit criteria use the Points option in the Limits tab of the Properties dialog box Also you can use the Force Auto Recalc feature to set the Point values for control limits To specify Points for control limits L 2 3 Click the Limits tab Click the Points radio button see figure Enter the a different Point for the XBar UCL CL and LCL control limits as follows Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Enter the a different Point for the R S UCL CL and LCL range or standard deviation as follows Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point If you want to use the current control limits elsewhere in your project or download them to a device indicate the floating point array Point of six 6 elements in the Setpoint ID field The Point contains six elements for all values to be
5. 1959 Quality Control and Industrial Statistics Charbonneau and Webster 1978 Introduction to Statistical Ouality Control Montgomery 1985 Statistical Process Control Chrysler Corporation Ford Motor Company and General Motors Corporation 1995 Professional groups that publish manuals and booklets about SPC are the American National Standards Institute American Society for Quality Control American Society for Testing and Materials CIMPLICITY SPC Operation Manual December 2000 GFK 1413E SPC Operation Overview GFK 1413E CIMPLICITY HMI performs a series of functions in order to provide you with information through the SPC option The following process supports SPC see figure SPC Configuration tells the Data Collector how and from where to collect the data The Data Collector gathers CIMPLICITY Point ODBC and manual entry data performs its required calculations and stores the results in the SPC ODBC data source The SPC ActiveX control displays the data from the SPC ODBC data source It can also send manual entry data back to the Data Collector for processing Process Data from SPC Configuration CIMPLICITY Points amp SPC ActiveX Control gt ODBC Tables a D Configuration Data Manual Data Entry SPC Data SPC ODBC Data Source Configuration Data Configuration Data SPC Configuration Files SPC Overview 2 3 SPC Chart
6. 2 568 2 266 2 089 1 970 1 882 1 815 1 761 1 726 1 679 1 646 1 618 1 594 1 572 1 552 1 534 1 518 1 503 1 490 1 477 1 466 1 455 1 445 1 435 GFK 1413E Appendix B X Individual Chart Calculations X Individual Chart Calculations The X Individual chart is sometimes called a pre control chart This type of chart is used to determine the stability of the center of the process The control limits are calculated by determining the standard deviation of the sample population X Individual Center Line For the X Individual chart the center line is calculated as y E Xi Xz Xn n where X7 through Xn are the values of each item in the set and n is the number of samples X Individual Standard Deviation The standard deviation is calculated as The formulas used for calculating the upper and lower control limits are UCL X 38 LCL X 35S GFK 1413E 2 1 Appendix C XBar R Chart Calculations XBar R Chart Calculations The XBar R chart displays two charts one for the Xbar values and the other for the Range values The formulas for calculating the center lines and control limits for the XBar R control chart are detailed in the following sections XBar R Chart Center Line Based on the sample size the mean for a given sample can be calculated as y E Xit Xota An n where X7 through Xn are the values of each observation in the sample and n is the number of observations in the sample Because a
7. 4 73 Components 1 3 Configuration Quick start 1 5 Control Test Exclusion Mode 4 36 Defect folder in the document tree 4 75 Features 1 3 Operation overview 2 3 Product folder in document tree 4 75 Quick start configuration 1 5 R chart Center line calculation C 2 R chart Control limit calculations C 2 S chart Center line calculation D 2 S chart Control limit calculations D 2 Suggested Readings 2 2 Upgrading charts J 1 What happens J 2 Upgrading Charts Procedure J 2 Upgrading old charts 1 4 XBar R chart Center line calculation C 1 XBar R chart Control limit calculations C 1 XbarRR chart factors for control limits A 1 Xbar S chart factors for control limits A 2 XBar S chart Center line calculation D 1 XBar S chart Control limit calculations D 2 X Individual chart Center line calculation B 1 X Individuals chart Control limit calculations B 1 SPC ActiveX Control Displaying test results 6 2 Getting started 5 1 Manual data entry 6 3 Manual data entry Attribute QC data 6 4 Manual data entry Defect QC data 6 6 vil Manual data entry Variable QC data 6 3 Runtime functions 6 1 SPC Administration Alarms 4 73 SPC Analysis Overview 2 1 SPC chart Bar chart properties 5 9 Configuring properties 5 5 SPC Chart Axis properties 5 8 Bar chart properties 5 9 Chart properties 5 5 Configuring properties 5 3 Creating in a web page 5 11 Creating in CimEdit 5 1 General properties 5 4 Lines properties 5 7 Report properties 5 10 SPC Ch
8. Logged for data collection 1 Click the Collection tab see figure 2 Click the Logged radio button 3 Use the ODBC data source drop down list to select the name of the database from which SPC will retrieve data Variable Collection Properties Logged Yanable Quality Characteristics Properties VAR General Collection Limits Alarm Automatic data collection CIMPLICITY Alarm Logging Point 6 Logged C None CIMPLICITY e cee CIMPLICITY Logging Tracker ODBC data source CIMPLICITY Alarm Logging et Ho Logging Database user Sandi Password reso Table ID WIDGET_LOG Bi Column ID LENGTH_3 Ei Match Point ID VAR MATCH la gt Match value js Batch Point ID ivi BATCH El El If Manual entry allowed Cancel Help 4 Inthe Database user field type a name for the user when logging into the ODBC data source 5 Inthe Password field type a password for the user when logging into the ODBC data source GFK 1413E Configuring SPC Data 4 19 6 Click E to browse for the Table ID where data is located 7 Click E to browse for the Column ID where data is located 8 Check the Manual entry allowed box to enable manual data entry for SPC chart sets at runtime clear to disable option No Collection for a Variable If you choose to enter your own data do not designate a data collection source uy To specify None for data collection 1 Click the Collection tab 2 Click the None radio bu
9. SPC file When you add a new chart you will need to select the SPC1 SPc file as the group file in the chart s General property page The configuration file tells chart what quality characteristics are available and where to find the data The data collection process also uses this configuration file to know what data to collect and on which data source to log results CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Index A About SPC 1 2 ActiveX Methods 5 12 ActiveX Methods and Properties 5 12 Adding Attribute quality characteristics 4 40 Adding a New Defect Category 4 68 Defect group 4 65 Product 4 9 Variable quality characteristic 4 12 Alarm Numbers 4 73 Alarms Setpoint 4 29 4 56 Setting 4 29 4 56 SPC Administration 4 73 Alarms and Setpoints for control tests 4 29 4 56 Attribute No collection 4 47 Point Collection 4 43 Attribute Control Test 1 Beyond upper lower limits 4 59 2 Same side of center line 4 60 3 Consecutive subgroups in a row 4 60 4 Alternating up and down 4 61 5 In a row in beyond A 4 61 6 In a row in beyond B 4 62 7 In a row in C 4 62 8 In a row beyond C 4 63 Attribute Control Test 0 Specification limit test 4 59 Attribute QC Data Manual data entry SPC ActiveX control 6 4 Attribute Quality Characteristics 4 39 Adding 4 40 General 4 41 Attributes Control limits 4 48 GFK 1413E Logged collection 4 45 Attributes Quality Ch
10. V ET R EE EA EEE EN A EE EEEE E A E EOE 4 9 Addn ora NeW Pro du last A a r ATOA kes 4 9 D tinine Product Properties a ned 4 10 Vanable Quality Chiara cten Sues il lo Li 4 11 Adding a New Variable Quality CharacteristIC oooooooooooooonocncnnnnnncnnnnnnnnonononononos 4 12 Specifying a Variable s General CharacteristiCS ooocccccccnncncnnnnnnnonnonononnnnnnnnnnnnnos 4 12 Defining a Variable s Collection CharacterlstlCS oooooooooooooccccnncnnnnnnnnnnononnnnnnnnnos 4 16 Setting Limits for Variable Quality Characteristics ccccccccccccnnnnnonnnonononnnnnnnnnnnoss 4 21 Setting Alarms for Variable Quality Characteristics ccccccccccnnonononnnonoonnnnnnnnnnnoss 4 29 Critetia tor Vanable Control Tesis prados 4 31 SPC Control Test Exclusi n Mode dd 4 36 Attribute Quality Characteristics sos loa 4 39 Adding a New Attribute Quality Characteristic ooooooooooooonncncnnnnnnncnnnnnnnnnnnnnnnnnos 4 40 Specifying an Attribute s General Characteristics oooccccccnnnncncnonnnnnonnnnononnnnnnnnnss 4 41 Defining an Attribute s Collection CharacterIstiCS oooooooonncncnnnnnnnnnnnnnnnnnnnnnnnnnos 4 42 Setting Limits for Attribute Quality CharacterIstiCS coocccconnonononnonnaonnnnnnnnonnnoss 4 48 Setting Alarms for Attribute Quality Characteristics ccccccccccncnnnnnnononnccnnnnnnnnnnnss 4 56 Entera FOr ADUE Cono Tests iso 4 58 ACHVE Macros hawt E A 4 64 GFK 1413D 1 v vi Defect Fo
11. Zone B or beyond same side of center This test checks to see if M out of N subgroups in a row on the same side of the center line are in Zone B or beyond The Mth subgroup that meets the test criteria will be marked with a red asterisk For example if M 2 and N 3 one Std dev Position cursor over plotted point to view tool tip Control Test 7 N subgroups in a row in Zone C above or below center This test checks to see if N subgroups in a row lie in Zone C on either side of the center line The Nth subgroup and all the following subgroups that meet the test criteria will be marked with a red asterisk For example if N 4 one Std dev Fann oF eS nT es ERE 111519399 1 57 38 PM 50 0000 Failed Tests 7 Position cursor over plotted point to view tool tip 4 62 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Control Test 8 N subgroups in a row beyond Zone C above or below center This test checks to see if N subgroups in a row lie beyond Zone C on either side of the center line The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 4 one Std dev FOO og F 111519399 05 41 PM 55 0000 Failed Tests Position cursor over plotted point to view tool tip GFK 1413E Configuring SPC Data 4 63 ActiveX The present ActiveX control is capable of displaying Histograms X Individual and XBar charts as well as gen
12. a Widget Defects 118 19 16 36 14 55 12 73 10 91 9 09 7 27 10 91 Detect Codes 100 DEFO Too light DEFY Too heavy DEFE Too narrow DEF Too wide a geen l DEFG Too short La 60 EFS Too hom 3 40 09 JEFA Diseoloured a amp Other a 244 44 ee DEFIQODEFS DEFA DEF DEF6 DEFS DEFA Ci Pareto Aral pris By Frequency Group Batch ID Start OC OC DEF End Product WIDGET a i CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E Reports You can display and print data from the SPC ActiveX control for each type of SPC chart The following 1s an example of a report created using SPC ActiveX Control vy Report cim Al ES File S Se 41 aleje wiew Help Group Batch ID Start dik Date Time 22507 10 58 11 AM S157 10 58 33 AM e157 10 58 35 AM 22507 10 58 38 AM 207 10 58 40 AM ST 10 58 42 AM MST 10 58 44 AM MST 10 58 46 AM SST 10 58 48 AM 2 S07 10 58 50 AM 207 10 58 52 AM 2SIO7 10 58 54 AM SST 10 58 56 AM 15007 10 58 58 AM 15007 10 59 00 AM 4 QC BRIGHTHESS Product BULB For Help press Fl SPC Overview BULE BULE BULE BULE ETLE ETLE ETLE ETLE ETLE ETLE ETLE ETLE ETLE ETILE ETILE Croup ID Product ID Gc ID GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGAT GE_LIGAT GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGHT GE_LIGHT GE LIGHT BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGH
13. all of the options 5 10 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Creating an SPC Chart in a Web Page The following is a sample HTML fragment that will display an SPC ActiveX control in a web page Microsoft s ActiveX Control Pad can automatically generate code for inserting the CIMPLICITY SPC control and we recommend it It is freely available from Microsoft s web site Www microsoft com lt HTML gt lt HEAD gt lt TITLE gt New Page lt TITLE gt lt HEAD gt lt BODY gt lt OBJECT ID Spc1 WIDTH 400 HEIGHT 300 CLASSID CLSID 8A843E25 2878 11D1 B6F5 00A02491B166 gt lt PARAM NAME _ Version VALUE 131079 gt lt PARAM NAME _ExtentX VALUE 10583 gt lt PARAM NAME _ExtentY VALUE 938 gt lt PARAM NAME Updatelnterval VALUE 00 00 10 gt lt PARAM NAME GroupName VALUE WIDGET gt lt PARAM NAME Product VALUE LEFT HAND WIDGET gt lt PARAM NAME Q0C VALUE WLength gt lt PARAM NAME ProjectGroup VALUE SPC_DEMO WIDGET gt lt OBJECT gt lt BODY gt Use of Netscape Navigator is not supported at this time Changing the Date Time Format on Charts SPC uses the short date style To change the date time format of that style on a chart use the Regional Settings option on your Windows Control Panel GFK 1413E Configuring SPC Charts 5 11 ActiveX Methods and Properties SPC charting provides you with a wide range of built in functionality However 1f you are f
14. based on the sample size See the Range Chart Factors for Control Limits table in Appendix A for values of D3 and D4 for sample sizes ranging from 1 to 25 If the sample size is greater than 25 the formulas are UCL R 3S LCL R 3S where is the standard deviation for the chart CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Appendix D XBar S Chart Calculations XBar S Chart Calculations The XBar S chart displays two charts one for the Xbar values and the other for the Sigma values The formulas for calculating the center lines and control limits for the XBar S control chart are detailed in the following sections XBar S Chart Center Line Based on the sample size the mean for a given sample can be calculated as y E Xit Xota An n where X7 through Xn are the values of each observation in the sample and n is the number of observations in the sample Because an XBar S chart displays the average of each sample in the set its center line is calculated as Nit Xo Ka m X where X 1 through Xm are the averages of each sample and m is the number of samples This grand average becomes the center line of the XBar chart GFK 1413E D 1 XBar S Chart Control Limits To construct the upper control limit UCL and lower control limit LCL for the XBar S chart we need to know the standard deviation of the data In a sample of size n the standard deviation 1s If s through S_ is the range of m
15. browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Attributes Limits Properties Auto recalculation Control limits Co Values Setpoint ID CSET_ARRAY3 3 Force Auto Recale CFORCE BOOL El gt Specification limits Upper Spec Limit Jas Browse Popup 4 Inthe Force auto recalc field indicate the Boolean Point ID that has been created to override the value control limits at runtime This feature can be configured to be turned on or off at runtime Point On When the Point is on set to TRUE auto recalculation is activated and all previous values are ignored Point Off When the Point is off set to FALSE auto recalculation is deactivated and the data collector continues to use the last calculated values Once enough data has been collected to calculate valid control limits deactivate auto recalculation and use Values or Points to set control limits for your process in the dialog box Do one of the following 4 54 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 5 Indicate the Upper Spec Limit for analysis ES Note Whenever the Force Auto Recalc Point is set to either TRUE or FALSE the data collector will drop the current sample and start fresh GFK 1413E Configuring SPC Data 4 55 Setting Alarms for Attribute Quality Ch
16. el oo ee BE le PP Properties En Products 1 SocCtal Result A new document will open SPC documents are numbered consecutively For Help press Fl NUM ee kh bh Important You must use the same data source for all SPC documents created in a project 14 To build directory hierarchy As you build your configuration you add a hierarchy of subfolders to the Products main folder as follows 1 Within the Products main folder a subfolder for each product included in the document 2 Within each Product subfolder are the following Variable QC item for each variable that will be tracked for that product and displayed on an XBar R or XBar S chart Attribute QC item for each attribute that will be tracked for that product and display on an p nP c or u chart GFK 1413E Configuring SPC Data 4 5 4 6 Defect folder for each group of defects that will be tracked for a product and displayed on one Pareto chart Included are all the defect categories that will be displayed as a bar on the group s Pareto chart CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Defining Document Properties The SPC document is the primary container for your quality control information You can set its properties to activate or deactivate data collection for every included product specify basic parameters including the logged update interval in seconds ODBC data source limit user access
17. folder example of right click method 2 Right click on the product to display the popup menu 1 Expand the main 3 Select Defect Folder Products folder Defect Folder Properties Seclig SFL Comlaguraton i Result The Defect Folder Properties dialog box displays For Help press Fl GFK 1413E Configuring SPC Data 4 65 Defining Defect Folder Properties The Defect Folder Properties dialog box is where you identify each group of Defect Categories that will be included on one Pareto chart Information you enter here applies to every defect category in the group see figure 14 To define Defect Folder properties 1 Check Active box to activate data collection for the Defect folder clear box to disable option The Document and Product must also be active for collection 2 Check the Manual entry allowed box to enable manual data entry for SPC chart sets at runtime clear to disable option 3 Type a Name for the Defect folder 4 Type a Description for the Defect folder optional Defect Folder Properties E4 General IY Active M Manual entry allowed Name lu nit Temp Description Defect in masimun temperature Match Point ID UNTMP_MATCH El gt Match value 160 Batch Point ID UNTMP_BATCH El gt Collection Method Cancel Help 5 Select a Point to indicate the Match Point ID numeric Point only in order to use the same data source that is identified by the Point ID
18. for multiple defects Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 4 66 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E In the Match value field enter the value to be matched against the Match Point ID to determine whether the collected data applies to this specific defect folder For example the data source may be used to measure a defect for example color for several products Product 1 Product 2 Product 3 You can enter a Match Point ID value of 1 to measure color for Product 1 and 2 to measure color for Product 2 If this is a batch process select a Batch Point ID This will allow you to distinguish between different batches for the same Product Quality Characteristic The value of the Batch Point is associated with the calculated data and can be used as search criteria for charts and reports Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Click the appropriate radio button to designate the Collection Method as described below When adding defect categories to your folder the method indicated here will determine the corresponding input fields in the Collection tab of the Defect Properties dialog box Point retrieves data from CIMPLICITY Point values Logged retrieves data from one or more ODBC database tabl
19. for the screen About SPC provides information about the SPC application such as version number GFK 1413E 6 1 Displaying Test Results You can perform up to eight 8 control tests on XBar R and XBar S data and up to nine 9 control tests on the p nP c and u data The results of these tests are displayed graphically on the appropriate chart Points on the chart that meet one or more test criteria are highlighted with red asterisks default In addition 1f you position the cursor over one of these points a tool tip will display a summary of the results see figure Example av TW gag Ma ee ie Falled Bar Tests 2 SS Eee O IE WAPA eee F 2 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Manual Data Entry If Manual Data Entry was selected as a collection option when the Variable Attribute or Defect QC was configured you can use the Manual Data Entry popup menu option to input QC data for the chart Variable QC Data When you select Manual Data Entry for a Variable QC chart the Manual Data Entry Variable QC dialog box opens 11 To manually enter data for a Variable QC chart 1 Inthe Raw Value field type the value to be manually entered gt f i 2 Press gt next to the input field to move the value into the list box 3 Continue to enter manual data in the same manner 4 Once all the manual data has been entered click Submit to send the data to the SPC Data Co
20. override the value control limits at runtime This feature can be configured to be turned on or off at runtime Point On When the Point is on set to TRUE auto recalculation is activated and all previous values are ignored Point Off When the Point is off set to FALSE auto recalculation is deactivated and the data collector continues to use the last calculated values Once enough data has been collected to calculate valid control limits deactivate auto recalculation and use Values or Points to set control limits for your process in the dialog box Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click 2 to designate a New Point GFK 1413E Configuring SPC Data 4 27 5 Indicate the Specification limits for Histogram analysis as follows Lower type the Lower Specification Limit LSL Upper type the Upper Specification Limit USL E4 Note Whenever the Force Auto Recalc Point is set to either TRUE or FALSE the data collector will drop the current sample and start fresh 4 28 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Setting Alarms for Variable Quality Characteristics SPC can track several different types of occurrences to warn you if a process 1s slightly off even if production has not exceeded its control limits on a regular basis As a result you can anticipate and handle potential problems before they occur Use the Alarm tab in the Variab
21. the number of nonconforming items in a population to the total number of items in that population Sample sizes need not be equal Data Available GFK 1413E N Number of units produced in each sample subgroup size R 1 K Number of units rejected in each subgroup K Inspection Quantity To be calculated Average Proportion Non conforming k Ri i l p a Ni Sigma standard deviation yP p SP N F Center Line and Control Limits The control limits are the process average plus or minus an allowance for the variation that could be expected if the process where in statistical control given the subgroup size For the study period of k subgroups calculate the upper amp lower control limits Center Line CLP P Upper Control Limit UCLP CLP 3 SP Lower Control Limit LCLP MAX 0 CLP 3 SP CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Appendix G nP Chart Calculations nP Chart Calculations The nP chart measures the number of nonconforming items in an inspection lot It 1s identical to P chart except that the actual number of nonconforming items rather than their proportion of the sample is plotted The inspection sample sizes must be equal in this case Data Available N Number of units produced in each sample subgroup size R 1 K Number of units rejected in each subgroup K Inspection Quantity To be calculated Process Average Number Non con
22. three standard deviations from the center line Performing multiple control tests In the Alarm tab of the Variable Quality Characteristics Properties dialog box you can run multiple control tests on your data by checking the appropriate boxes At runtime each data value will be compared with all of the selected alarm conditions and plotted on your configured SPC chart When you position your cursor over the red asterisk default character a detailed tool tip will display with the date time point value and failed test data i e the control test number s Ex Note When you create a control chart you can select samples for exclusion See SPC Control Test Exclusion Mode for instructions The following example depicts the standard Zone Std dev Configuring SPC Data 4 3 14 To perform variable control tests 1 Check the appropriate box in the Alarms tab for each of the tests to be performed 2 View test results by accessing a configured SPC chart to view runtime data or configuring a new SPC chart Control Test 1 One subgroup beyond upper or lower limits This test checks to see 1f any subgroups on the chart have a value greater than the upper control limit or less than the lower control limit Subgroups that meet test criteria will be marked with a red asterisk For example Control Test 2 N subgroups in a row on same side of center line This test checks to see if N subgroups in a row are on the sa
23. types You can use the SPC ActiveX control to display charts for variable attribute or defect data Data can also be displayed in report format The SPC ActiveX Control can display the following types of charts and reports Variable Data Attribute Data Defect Data Reports X Individual chart pchart Pareto chart Sample Report XBar R chart nP chart XBar S chart c chart Histogram u chart In general a control chart consists of a center line corresponding to the average value at which the quality characteristic should perform and lines corresponding to the upper and lower control limits for the characteristic The upper and lower control limits are also referred to as the upper and lower three sigma control limits X Individual Chart The X Individual chart is sometimes called a pre control chart This type of chart is used to determine the stability of the center of the process The control limits are calculated by determining the standard deviation of the sample population The formulas for calculating the standard deviation and control limits are detailed in Appendix B The following is an example of an X Individual chart that was created using SPC ActiveX Control _ En a Widget Length UCL 0 625 0 5703 wi jak 0 424 2 CL 0 032 30 2795 n E 0 134 LCL 0 079 1 3 5 7 91113 15 17 19 21 23 25 Observation Number Group Batch ID Start QC QC_LEN end Product WIDGET e 2 4 CIMPLICITY SPC
24. use Points values can be changed at runtime see figure To specify Points as sampling parameters 1 Inthe Sampling Parameters group click Points radio button 2 Select a Point to indicate the Subgroup size Note that the same size can be changed at runtime Do one of the following Configuring SPC Data 4 13 4 14 Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Select a Point to indicate the Gap size that is how many units will be skipped before the next sample is taken as follows Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Sampling Parameters Yalues 5 Points Subgroup size wIDGET_LEMGTH K gt Gap size wIDGET_GAP gt CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E dl Using Values to Specify Sampling Parameters You can use Values to specify sampling parameters as described below see figure To specify Values as sampling parameters 1 Inthe Sampling Parameters group click the Values radio button 2 Type a value for the Subgroup size sample size 3 Type a value for the Gap size that is how many units will be skipped before the next sample 1s taken Sampling Parameters Values C Points Subgroup size E Gap size 100 Configuring SPC Data 4 15 4 16 Defining a Variable s Collection Characteristics
25. will display the zones in which these averages fall At runtime each subgroup that does not meet one or more of the selected tests will be displayed with a special character the default is a red asterisk The following zones are used in these tests Zone C is the area up to one standard deviation from the center line Zone B is the area between one and two standard deviations from the center line Zone A is the area between two and three standard deviations from the center line Performing multiple control tests In the Alarm tab of the Attribute Quality Characteristics Properties dialog box you can run multiple control tests on your data by checking the appropriate boxes At runtime each data value will be compared with all of the selected alarm conditions and plotted on your configured SPC chart When you position your cursor over the red asterisk default character a detailed tool tip will display with the date time point value and failed test data i e the control test number s Ex Note When you create a control chart you can select samples for exclusion See SPC Control Test Exclusion Mode for instructions The following example depicts the standard Zone Std dev 4 58 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E 14 To perform attribute control tests 1 Check the appropriate box in the Alarms tab for each of the tests to be performed 2 View test results by accessing a configured SPC ch
26. 5 If you want to use the current control limits elsewhere in your project or download them to a device indicate the floating point array Point of six 6 elements in the setpoint ID field The Point contains six elements for all values to be set in the following order XBar LCL XBar CL XBar UCL R S LCL R S CL R S UCL Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 6 Indicate the Specification limits for Histogram analysis as follows Lower type the Lower Specification Limit LSL Upper type the Upper Specification Limit USL Configuring SPC Data 4 23 4 24 41 To use auto recalculation to set control limit values Inthe Force auto recalc field indicate the Boolean Point ID that has been created to override the value control limits at runtime This feature can be configured to be turned on or off at runtime Point On When the Point is on set to TRUE auto recalculation is activated and the XBar R S control limits are recalculated Pre set values are ignored Point Off When the Point is off set to FALSE auto recalculation is deactivated and the last calculated values are used Pre set values are ignored until the data collector is restarted or dynamically refreshed Do one of the following see figure Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point
27. 5 569 60 5538 LOL 52 19 30 2769 g 2 4 Bi 5 10 12 Subgroup Humber Group WRU ALPHARPCCFs1 Batch ID Start ic ATT End Product PROD GFK 1413E CIMPLICITY SPC Operation Manual December 2000 C Chart The C chart measures the number of nonconforming items discrepancies or defects in an inspection lot The C chart requires a constant sample size The following 1s an example of a C chart created using SPC ActiveX Control 122 D8 UCL 102 5 456 pe CL 76 3 61 04 LL 50 30 52 o 2 4 z a 10 Subgroup Mumber Group WRI _ALPHARPCCR GT Batch ID start 11 04 35 am 1171571999 al ATT End 11 05 53 AM 11151999 Product PROD U Chart The U chart measures the number of nonconforming items per inspection unit in subgroups which can have varying sample sizes It is similar to C chart except that the number of nonconforming items is expressed on a per unit basis The following is an example of a C chart created using SPC ActiveX Control 0 3052 UCL 0 2563 m 0 2289 l T EL 0 1908 0 1526 LEL 0 1252 0 0763 g 2 4 E 5 10 Subgroup Humber Group WPRJ_ALPHASPECFG1 Batch ID Start 11 08 01 am 117151999 cl ATT End 11 10 27 AM 117151999 Product PROD 2 9 GFK 1413E SPC Overview 2 10 Pareto Charts The Pareto chart displays the data for the defect categories and quantities you define for a defect folder The following 1s an example of a Pareto chart created using SPC ActiveX Control
28. BarLCL KBAR_LCL EE ees tee RS_LOL JE Setpoint ID WSET_ARRAYE Sa Force Suto Recalc fWwFORCE_BOOL El gt Specification limits Lower 25 Upper E OF Cancel Help ES Note Whenever the Force Auto Recalc Point is set to either TRUE or FALSE the data collector will drop the current sample and start fresh 4 26 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Auto Recalculation Control Limits In order to automatically set control limits for a new process or when your process is in optimum condition use the Auto Recalculation option 14 To use auto recalculation to automatically set values 1 Click the Limits tab 2 Click the Auto recalculation radio button see figure 3 If you want to use the current control limits elsewhere in your project or download them to a device indicate the floating point array Point of six 6 elements in the Setpoint ID field The Point contains six elements for all values to be set in the following order XBar LCL XBar CL XBar UCL R S LCL R S CL R S UCL Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Variables Properties dialog Limits tab Auto Recalculation Option Setpoint ID WSET_ARRAYTE El Popup Force Auto Recalc WFORCE_BODL T Browse Specification limits Lower 25 4 Inthe Force auto recalc field indicate the Boolean Point ID that has been created to
29. Charts 5 5 5 Type a Title for your report or chart and click the Show title box to display the title on screen 6 Click Font to display the Font dialog box Adjust the font style and size of your title using the available options 7 In the Color group click the arrows next to Foreground Background and Chart to display the color Palette and Special options Select options to customize the display of your report or chart 8 Click the Show legend box to display legend information on your report or chart Clear check box to disable 9 Check Exclusion Mode to enable exclusion mode on your chart Clear check box to disable Note See Configuring SPC Data for complete information and instructions on Exclusion Mode CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Line Properties You can choose to display control lines on your chart in the SPC Control Properties dialog box see figure uy To set line properties 1 Click the Lines tab SPC Control Properties Check boxes to show lines on your chart Clear boxes to hide lines 4 E e Apply 2 Check boxes to show lines on your chart or clear boxes to hide lines Lines display as follows Show UCL Displays upper control limit line Show CL Displays center line Show LCL Displays lower control limit line Show zones Displays zone lines GFK 1413E Configuring SPC Charts 5 7 Axis Properties You can choose to display the X and Y axi
30. Defect Folder Defining properties 4 66 SPC 4 75 Defect Folder Properties SPC configuration 4 65 Defect Group Adding 4 65 Defect QC Data Manual data entry SPC ActiveX control 6 6 Defining Defect folder properties 4 66 Product properties 4 10 Display Attributes Changing SPC configuration 4 76 Displaying Test Results SPC ActiveX control 6 2 Document Tools 4 74 Document Tree SPC 4 74 E Enhanced Features 1 3 Exclusion Mode Control test 4 36 Toggle 4 36 F Finding a Product Quality Characteristic SPC configuration 4 78 G General Properties Defect category SPC configuration 4 69 SPC chart 5 4 Variable quality characteristics SPC configuration 4 12 Getting Started SPC ActiveX control 5 1 Group Chart properties 5 4 H Histogram chart Properties 5 9 5 10 Histogram Chart Description 2 6 Histogram Chart Calculations E 1 HTML Code Embedding SPC chart in web page 5 11 L Limits Properties Attributes quality characteristics SPC configuration 4 48 Variable quality characteristics SPC configuration 4 21 Lines Properties SPC chart 5 7 Logged Collection Attributes 4 45 Defect Category 4 71 Variable 4 19 Manual Data Entry Attribute QC data 6 4 Defect QC data 6 6 SPC ActiveX control 6 3 Variable QC data 6 3 Methods ActiveX 5 12 N New Product Adding 4 9 Defining properties 4 10 New Variable Quality Characteristic 4 12 No Collection For a defect category 4 72 For an attribute 4 47 nP Chart
31. Define SPC s collection method and the source of the variable input data using the Collection tab in the Variable Quality Characteristic Properties dialog box Collection methods include Automatic Data Collection either Point Logged or None The type selected will activate corresponding fields in the dialog box When you use an Automatic Collection method you can also use the same data source for multiple attributes Match Point a batch process Batch Point ID or Batch Column ID Point Data Collection one or more CIMPLICITY Points are specified along with start and end indices for array Points and any engineering unit conversion default Logged Data Collection retrieves data from an ODBC database table Define the ODBC data source table and column names None specify whether or not manual entry will be allowed Manual entry can be allowed for any type of data collection you choose SPC automatically includes manual entry when you select None Select this option to prevent automatic data collection CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di Point Collection for a Variable You can designate Points for data collection using the Collection tab of the Variable Quality Characteristics Properties dialog box Here the scope of the collection can also be specified To specify Points for data collection 1 Click the Collection tab 2 Click the Point radio button see figure 3
32. Description 2 8 nP Chart Calculations G 1 vi CIMPLICITY SPC Operation Manual December 2000 GFK 1413E O Opening a New Document 4 4 Operation Overview SPC 2 3 Overview SPC analysis 2 1 Overview of Data Configuration Steps 4 2 P P Chart Description 2 7 P Chart Calculations F 1 Pareto Chart Description 2 10 Point Collection Attribute 4 43 Defect Category 4 70 Variable 4 17 Points Control Limits 4 25 4 52 Procedure for Upgrading SPC Charts J 2 Product Adding 4 9 Chart properties 5 4 5 5 Properties defining 4 10 Product Folder SPC 4 75 Products SPC configuration 4 9 Properties SPC chart 5 3 5 5 Q QC Chart properties 5 4 Quality Data Charts C Chart description 2 9 Histogram chart description 2 6 nP Chart description 2 8 P Chart description 2 7 U Chart description 2 9 XBar R chart description 2 5 XBar S chart description 2 5 X Individual chart description 2 4 Quick start SPC configuration 1 5 R R chart Center line calculation C 2 Control limit calculations C 2 Report Properties GFK I1413E Index SPC chart 5 10 Reports SPC 2 11 Runtime Functions SPC ActiveX control 6 1 S S chart Center line calculation D 2 Control limit calculations D 2 Sampling Parameters Using points 4 13 Using values 4 15 Setpoint Alarm 4 29 4 56 Setting Alarms for Attribute Quality Characteristics 4 56 Setting Alarms for Variable Quality Characteristics 4 29 SPC About 1 2 Administration Alarms
33. E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point In the Match value field enter the value to be matched against the Match Point ID to determine whether the collected data applies to this specific attribute quality characteristic If this is a batch process select a Batch Point ID This will allow you to distinguish between different batches for the same Product Quality Characteristic The value of GFK 1413E Configuring SPC Data 4 43 the Batch Point is associated with the calculated data and can be used as search criteria for charts and reports Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 9 Base Sampling parameters on Value or Point by clicking the appropriate radio button 10 Indicate the Subgroup size sample as follows see figure a If based on Value type a value for the sample size or b If based on Point do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Value option Point option M Walue o Piani Subgroups be suBGRF Ta Popup 24 Browse hr Manual snip slaved F EU conversan 11 Check the Manual entry allowed box to enable manual data entry for SPC chart sets at runtime clear to disable option 12 Check the EU conversion box if the SPC Da
34. ES FANUC GE Fanuc Automation CIMPLICITY Monitoring and Control Products CIMPLICIT Y Statistical Process Control Operation Manual GFK 1413E December 2000 GFL 005 Following is a list of documentation icons Fa A Warning notices are used to emphasize that hazardous voltages currents temperatures or other conditions that could cause personal injury exist in the equipment or may be associated with its use 0 Caution provides information when careful attention must be taken in order to avoid damaging results el Important flags important information 147 To do calls attention to a procedure Note calls attention to information that is especially significant to understanding and operating the equipment or software IP Tip provides a suggestion Akk Guide provides additional directions for selected topics This document is based on information available at the time of publication While efforts have been made to be accurate the information contained herein does not purport to cover all details or variations in hardware or software not to provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all hardware and software systems GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made GE Fanuc Automation makes no represent
35. Identify the Point ID data source from which the SPC Data Collector retrieves data The Point ID cannot have a Text type Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 4 When using any array specify the number where SPC should begin to collect values in the Start element field Note that the default is 0 5 When using any array specify the number where SPC should finish to collect values in the End element field Note that the default is 0 6 Check the EU conversion box if the SPC Data Collector is to use the EU value s for the Point Clear 1f the SPC Data Collector should use the raw value s for the Point Variable Collection Properties Point Automatic data collection Point C Logged None Point 1D WIDGET_LENGTH E gt Stark element End element M EU conversion Configuring SPC Data 4 18 10 CIMPLICITY SPC Operation Manual December 2000 Select a Point to indicate the Match Point ID numeric Point only in order to use the same data source that is identified by the Point ID for multiple variables Do one of the following Click ES to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point In the Match value field enter the value to be matched against the Match Point ID to determine whether the collected data applies to this specific variable quality c
36. LCL CL UCL RrS_LC R S CL Match_Point_ID Down to change its order in the list Remove All L Click Remove Click Add All gt All gt to remove to add all of the all the attributes attributes from the from the Display Available list to list to the the Display list Available list The lists are displayed in the dialog box and are described as follows Available attributes list of attributes to choose from for display purposes Display attributes list of attributes in the order in which they are currently being displayed CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Continue from Method 1 or Method 2 1 Add and remove attributes and change their order in the Display list as follows Add one attribute to the Display list Select an attribute in the Available attributes list Click Add Add all attributes to the Display list Click Add All gt Remove an attribute from the Display list Select the attribute Click Remove gt Remove all the attributes from the Display list Click Remove All Change the order of the attributes in the Select the attribute Display list Click Move Up to move it up in the list Click Move Down to move it down in the list 2 Click OK to effect changes or Cancel to cancel the operation Result The columns in the detail view display will reflect the selected attributes and their order as defined in the Confi
37. Operation Manual December 2000 GFK 1413E XBar R Chart The XBar R chart displays two charts one for the XBar values and the other for the Range values The formulas for calculating the center lines and control limits for the XBar R control chart are detailed in Appendix C The following 1s an example of an XBar R chart created using SPC ActiveX Control E z Widget Length iiias UCL 100 8 i 100 6 fs 7 5100 57 CL 100 61 100 46 LCL 100 4 1 3 5 f OTT 14 17 20 23 UCL 0 706 a U 62 a 20 43 eh 5024 CL 0 334 0 05 LCL 0 000 1 3 5 f 911 14 17 20 23 Subgroup Humber Group Batch ID Start QC QC LEN End Product WIDGET 2 XBar S Chart The XBar S chart displays two charts one for the XBar values and the other for the Sigma values The formulas for calculating the center lines and control limits for the XBar S control chart are detailed in Appendix D The following is an example of an XBar S chart created using SPC ActiveX Control i E EEE UCL 100 7 E Jeep Se 1008 CL 100 3 1 2 3 4 5 6 7 8 910 12 ae UCL 0 284 2 0 17 i 3010 CL 0 134 0 02 LCL 0 000 1243 45 6 8 9 10 12 Subgroup Number Group Batch ID start QC QC LEN S End Product WIDGET GFK 1413E SPC Overview 2 5 2 6 Histogram The Histogram shows you the distribution the central tendency and the scatter or variability of the sample data and calculates process capability The formulas for calculating process capability
38. Pareto chart you can set display parameters in the SPC Control Properties dialog box see figure If configuring a report or other chart type you can skip this section To set bar chart properties a Click the Bar Chart tab Result If you are configuring a Histogram the Histogram group will be active in the dialog box and the Pareto group will be dimmed The reverse is true if you are configuring a Pareto chart Histograms Group Check boxes and enter data using the definitions for options as follows Show spec limits to display the Upper and Lower Specification Limits configured for the data Clear check box to disable option Show normal curve to superimpose a normal distribution curve over the histogram data Clear check box to disable option Max samples enter the maximum number of samples to be displayed in the histogram Check box to display parameters on your Histogram or Pareto chart SAC Control Proporta fr Shon apec brits Pareto charts only Check box to superimpose a normal distribution curve Sho poma curve Check box and enter the over data number of bars to be Jan samples ET displayed on the Pareto a chart Enter the maximum fz number of samples Show fied number of bare 5 to display on the E Siew ber el wing defects histogram gt 2 Check box to display GFK 1413E Other defects on a separate bar Note The Histograms and Pareto groups are not both active at the sa
39. Properties UCLLineProperties ISpcLineProperties CLLineProperties ISpcLineProperties LCLLineProperties ISpcLineProperties ZoneLineProperties ISpcLineProperties SpecLimitLineProperties ISpcLineProperties NormalCurveLineProperties ShowUpperControlLimit ShowCenterLine ShowLowerControlLimit ShowZones ShowSpecLimits ShowNormalCurve ShowInfoBox ShowFixedNumberOfBars ShowRemainingDefects ShowValues MaxHistogramSamples NumberOfZones float UpperSpecLimit float LowerSpecLimit Configuring SPC Charts 5 13 Using SPC Charts Runtime Functions You can perform several functions from within an SPC ActiveX control using options on the popup menu 14 To perform runtime functions 1 Display an SPC ActiveX control 2 Position the cursor over the control and right click 3 Select an option from the popup menu see figure Update Manual Data Entry Print Exclusion Mode Properties Use Ambient Properties About SPC Popup Menu Option Descriptions Update updates the display with current data Manual Data Entry opens the Manual Data Entry dialog box for quality characteristics Print opens the Print dialog box for printing screen contents Properties opens the SPC Control Properties dialog box to set properties for the control Use Ambient Properties changes the foreground and a background color used by the ActiveX control to the ambient colors defined
40. SPC applets display in the project directory see figure ir SCPeens J Equipment J Security 2 Status Logs E Runtime 2 Ad d Database Logger an applet displays SPC applet displays f Double click the SPC applet and configure an SPC document For complete instructions see Configuring SPC Data 3 Run your project Result SPC data collection automatically starts 1 6 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E 4 Configure an SPC chart s For complete instructions see Configuring SPC Charts a Insert the CIMPLICITY SPC Control in an ActiveX container such as a CimEdit screen or Internet Explorer b Edit the chart properties click the General tab and do the following Browse for and select the SPC document Select the product to be displayed Select one of the configured QCs variable attribute or defect for the product Select the chart type for the display Select the chart duration c Click the Chart tab and do the following Select the type of chart to be displayed If you selected Show most recent values on the General tab enter the update interval Note Other chart properties are configured for your convenience You may use these default properties or tailor them to your application Introducing Statistical Process Control 1 7 SPC Overview SPC Analysis GFK 1413E SPC uses statistical methods to determine whether processes are within re
41. Specifying a Defect Category s General Characteristics Begin configuring a new defect category by defining its general characteristics in the General tab of the Defect Properties dialog box Characteristics are defined when a code is assigned and a description is indicated J1 To define general defect characteristics 1 Click the General tab 2 Type a text description for the defect in the Description field Type a description for the defect category Defect Properties CAT General Collection l Description IT EMP_TOO_HOT Cancel Help Note During your configuration and at runtime if SPC detects configuration inconsistencies it will display an SPC_ADMIN_ALARM in the Alarm Viewer See SPC Administration Alarms in this chapter GFK 1413E Configuring SPC Data 4 69 4 70 Defining Defect Category Collection Properties dl All Defect Categories in a Defect folder use the same collection method therefore specify the collection method in the Defect Folder Properties dialog box The Collection tab displayed for a Defect Category depends on what you selected for the Defect Folder Point Collection for a Defect Category When Point collection is designated in the Defect folder the Point input fields display in the Defect Properties dialog box Collection tab To specify Point collection for defect 1 Click the Collection tab see figure 2 Identify the Point ID data source from which the SPC Data Co
42. THESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS BRIGHTHESS 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 4 00 Batch o Suba Pay of y 2 11 SPC Data Source Overview SPC Data Source GFK 1413E SPC automatically creates a default Microsoft Access data source for you called CIMPLICITY SPC New SPC documents will use this data source by default You have the option of creating your own data source using another database such as SQL Server or Oracle if you want better performance or if you want to share the same data source across a network All the SPC documents in a CIMPLICITY HMI project must log their data to the same SPC data source You can share an SPC data source between projects or you can create a data source for each project See the CIMPLICITY HMI Base System User s Manual GFK 1180 for detailed instructions on creating custom data sources for Microsoft Access SOL Server and Oracle Note The SPC data source must be a System data source 3 1 Configuring SPC Data Introduction SPC offers several data collection types including using Points to track the quality of variables and attributes and the frequency of defects You can also implement several types of control tests the results of which can be displayed on XBar R or XBar S chart sets for variables and p nP c and u chart sets for attributes With this in mind begin con
43. This is a more efficient indicator of process variability especially with larger sample sizes However it is less sensitive in detecting special causes of variation that result in only a single value in a subgroup to be unusual From Statistical Process Control Chrysler Corporation Ford Motor Company and General Motors Corporation 1995 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E J4 Step Four Add and Configure Attribute Quality Characteristics Specify the attributes you want to measure for each product For each attribute indicate the following information Description for example Color_Light Collection characteristics Limits Alarms Calculation Type In addition you can select from among the following chart types p chart set measures the proportion of nonconforming discrepant or defective items in a group of units being inspected Proportion is defined as the ratio of the number of nonconforming items in a population to the total number of units in that population Sample sizes need not be equal nP chart set measures the number of nonconforming units in an inspection lot It is identical to p chart except that the actual number of nonconforming units rather than their proportion of the sample are plotted The inspection sample sizes must be equal in this case c chart measures the number of nonconforming units discrepancies or defects in an inspection lot The c chart requires a co
44. able ID where data is located Click El to browse for the Column ID where data is located Defect Properties dialog box Defect Properties CAT xl CIMPLICITY Alarm Logging CIMPLCIT Y Logging Alarms General Collection CIMPLICITY Logging SPC CIMPLCIT Y Logging Tracker CIMPLICITY Pont Logging CIMPLICITY SPC ODBC data source CMPLICITY SPC Database user Eric Password p Table ID Uni Temp Log ea Column ID Temp A E Cancel Help Configuring SPC Data 4 71 No Collection for a Defect Category When no collection method is specified in the Defect folder there are no applicable input fields in the Collection tab Manual data entry 1s automatically enabled Defect Properties CAT 4 72 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E SPC Administration Alarms GFK 1413E During runtime the SPC application detects the following kinds of inconsistencies Points are unavailable limits are out of sequence sampling parameters are invalid Therefore SPC comes with a built in SPC_ADMIN_ALARM to alert operators to those conditions This alarm is generated because of configuration inconsistencies in contrast to SPC alarms that are generated because of process problems Each instance of this alarm which will display in your Alarm Viewer provides you with Group Name Product Name QC Name Alarm number Alarm Numbers are as follows Required Points s are unavailable XBar con
45. alculations Appendix D XBar S Chart Calculations Appendix E Histogram Calculations Appendix F P Chart Calculations Appendix G nP Chart Calculations Appendix H C Chart Calculations Appendix I U Chart Calculations Appendix J Upgrading Quality Charts to Enhanced SPC Charts GFK 1413E iii Related Publications For more information about CIMPLICITY HMI software refer to these publications CIMPLICITY Base System User s Manual GFK 1180 CIMPLICITY CimEdit Operation Manual GFK 1396 iv CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Contents Introducing Statistical Process Control 1 1 Welcome to Statistical Process COMO id 1 1 About the CIMPLICTTY HMI SPC Option susi les 1 2 JO A are te an En EE Te E ee 1 3 SPE COMpOne mts sax cio 1 3 Upgrade Old SPC CliattS a cds aa 1 4 Quick Start Install and Configure the SPC Opti0ON oocccccccnnnnnccnnnnnnnnnnnnnnonnncnnnnnnncnnnnonononnnoss 1 5 SPC Overview 2 1 SPC AMAS a O 2 1 a Ie CN CAC INOS sidli austin sc phonoanaaneutoacuimatnanssagt0k eananssatecantuaanenvacanteniGain AR 2 2 SPC Operation Very W cada 2 3 JO E E aaneneneaiues 2 4 SPC Data Source Overview 3 1 Se Data OC ios 3 1 Configuring SPC Data 4 1 TNEPOCUC HOM ta ias 4 1 Overview of Data Configuration tepS ccccccconooooonononccnnnnnnnnnnnnnnonononononannnnnnnnnnnnnnnnnnnnnnnnnnnnnos 4 2 SPC DOCUINE oi ino 4 4 Opening a New Document ii 4 4 D etinine Document Properties intensa i a a 4 7 O
46. amiliar with ActiveX and want to add to that functionality as you design your screens the following methods and properties are available void AboutBox Calls the About dialog box Boolean GetControlLimits ucl cl lcl rucl Gets the current control limits displayed rel rlcl on the chart void Print Calls the Print dialog box void UseAmbientProperties Automatically changes an ActiveX control to use the ambient properties of the container 5 12 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E ActiveX Properties BSTR ChartTitle BSTR Updatelnterval short ChartType boolean ByTime BSTR StartTime BSTR EndDate BSTR EndTime short MaxDisplay boolean Exclusion mode OLE_COLOR BackgroundColor OLE_COLOR ChartColor OLE_COLOR ForegroundColor BSTR StartDate IFontDisp TitleFont boolean boolean boolean boolean UseAmbientBgColor UseAmbientFgColor UseAmbientChartTitleFont UseAmbientChartColor BSTR BatchID BSTR ProjectGroup BSTR Product BSTR C boolean boolean boolean boolean boolean boolean boolean boolean ShowLegend ShowChartTitle ShowXAxisLabels ShowXAxisTitle ShowYAxisLabels ShowYAxisTitle UseAmbientAxisLabelFont UseAmbientAxisTitleFont IFontDisp AxisLabelFont IFontDisp AxisTitleFont short ReportFields boolean boolean boolean boolean boolean boolean boolean boolean boolean boolean ISpcLine
47. an be configured for a single product at a time A maximum of four charts can be configured per product Attributes Properties General tab General Collection Limita Alarm e Active Descriptions Sample P Chart P CHART Calculation type JP CHART ce Data setpoint ID COLLECTION M a Browse Popup GFK 1413E Configuring SPC Data 4 4 4 42 Defining an Attribute s Collection Characteristics Define the SPC collection method and the source of the attribute input data using the Collection tab in the Attribute Quality Characteristic Properties dialog box Collection methods include Automatic Data Collection either Point Logged or None The type selected will activate corresponding fields in the dialog box When you use an Automatic Collection method you can also use the same data source for multiple attributes Match Point a batch process Batch Point ID or Batch Column ID Point Data Collection one or more CIMPLICITY Points are specified along with start and end indices for array Points and any engineering unit conversion default Logged Data Collection retrieves data from an ODBC database table Define the ODBC data source table and column names None specify whether or not manual entry will be allowed Manual entry can be allowed for any type of data collection you choose SPC automatically includes manual entry when you select None Select this option to prevent automatic data collect
48. aracteristic Properties Limits SPC configuration 4 48 Auto Recalculation for Control Limits 4 22 4 49 Axis Properties SPC chart 5 8 B Bar chart properties SPC chart 5 9 Bar Chart Properties SPC chart 5 9 Batch ID Chart properties 5 4 5 5 Begin Configuration 4 4 C C Chart Description 2 9 C Chart Calculations H 1 Changing the Date Time Format 5 11 Chart factors for control limits Xbar R charts A 1 Xbar S charts A 2 Chart properties Batch ID 5 4 5 5 Group 5 4 Histogram 5 9 5 10 Product 5 4 5 5 QC 5 4 Update interval 5 5 Chart Properties SPC chart 5 5 Chart Types SPC 2 4 CimEdit Creating an SPC chart 5 1 Collection Attribute point 4 43 Attributes logged 4 45 Defect category logged 4 71 Defect category point 4 70 Variable logged 4 19 Variable point 4 17 Collection Properties Defect category SPC configuration 4 70 Variable quality characteristics SPC 4 16 Components of SPC 1 3 Configuration Building 4 5 Control Limits Attributes 4 48 Auto recalculation 4 22 4 49 Control Test Exclusion Mode 4 36 Control Tests Alarms and setpoint 4 29 4 56 Criteria for Attribute Control Tests 4 58 Criteria for Variable Control Tests 4 31 D Date Time Changing 5 11 Defect Categories SPC configuration 4 68 Defect Category Adding 4 68 Logged collection 4 71 No collection 4 72 Point collection 4 70 Defect Category Properties Collection SPC configuration 4 70 General SPC configuration 4 69
49. aracteristics You can use Alarm settings to warn you if a particular process is slightly off even when production has not exceeded its control limits on a regular basis This enables you to anticipate and handle potential problem areas in your production facility Use the Alarm tab in the Attribute Quality Characteristics Properties box to specify the type of alarm that will be triggered Setpoint ID control test criteria that will initiate alarms or change Setpoints Alarms and Setpoints When one of the control tests meets your criteria for issuing a warning 1t will generate the type of warning you configure including an alarm to alert operators that criteria have been met for one of the control tests If alarms are generated for more than one control test they will stack up and be deleted according to specifications you enter in the CIMPLICITY HMI Alarm Configuration a Setpoint that will change to the number 0 9 of the Attribute characteristic tests alarm state 1 8 and Upper Specification Limit 0 Setpoints provide you with a way to automate corrective action You can write scripts that trigger the appropriate action whenever the criteria have been met for one of the control tests The value of the Setpoint reflects that last test for which an alarm was triggered J4 To specify an alarm and Setpoint 1 Click the Alarm tab see figure 2 You can select the SPC_ALARM system Alarm ID or you can creat
50. art Types 2 4 C Chart Description 2 9 Histogram chart Description 2 6 nP Chart Description 2 8 P Chart Description 2 7 Pareto chart Description 2 10 U Chart Description 2 9 XBar R chart Description 2 5 XBar S chart Description 2 5 X Individual chart Description 2 4 SPC Charts C Chart Calculations H 1 Histogram Chart Calculations E 1 nP Chart Calculations G 1 P Chart Calculations F 1 U Chart Calculations I 1 XBar R Chart Calculations C 1 XBar S Chart Calculations D 1 X Individual Chart Calculations B 1 SPC configuration Attribute quality characteristic properties Limits 4 48 Products 4 9 Variable quality characteristic properties Collection 4 16 Variable quality characteristic properties Limits 4 21 SPC Configuration Adding a variable 4 12 Attribute quality characteristics 4 39 Changing display attributes 4 76 Defect categories 4 68 Defect category properties General 4 69 Defect category properties Collection 4 70 Defect folder properties 4 65 Finding a product quality characteristic 4 78 viii CIMPLICITY SPC Operation Manual December 2000 Variable quality characteristic properties general 4 12 SPC datasource Creating 3 1 SPC Document Opening 4 4 SPC Reports 2 11 Suggested Readings SPC 2 2 T Time Date Changing 5 11 U U Chart Description 2 9 U Chart Calculations I 1 Update interval Chart properties 5 5 Upgrading old SPC charts 1 4 Upgrading SPC Charts J 1 Procedure J 2 What happens J 2 Usi
51. art to view runtime data or configuring a new SPC chart Control Test 0 Specification limit test This test checks the calculated acceptable percentage of nonconforming units or defects to the total sample size Subgroups that meet test criteria will be marked with a red asterisk For example if UCL 10 one Std dev 3 A JEA 3 n Oo 1171571999 2 16 05 PM 100 0000 Failed Tests 0 Ao E FF Position cursor over plotted point to view tool tip Control Test 1 One subgroup beyond upper or lower limits This test checks to see if any subgroups on the chart have a value greater than the upper control limit or less than the lower control limit Subgroups that meet test criteria will be marked with a red asterisk For example one Std dev 3 2 1 3 2 114151999 11 18 39 AM 32 0000 Failed Tests 1 Position cursor over plotted point to view tool tip GFK 1413E Configuring SPC Data 4 59 Control Test 2 N subgroups in a row on same side of center line This test checks to see if N subgroups in a row are on the same side of the center line The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 3 one Std dew A 2 cK RK Rue O ES 11 15 1999 11 25 43 4H 100 0000 Faled Test 2 ENE Vy ee B O A G A Position cursor over plotted point to view tool tip Control Test 3 N consecutive subgroups in a row all incr
52. ation of warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purpose shall apply CIMPLICITY is a registered trademark of GE Fanuc Automation North America Inc Windows NT Windows 2000 and Windows 98 are registered trademarks of Microsoft Corporation This manual was produced using Doc To Help by WexTech Systems Inc Copyright 2000 GE Fanuc Automation North America Inc All rights reserved Preface Content of this Manual This manual is composed of the sections described below Chapter 1 Introducing Statistic Process Control Describes the SPC features Chapter 2 SPC Overview Describes how SPC operates provides illustrations of the chart types and suggested reading for additional information on statistical process control Chapter 3 SPC Data Source Overview Discusses the SPC data source and its configuration Chapter 4 Configuring SPC Data Provides instruction on configuring SPC data using abundant graphics to enhance the procedures Chapter 5 Configuring SPC Charts Describes the available options for creating SPC ActiveX controls Chapter 6 Using SPC Charts Describes the runtime options for SPC ActiveX controls Appendix A Table of Constants for Control Charts Appendix B X Individual Chart Calculations Appendix C XBar R Chart C
53. by default to activate data collection for the product clear to disable option Note that the Document must also be active for collection 2 Inthe Product name field type a name for the product folder 3 Optionally type a Description 4 Inthe Resource ID field indicate the resource to be used by alarms generated for this product as follows Click Ej to browse for an existing resource in the Select a Resource dialog box or Click gt to designate a New Resource Product Properties El General e Active Product name GE APF Description ppliance components Resource ID ASSMBLE_1 E OR Cancel Popup Browse 4 10 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Variable Quality Characteristics GFK 1413E Once you have created a new product define the variables to be tracked for each Information that you enter in the Variable Quality Control Characteristics dialog box is used to configure a detailed Histogram and either an XBar R or XBar S chart set Use the Variable Quality Characteristics Properties dialog box to create and define characteristics as follows General characteristics including the name of the characteristic whether or not data is to be collected for the characteristic whether you want to use an XBar S or XBar R chart set the subgroup size and gap size Collection characteristics specifies the data collection method Limits lt sets control and specifica
54. ce search results as follows Searches for any number of characters in the string For example to display the list of products whose name starts with M and ends with X enter M X in the Product Name field Searches for any number of characters at this Point in the string For example to display the list of products that are three characters long and whose name starts with M and the third character is X enter M X in the Product Name field Click Browse to display results in dialog box Double click the item in the list to go to the item in its folder in the SPC directory or click OK to close the dialog box Note There are no implied wildcards If you do not include or end your search string with an asterisk only an exact match will be returned in the result list Configuring SPC Data 4 79 Configuring SPC Charts Getting Started After you create your ODBC data source and configure your SPC data collection you can configure SPC ActiveX controls in CimEdit CimView screens or other ActiveX containers such as Internet Explorer to display your SPC data Creating an SPC Chart in CimEdit 311 To create an SPC chart in a CimEdit screen Method 1 Click the SPC button El on the toolbar Result A new SPC Control is placed in the upper left corner of the CimEdit screen The SPC control initially is empty and displays a message for editing the control Method 2 1 Click the OLE button
55. click on the SPC Configuration applet E in the project directory Result The first time you double click the SPC Configuration applet a new document will open with one Products folder displayed in the directory All related products and their accompanying variables attributes and defects will be placed in this main Products folder see figure Start from the Workbench in the project directory AI TRACKPROJ CIMPLICITY Workbench Mal Fa ly Screens El SpcCigl SPC Configuration s Y Objects File Edit View Tools Help ME Classes aa Points 1 gt Ej de N Hy ez Result The SPC Configuration window displays al Databaze with the main Products folder AA Basic Cor For Help press Fl created in the directory 7 Double click the SPC applet Ex Note More than one document can exist in a project 4 4 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E 41 To create additional documents 1 Click File on the menu bar 2 Select New 3 Select SPC Configuration Document from the pullout menu Result A new SPC configuration window will display SPC documents are numbered consecutively see figure 3 Select SPC 1 Click File on Configuration Document the menu bar is SpeCfgl SPC Configuration MES Edit 2 Select New Wel SPC Configuration Document View Tools Help i SpcCfg SPC Configuration OF ES Edt View Too Help at D W
56. defect categories in Lie PRODE subfolder in the detail view m i SPCTEST where ye is a Defect Category Double click on the applet to view its properties right click on the applet to access a popup menu with additional options Configuring SPC Data 4 75 4 76 Changing Display Attributes You can change the type of attributes displayed for a QC or defect category and their order in the detail view of the SPC document using the Configure Display Attributes dialog box A column will be added to the detail view of the SPC document for each attribute that you choose to display J4 To change display attributes do one of the following Method I View menu 1 Click View on the menu bar 2 Select Attributes Method 2 Quick keys 1 Press Ctrl A Result Using either method the Configure Display Attributes dialog box opens Select the attribute from the Select the attribute from the list to be ADDED to the list to be Removed to the Display attributes list and Available attributes list and then click Add gt then click Remove gt Configure Display Attributes Available attributes Type Active Mame Select the attribute Add gt Description AA in the Display list Collection Point ld Batch_Point_ID 7 U and click either Calculation_T ype lt Rlemove Collection _ Type ove ZP Move Up or Move SubGroup Size Gap size Add All gt Match_Value Move Down Data SetPoint Manual Eritry Allover
57. e and click gt to move data to the Subgroup Size and Values boxes CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E Variable 1 Inthe Subgroup Size field type the value to be manually entered 2 Inthe Raw Value field type the value to be manually entered gt f f i 3 Press gt to move data into the Subgroup Size and Values boxes respectively 4 Continue to enter manual data in the same manner 5 Once all the manual data has been entered click Submit to send the data to the SPC Data Collector Tip Use the Clear All button to quickly delete all of the data from the list box es Using SPC Charts 6 5 F 6 Defect QC Data di When you select Manual Data Entry for a Defect QC chart the Manual Data Entry Defect QC dialog box opens To manually enter data for a Defect QC 1 Type the Defect Category name in the Defect Code field 2 Type the number of occurrences for the Defect Category in the Num of Occ field 7 3 Press E next to the Num of Occ field to move the value into the list box 4 Continue to enter manual data in the same manner 5 Once all of the manual data has been entered click Submit to send the data to the SPC Data Collector Manual Data Entry Detect QC E Product WIDGET DE Jac_DEF Defect Code Number of Occ Defect Code Mum OF Oce nl Close Clearall CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Appendix A Tab
58. e project icon in the window to display it in the Workbench Click Tools on the menu bar Select Upgrade Old SPC Charts Follows the prompts to upgrade the charts Tip To open a project quickly in the Workbench create a shortcut on your Windows desktop What Happens during the Upgrade Procedure When you upgrade your old SPC charts to the latest version of the software you will be prompted for information in order to facilitate the transition The following list explains what happens during the upgrade procedure The upgrade procedure begins by prompting you for an ODBC data source for storing the results of intermediate SPC calculations The ODBC data source is where the SPC data collector process will store its data After prompting for an ODBC data source the upgrade procedure searches through all CimView screens starting in the directory you specify and recursing through all its subdirectories As the utility finds references to old style Quality Charts in these screens it prompts you for a Product Name and QC Name for each of the charts Then it replaces the charts Finally the upgrade procedure generates a single SPC configuration file called SPC1 SPC It places this configuration file in your project s SPC directory All charts in the project need to know the location of this configuration file The upgrade procedure takes care of this for existing charts that it upgrades Caution Do not move rename or delete the SPC1
59. e the Control limits Center Line CLU 5 u Upper Control Limit UCLU CLU 3 SU Lower Control Limit LCLU MAX 0 CLU 3 SU CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Appendix J Upgrading Quality Charts to Enhanced SPC Charts Upgrade Quality Charts to Enhanced SPC Charts GFK 1413E You must upgrade your existing Quality Charts if one of the two items listed below is true Charts were created using a version of CIMPLICITY HMI prior to v3 1 Charts were created using CIMPLICITY HMI v3 1 but you did not purchase and install the Enhanced SPC software IC646NSPOOOA prior to creating the charts If you are currently using CIMPLICITY HMI v3 2 or later and you attempt to display a screen containing one of these charts you will see a message indicating that the charts must upgraded Before beginning the upgrade make sure you back up all necessary CIMPLICITY HMI projects as the upgrade procedure will alter both your screens and your project verify that an SPC ODBC data source exists See Creating the SPC Data Soiurce for additional information J J 2 Starting the Upgrade Procedure di To start the upgrade procedure O ONDA FF WN From your Windows desktop press Start Select Programs gt CIMPLICITY gt HMI gt Workbench to open the Workbench window Click File on the menu bar Select Open to display the Open window Navigate to your SPC project Double click on th
60. e your own alarm in the Alarm ID field Use the SPC_ALARM type when creating your own alarm Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point The alarm message for SPC alarms consists of the following strings Document Name Product Name Quality Defect Characteristic Name A description of the control check that triggered the alarm The value of the sample that triggered the alarm 4 56 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E 3 Inthe Setpoint ID field indicate a Point to be set when an SPC alarm occurs A Setpoint will change to 0 9 of the Attribute QC tests Alarm state 1 8 and Upper Specification Limit 0 Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click to designate a New Point Attribute Quality Characteristics Properties ATT A PRATT a Check to enable alarming Check boxes to activate control tests and indicate test criteria M m E E E m E m E m 4 Check the Alarm enabled box to activate alarming for the attribute clear to disable option 5 Proceed to next section Criteria for Attribute Control Tests for complete instructions and information GFK 1413E Configuring SPC Data 4 57 Criteria for Attribute Control Tests SPC plots the averages of the samples you define on n nP c and u chart sets These charts
61. easing or decreasing This test checks to see if N subgroups in a row are increasing in value or decreasing in value The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 3 one Std dev T aa nD p Position cursor over plotted point to view tool tip 4 60 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Control Test 4 N subgroups in a row alternating up and down This test checks to see if N subgroups in a row are alternately increasing in value then decreasing in value The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 3 one Std dev 3 2 AA LAA Ripe A poe SRAM Y Y OO ee 144181999 11 42 05 4M 530000 Faled Tests 4 apo YF T noD B Position cursor over plotted point to view tool tip Control Test 5 M out of N subgroups in a row in Zone A or beyond same side of center This test checks to see if M out of N subgroups in a row on the same side of the center line are in Zone A or beyond The Mth subgroup that meets the test criteria will be marked with a red asterisk For example if M 2 and N 3 one Std dev E E E E A a E AL A 81999 11 48 11 SM 81 0000 Failed Tests 5 Position cursor over plotted point to view tool tip GFK 1413E Configuring SPC Data 4 61 Control Test 6 M out of N subgroups in a row in
62. ecember 2000 GFK 1413E GFK 1413E Click on the Product directory to view its contents in detail view Product Folder in the Document Tree Each SPC Product folder contains a collection of Variable Quality Characteristics Attribute Quality Characteristics and Defect folders that can be used to determine the quality of the product When you click on a Product folder in the directory the contents of the folder are displayed in the Detail view see figure Detail view of the product subfolder All configured QC and defect folders are displayed subfolder in the where 3 is a Variable Quality Characteristic for the product Double click on the applet to view its properties right click on the applet to access a popup menu with additional options is an Attribute Quality Characteristic for the product Double click on the applet to view its properties right click on the applet to access a popup menu with additional options ES 1s a Defect folder for the product that holds configured defect categories Click on the folder to display 1ts Defect codes in the Detail view Defect Folder in the Document Tree Defect folders contain its configured Defect Categories When you click on a Defect folder in the directory the contents of the Details frame look like the following Detail view of the defect subfolder All configured defect categories are displayed Click on the Defect 54 ae directory to view f BE cariz
63. ements displayed by this chart C p and C pk Depending on whether the source of the data is an XBar R or XBar S chart the estimate of the process standard deviation differs For XBar R data the estimate of the process standard deviation is R d SO ii For XBar S data the estimate of the process standard deviation is o S cC Ola Capability Index Cp is the capability index defined as the tolerance width divided by the process capability irrespective of process centering For XBar R data it is calculated as USL LSL N Oka For XBar S data it is calculated as USL LSL N Sic GFK 1413E E 1 Capability Index for Process Centering Cr is the capability index which accounts for process centering and is defined as the p p y p 8 minimum of the upper and lower capability indexes It relates the scaled distance between the process mean and the closes specification limit to half the total process spread For XBar R data the upper and lower indexes are calculated as USL X X LSL PUSE MEP A IO 4 3 Oka For XBar S data the upper and lower indexes are calculated as USL X X LSL CPU s and CPL 305 305 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Appendix F P Chart Calculations P Chart Calculations The P chart measures the proportion of nonconforming discrepant or defective items in a group of items being inspected Proportion is defined as the ratio of
64. erating reports for variable QC data For attribute QC data p nP c and u charts can be displayed as well as generating reports Pareto charts are available for displaying Defect data It also handles Manual entry of data for variable attribute and defect charts You can embed SPC ActiveX objects into any CimEdit screen by inserting and OLE object or by configuring charts using the SPC Properties dialog box 4 64 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Defect Folders In addition to entering product variable and attribute information you can enter information that SPC will use to track a product s defects SPC displays each group of defects on a Pareto chart Configure defects by creating a Defect folder will display as a Pareto chart adding defect categories will each display as one bar on the chart Adding a New Defect Group Within a product you can create one or more Defect folders for SPC Pareto chart analysis 441 To create a Defect folder for a product Method 1 File menu 1 Expand the Products folder and select the product in the directory 2 Click File on the menu bar 3 Select New 4 Select Defect Folder from the pullout menu Method 2 Popup menu 1 Expand the Products folder and select the product in the directory 2 Right click and select New Defect Folder from the popup menu Result Using either method the Defect Folder Properties dialog box opens New Defect
65. es None no data is to be collected by the SPC Data Collector The Manual entry allowed box is checked by default Note All Defect Categories in this Defect folder will use the collection method you designate for the folder Configuring SPC Data 4 67 Defect Quality Characteristics Once you have created a Defect folder add the defect quality characteristics that will appear together by creating a defect category for each A bar on the Pareto Chart represents each Defect Category Use the Defect Properties dialog box to create and define defects as follows General characteristics Includes the name of the characteristic and an optional description Collection characteristics Describes how the data will be collected The type of data collection used is determined by the collection method you select for the Defect folder Adding a New Defect Category 44 To place a new Defect Category in a Defect folder do one of the following Method 1 File menu 1 Select the Defect folder 2 Click File on the menu bar 3 Select New 4 Select Defect Category from the pullout menu Method 2 Popup menu 1 Navigate to the Defect folder in the directory 2 Select the folder and right click on it 3 Select New Defect Category from the popup menu Result Using either method the Defect Category Properties dialog box opens defaulted to the General tab 4 68 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E
66. es may be available in the drop down list Defect QC Variable QC Attribute OC Pareto chart XBar R or XBar S p Report X Individual nP Report c u Report In the Max to display field type the maximum number of elements to display on the chart using the following guidelines XBar R S charts number of subgroups X ndividuals charts histograms n nP u c and Pareto charts number of samples In the Update Interval field enter the time in hh mm ss to update chart data Note that this field is disabled 1f you are using logged data 7 Use the pullout Palette amp Special menus to customize 1 Select the chart type the foreground background from the drop down list and chart characteristics General Chat Linss Avis Bar Char Report Color Tepe F chas AA a daw to dapi 25 Background _ indo TI Sekred daras 3 Enter the time in hh mm ss to update the chart Field is disabled if using logged data 4 Type the title of the chart Click Font to designate the font point size and color Click Show title to display the chart title on screen otherwise clear box r EA a Winds _ Selected hem le gt Lindiste miena no LIE fer 6 Toate gt Chal Giles hrs bere Me ToolTip ten Tite SPC Pro P Chat Le Show fille Font 5 Check to enable 6 Check to Show Exclusion Mode clear the chart legend to disable clear to disable GFK 1413E Configuring SPC
67. evand Control LINIS e dd F 2 Appendix G nP Chart Calculations G 1 ME Carl Cae WAT A DEET EEA TOETA ee Deed ee G 1 Data dd ad een di G 1 Center Line and Control Limits ooooococnonnccnoconcnnnnnnononcnoconcoronnonconcnacononcnocnnos G 1 Appendix H C Chart Calculations H 1 CoG That AIC UA OS asian a o te lr ll We a ar H 1 MAC A O H 1 Center Line and Control Limits oococconnocnocncconnonononononcnoconcnrnnnnnconcnncononnnacnnss H 1 Appendix I U Chart Calculations l 1 AE A A a e a A A I 1 DS NI A dec ake tute A A 1 1 Center Line and Control Limits oococcncnocnocnccncnncnocnocnocnonnnnno noc nonnonnr nor nnononnnnncnncnoos 1 2 Appendix J Upgrading Quality Charts to Enhanced SPC Charts J 1 Upgrade Quality Charts to Enhanced SPC ChartS occccccccccccnnnnnnnnnnononanocnnnnnnnnnnnnonnnnnnnnnnnnnnnnos J 1 Staring the Uperade Procedure sicssci seecainestaccosnenssicsseadaninsnausbaatanaadamhawtealentamaneniaes J 2 What Happens during the Upgrade Procedure oocccccccccccnncccnononocnnnnnnnnnnnnnnnnnnnnnnnnnns J 2 lossary of Terms i Index V Contents vii Glossary of Terms GFK 1413D 1 Attribute Data The qualitative data that can be counted for recording and analysis Attribute data is usually gathered in the form of nonconforming units The units are analyzed by P nP C and U control charts Attribute Quality Characteristic A distinguishing feature of a process or its out
68. figuring your SPC application s considering which factors will be needed to support your quality control program Consider the following Who will use SPC and in what manner Configure SPC for users who will have SPC on a server and will be able to configure SPC data will have a runtime version and will make runtime decisions What products SPC will be tracking for data Which variables are to be monitored for quality for example Widget_length In order to keep data management under control begin with a few of the most critical variables This will prevent you from becoming overwhelmed by too much information Also avoid collecting data too frequently Which attributes require monitoring for quality Again select only the most critical attributes when you first begin Which defects for each product need to be tracked for example Color_too_light kh bh Important The SPC Data Collector logs its raw and calculated data to an ODBC data source Before you start configuring SPC for a project make sure that the CIMPLICITY Database Logger is installed and configured for the project GFK 1413E 4 1 Overview of Data Configuration Steps diy diy diy 4 2 In order to configure SPC to collect analyze and display statistical data follow the steps outlined below Detailed procedures for each for each of the steps are provided in this chapter Step One Add and Configure an SPC Document The SPC document is the co
69. followed for control limits still apply to both SPC automatic recalculation options as follows When your process is new or in optimum condition calculate the limits using the Auto Recalculation or Force Auto Recalculation option Once you determine that SPC has automatically collected enough data to calculate the correct control limits disable the automatic calculation option The calculated control limits are then used for the life of the process Remember that the control limits produced by auto recalculation are valid only when your process is in control If you calculate them while your process is going out of control then the limits will be incorrect CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di Control Limits for Specific Values You can use your own criteria to set control limits using the Values option in the Limits tab of the Properties dialog box Also you can use the Force Auto Recalc feature to override limit values set in the dialog box To specify Values for control limits 1 Click the Limits tab 2 Click the Values radio button see figure below 3 Enter the values for the XBar chart s control limits as follows XBar UCL Upper control limit XBar CL Center line XBar LCL Lower control limit 4 Enter the values for the R or S chart s range or standard deviation as follows R S UCL Upper control limit R S CL Center line R S LCL Lower control limit
70. forming Sigma Standard deviation snp N p 1 p Center Line and Control Limits GFK 1413E Calculate the Control limits Center Line CLNP N p Upper Control Limit UCLNP E CLNP 3 SNP Lower Control Limit LCLNP MAX 0 CLNP 3 SNP G 1 Appendix H C Chart Calculations C Chart Calculations The C chart measures the number of non conformities discrepancies or defects in an inspection lot The C chart requires a constant sample size Data Available N 1 R 1 K Number of defects in each subgroup K Inspection Quantity To be calculated Process Average Number Non conformities Sigma SC VC Center Line and Control Limits Calculate the Control limits Center Line CLC C Upper Control Limit UCLC gt CLC 3 SC Lower Control Limit LCLC i MAX 0 CLC 3 SC GFK 1413E H 1 Appendix U Chart Calculations U Chart Calculations The U chart measures the number of non conformities per inspection unit in subgroups which can have varying sample sizes It is similar to C chart except that the number of non conformities is expressed on a per unit basis Data Available N Subgroup size T 1 K Total produced K Inspection Quantity D 1 K Total Defects in sample To be calculated Process Average Non conformities Per Unit u U 1 K where Ur D Ti Sigma Standard deviation VU SU N GFK 1413E El 1 2 Center Line and Control Limits Calculat
71. from the Histogram chart are detailed in Appendix E The following 1s an example of a Histogram created using SPC ActiveX Control E a Widget Length 35 Mean 35 3 4L5L USL Cp 1 1 Cpk 0 827 USL 101 AS LSL 100 5 Mean 101 Range 0 175 a epa Sigma 0 151 mo Samples 25 5 85 0 00 1 0e 002 1 0e 002 1 0e 002 Samples Group Batch ID Stat QC QC LEN end Product WIDGET e CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E P Chart The P chart measures the proportion of nonconforming discrepant or defective items in a group of items being inspected Proportion is defined as the ratio of the number of nonconforming items in a population to the total number of items in that population Sample sizes do not have to be equal The following is an example of a P chart created using SPC ActiveX Control UCL 0 2529 z CL 01936 LEL 01343 5 10 15 20 25 Subgroup Pumber Group WPRJ_ALPHASPECFG1 Batch ID Start ie ATT End Product PROD SPC Overview 2 7 2 8 nP Chart The nP chart measures the number of nonconforming items in an inspection lot It is identical to p chart except that the actual number of nonconforming items is plotted rather than their proportion of the sample The inspection sample sizes must be equal in this case The following is an example of an nP chart created using SPC ActiveX Control 121 1077 UCL 99 49 T 90 8306 T CL 7
72. gure Display Attributes dialog box GFK 1413E Configuring SPC Data 4 77 Finding a Product Quality Characteristic An SPC document can contain many products and many quality attribute and defect characteristics You can use the Find function to quickly search for a specific characteristic or subset of characteristics 44 To initiate a search do one of the following Method 1 Tools menu 1 Click Tools on the menu bar 2 Select Find Method 2 Quick keys 1 Press Ctrl F Result Using either method the Find a Product Quality Characteristic dialog box opens see figure 1 Click Tools onthe 2 Select Find menu bar Product Home a OC Harre pr Caral Spcligi SPC Configuration 1 3 Do one of a b or c to find a product or quality characteristic EJ 4 Click Browse ae T a Type a product name or use search criteria to locate a product O c b Type a quality characteristic name or use search criteria c Type a quality type or use search criteria 4 78 CIMPLICITY SPC Operation Manual December 2000 to display results in the dialog box GFK 1413E GFK 1413E Continue from Methods 1 amp 2 1 In the appropriate field use the following filters to reduce the list of quality and defect characteristics Product name Quality Attribute Defect characteristic name Quality Attribute Defect characteristic type You can also use wildcards to redu
73. haracteristic For example the collected Point ID data source may be used to measure a variable for example length for several products Product 1 Product 2 Product 3 You can enter a Match Point ID value of 1 to measure length for Product 1 and 2 to measure length for Product 2 If this is a batch process select a Batch Point ID This will allow you to distinguish between different batches for the same Product Quality Characteristic The value of the Batch Point is associated with the calculated data and can be used as search criteria for charts and reports Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Check the Manual entry allowed box to enable manual data entry for SPC chart sets at runtime clear to disable option Variable Collection Properties Point Match Point ID WAR MATCH Eel Match value 15 Batch Point ID V4R_BATCH E gt e Manual entry allowed GFK 1413E Logged Collection for a Variable If you select Logged SPC retrieves data from an ODBC database table that has already been updated by CIMPLICITY HMI Define logged collection in the Variable Quality Characteristics Properties dialog box Note SPC logs all of its data Therefore the Logged option is not necessary for saving data It refers to using an additional data source for input The Point collection method is more efficient J4 To specify
74. he corresponding fields 4 Select the quality characteristic to be examined for the product This will determine the chart type 1c Double click the 1b Click Browse to retrieve document containing the the configured documents in data to be displayed the project 4 Select the Quality Characteristic QC to be examined for the product using the drop down list You will have two or more options to choose from based on the calculation for the product and the selected QC Report and chart type s 5 Click the appropriate radio button to select the duration for data collection Show most recent values displays the most recent values collected in the chart Time span indicate the start time and date and the ending time and date to collect data to be displayed on the chart 5 4 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Chart Properties You can choose to display a report or a chart and you can also customize the look of your display in the SPC Control Properties dialog box see figure 44 To define SPC chart properties L Ze 2 Enter the maximum number of elements to display on the chart SPC Control Properties Click the Chart tab The drop down list in the Type field will display two or more options Report and available chart type s The chart type is dependent on the QC selected in the General properties and the configuration calculated for the product The following typ
75. i 2 Whether it will have an XBar R or XBar S chart set 3 Sampling parameters including whether the sample parameters will be based on Points or specific values subgroup sample size gap size To specify general characteristics 1 Click the General tab see figure 2 The Active box is checked by default to activate data collection for the product clear to disable option Note that the Document must also be active for collection Variable Properties dialog General tab General Collection Limits Alarm e Active Description Cycle Time Bar Calculation type Barth al e e j Data setpoint ID CYCLE_VAR_SET me Browse Popup Type a Description for the variable which will display in the directory 4 Select XBar R or XBar S chart set from the Calculation type drop down list 5 If you want to use the current XBar R or S value elsewhere in your project or download them to a device indicate the floating point array Point of two 2 elements in the Setpoint ID field The array contains numbers for XBar and range or XBar and standard deviation Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click 2 to designate a New Point 6 Click Values or Points to specify the sampling parameters see next sections for details Using Points to Specify Sampling Parameters You can use Points to specify sampling parameters as described below When you
76. ing SPC Data 4 47 Setting Limits for Attribute Quality Characteristics Once you have defined the attribute s general characteristics and collection methods you are ready to set control limits for your p nP c and u chart sets in the Attributes Quality Characteristics Properties dialog box Included are Control limits and Specification limits Control Limits for an Attribute In order to set control limits for your chart sets SPC provides you with several different options If you know the limits that you want to set you can use Points or Values If the process is new and you would like to have limits calculated automatically for you you can use the auto recalculation features Whatever your preference SPC provides you with an option You can specify values for control limits by entering values or using auto recalculation You can enter values as specific values Points Caution If you enter specific values during configuration and SPC detects an inconsistency it will display an error message and will not allow you to save the configuration until you correct the error Example You select Values to enter an attribute s control limits and enter 25 for an Upper Control Limit and 50 for a Lower Control Limit SPC will display the following error message The upper control limit must be greater than the center line and the center line must be greater than the lower control limit Note If you
77. ion CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Point Collection for an Attribute You can designate Points for data collection using the Collection tab of the Attribute Quality Characteristics Properties dialog box Here the scope of the collection can also be specified 11 7 To specify Points for data collection L 2 3 Click the Collection tab In the Automatic data collection group click the Point radio button see figure Identify the Point ID data source from which the SPC Data Collector retrieves data The Point ID cannot have a Text type Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click 2 to designate a New Point When using any array specify the number where SPC should begin to collect values in the Start element field Note that the default is 0 When using any array specify the number where SPC should finish collecting values in the End element field Note that the default is 0 Attribute Collection Properties Point Automatic data collection e Point Logged None Point ID TRIAL_COLLECTION A Start element lo End element E Match PointID MATCH_POINT ae Match value E Batch Point ID BATCH_POINT Popup Browse Select a Point to indicate the Match Point ID numeric Point only in order to use the same data source that is identified by the Point ID for multiple attributes Do one of the following Click
78. islas rienda Manual Data EOU y a E nan Varable OG Data olas AORE OC Dita Defect OC Dita caisstiita versie salen A Appendix A Tables of Constants for Control Charts XBar and R Chart Factors for Control Limits ooccoccocnccncnncnocnocncnnannnnocnonns XBar and S Chart Factors for Control Limits cccccc ccc eccescescecceccscescescecs Appendix B X Individual Chart Calculations X Individual Chart Calculations o Gels X lndividial Center Lit isa X Individual Standard Deviation cccccescecceccsccscesceccecescesceces Appendix C XBar R Chart Calculations XBat R Chart Calculations anal ABAR Chn Center Tine retail lib XBar R Chart Control LIMITS occcooccnnnccnnncccnnncnnnoccnonoconancnnonacinanoss RCM Conte io R Chart Control Litunia iros CIMPLICITY SPC Operation Manual December 2000 Deo 5 13 GFK 1413E GFK 1413E Appendix D XBar S Chart Calculations D 1 ADS Char O a eo agil D 1 XBar S Chart Center Line cc ccc ceccecescecceccscccccceccscceccscceceeccceccecescesceccscescescecens D 1 XBars C hart Control as ed rate dl D 2 S Chait Contento tesoros D 2 SS CRA ENT AMS acicate D 2 Appendix E Histogram Chart Calculations E 1 Histogram Chart Cal culations 2 a E 1 Capabilit Index isso d E 1 Capability Index tor Process Centering cuand E 2 Appendix F P Chart Calculations F 1 P Gel se ei Cati AMA TOT RPT Oe ORT OO RO F 1 Data Available cr e oidos F 1 Center in
79. istics Properties dialog box opens with the General tab displayed see figure New Variable Quality Characteristic example of right click method Sy eee A TT Specltgl SPC Configuration File Edt Yiew Took Help Oa brm 3 General Collection Limit Am Data seponti gt Sampling Parsmeless Values C Points fubpopse a Delte Humba ap fo Result The Variable Quality iE j O Characteristic Properties dialog box displays on the General tab 1 Expand the main Products folder Products Hee Yabe Judy Lael New dttritade Qualip Chatacte ot 3 Select New Variable b Cut Cori Quality Characteristic ay Copy Cola from the popup menu rF Pas 2 Right click on the Product in the directory ES Note When you create a new characteristic SPC calls it VAR in the document tree If there is more than one variable that you have not named SPC numbers them in the order they were created and lists the description you input in the General tab of the Properties dialog box You can rename the variable at any time in the directory Specifying a Variable s General Characteristics Begin configuring a new variable by defining its general characteristics using the General tab of the Variable Quality Characteristics Properties dialog box Enter the following information 1 A description of the variable 4 12 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di d
80. itions The charts were created prior to CIMPLICITY HMI v3 1 The charts were created using CIMPLICITY HMI v3 1 but you did not purchase and install the Enhanced SPC software IC646NSPOO0O0A prior to making them Note When attempting to view a screen containing an old SPC chart an error message will display indicating that the charts must be upgraded See Upgrading Quality Charts to Enhanced SPC Charts for information on upgrading SPC charts CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Quick Start Install and Configure the SPC Option Before you can begin to use the powerful features offered by the SPC option make sure the option is installed on all computers where you want to collect or view SPC data Installing the SPC option is quick and easy using your original installation CD for CIMPLICITY HMI 14 To install the SPC option l A O e e HHI Server Options Place the installation CD in the CD ROM drive The CD will AutoPlay OR from the Windows desktop press Start gt Run Type d setup bat where d is the CD ROM drive and click OK Select Install CIMPLICITY HMI from the menu Proceed to the CIMPLICITY HMI Setup dialog box Click the Review Add Options radio button Click Next to display the HMI Server Options dialog box see figure 1 Click Applications Options 2 Click SPC Charts box box Clear all other boxes in Clear all other boxes in the the Components group Options gro
81. its at runtime This feature can be configured to be turned on or off at runtime Point On When the Point is on set to TRUE auto recalculation is activated and the chart s control limits are recalculated The data collector will set the control Points specified in the dialog box fields to the calculated values Point Off When the Point is off set to FALSE auto recalculation is deactivated and the last calculated values are used until the control Points are updated Do one of the following see figure Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point ES Note Whenever the Force Auto Recalc Point is set to either TRUE or FALSE the data collector will drop the current sample and start fresh Configuring SPC Data 4 53 Auto Recalculation Control Limits In order to automatically set control limits for a new process or when your process is in optimum condition use the Auto Recalculation option 14 To use auto recalculation to automatically set values 1 Click the Limits tab 2 Click the Auto recalculation radio button see figure 3 If you want to use the current control limits elsewhere in your project or download them to a device indicate the floating point array Point of three 3 elements in the Setpoint ID field The Point contains three elements for all values to be set in the following order LCL CL UCL Do one of the following Click E to
82. lders cenere a a oree teat Adding a New Defect Group ici iii aa Defining Defect Folder Properties cccccscseeesssseeeeeeeeeeeecceeeees Defect Quality Characters ias Adding a New Defect Category ooooooonnnncncncnononnnonononnnnnncnnnnnnnncnnnnnnos Specifying a Defect Category s General Characteristics Defining Defect Category Collection Properties SPC Administration Alarms c0 ceseccssacuieavseedenchinasineavscedendssacvecesesedaedsondetenoseeses Document Tools cada canai s Documentados Changing Display Attributes ooooooooooccccnnnnnnnnnnnnnnnnnnononnnononnnnnnos Finding a Product Quality Characteristic oooooooooooncccoccnnnnnnnnnnnnnnos Configuring SPC Charts Gelli Stated estas aa ici Creating an SPC Chart in CimEdit oooooooooooooonccccnnnnnnnnnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnos Contisurmo SPC Chart Propere Seon n RE RAE General Properties sensein a e a tec latesees Chart Properties anean a o todo de ias li deceid oos Line Propers nta ASIS POPE eS sta citas Bar Chart Properties aran A ne ean to res a Tar area E UNS racine Racy wre ta Creating an SPC Chart in a Web Page ooooonnnnnccccncnccccnnnnnnonononononnnnnnnnnnnnnnnnnos Changing the Date Time Format on Charts cccccccccccnnnnnnnnnnnonnnnnnnnnnnonnnnnnnnnos ActiveX Methods and Properties iii aldea aci n ACNE PrOpe RIES cool ocio dao a Using SPC Charts Runtime PUC a Displaying Test RESUS csi lalola aani ros
83. le ID where data is located 7 Click E to browse for the Column ID where data is located GFK 1413E Configuring SPC Data 4 45 8 Click El to browse column ID to match against when using the same data source for multiple attributes 9 Inthe Match value field enter a value integer to be matched against the Match Column ID to determine whether the collected data applies to this specific attribute quality characteristic 10 If the process 1s a batch process click El to browse for the Batch Column ID that will allow you to distinguish between different batches for the same Product Quality Characteristic The value of the Batch Point is associated with the calculated data and can be used as search criteria for charts and reports 11 Indicate the Subgroup size as follows Enter a numeric value or Click Ej to browse for the column where the subgroup size is located 12 Check the Manual entry allowed box to enable manual data entry for SPC chart sets at runtime clear to disable option 4 46 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E aa No Collection for an Attribute If you choose to enter your own data do not designate a data collection source To specify None for data collection 1 Click the Collection tab 2 Click the None radio button Result The Manual entry allowed box is checked by default to enable manual data entry Attribute Quality Characteristics Properties ATT Configur
84. le Quality Characteristics Properties box to specify the type of alarm that will be triggered Setpoint ID control test criteria that will initiate alarms or change Setpoints Alarms and Setpoints When one of the control tests meets your criteria for issuing a warning it will generate the type of warning you configure including an alarm to alert operators If alarms are generated for more than one control test they will stack up and be deleted according to specifications you enter in the CIMPLICITY HMI Alarm Configuration a Setpoint that will change to the number 1 8 of the XBar test that is in an alarm State Setpoints provide you with a way to automate corrective action You can write scripts that trigger the appropriate action whenever the criteria have been met for one of the control tests The value of the Setpoint reflects the last test for which an alarm was triggered J4 To specify an alarm and Setpoint 1 Click the Alarm tab see figure 2 You can select the SPC_ALARM system Alarm ID or you can create your own alarm in the Alarm ID field Use the SPC_ALARM type when creating your own alarm Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point The alarm message for SPC alarms consists of the following strings Document Name Product Name Quality Defect Characteristic Name A description of the co
85. les of Constants for Control Charts XBar and R Chart Factors for Control Limits The values for samples ranging in size from 0 to 25 for XBar and R charts are Chart for Averages Chart for Ranges Sample Size A gt D D 0 0 000 0 000 0 000 1 2 660 0 000 3 267 2 1 881 0 000 3 268 3 1 023 0 000 2 574 4 0 729 0 000 2 282 5 0 577 0 000 2 114 6 0 483 0 000 2 004 7 0 419 0 076 1 924 8 0 373 0 136 1 864 9 0 337 0 184 1 816 10 0 308 0 223 1 777 11 0 285 0 259 LISO 12 0 266 0 284 1 717 13 0 249 0 308 1 692 14 0 235 0 329 1 671 15 0 223 0 348 1 652 16 0 212 0 363 1 637 17 0 203 0 378 1 622 18 0 194 0 391 1 608 19 0 187 0 403 1 597 20 0 180 0 415 1 585 21 0 173 0 425 1 575 22 0 167 0 434 1 566 23 0 162 0 443 1 557 24 0 157 0 451 1 548 25 0 153 0 459 1 541 GFK 1413E XBar and S Chart Factors for Control Limits A 2 The values for samples ranging in size from 0 to 25 for XBar and S charts are Chart for Averages Sample Size As 0 1 2 2 659 3 1 954 4 1 628 5 1 427 6 1 287 7 1 182 8 1 099 9 1 032 10 0 975 11 0 927 12 0 886 13 0 850 14 0 817 15 0 789 16 0 763 17 0 739 18 0 718 19 0 698 20 0 680 21 0 663 22 0 647 23 0 633 24 0 619 25 0 606 for Standard Deviations Bs 0 000 0 000 0 000 0 000 0 000 0 000 0 030 0 118 0 185 0 239 0 284 0 321 0 354 0 382 0 406 0 428 0 448 0 466 0 482 0 497 0 510 0 523 0 534 0 545 0 555 0 565 CIMPLICITY SPC Operation Manual December 2000 Ba 3 268
86. llector Manual Data Entry Variable QC Product PWIDGE T OC ja C_LEN Faw Value N Close Clear All GFK 1413E Using SPC Charts 6 3 Attribute QC Data When you select Manual Data Entry for an Attribute QC chart the Manual Data Entry Attribute QC dialog box opens di Fixed only 1a Click Fixed for a To manually enter data for an Attribute QC chart Click the appropriate radio button to establish the Subgroup Size as follows Fixed subgroup size is constant Variable subgroup size is subject to change Result The input fields will reflect the selected option Fixed or Variable see figure Fixed 1 Inthe Raw Value field type the value to be manually entered 2 Press gt to move the value into the Value box 3 Continue to enter manual data in the same manner 4 Once all the manual data has been entered click Submit to send the data to the SPC Manual Data Entry MAbbtribube OC Data Collector Variable only 2a Click variable to be able to change the subgroup size constant subgroup size 1b Type value and click gt to Manual E move it to the Value box Produrt r Subgioup Sine 1c Once all the values have been entered click to submit data F 4 Fred is Wariable Subgroup Soe How Yale 2d Once all the values have been entered click to submit data 2b Type subgroup 2c Type corresponding size valu
87. llector retrieves data The Point ID cannot have a Text type Do one of the following Click El to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 3 When using any array specify the number where SPC should begin to collect values in the Start element field Note that the default is 0 4 When using any array specify the number where SPC should finish collecting values in the End element field Note that the default is 0 5 Check the EU conversion box if the SPC Data Collector is to use the EU value s for the Point Clear if the SPC Data Collector should use the raw value s for the Point Defect Properties CAT General Collection Point ID TEMF_OFCT KE Start element End element CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di Logged Collection for a Defect Category When Logged collection is designated in the Defect folder the Logged input fields display in the Defect Properties dialog box Collection tab To specify Logged collection for defect L Ze Click the Collection tab see figure Use the ODBC data source drop down list to select the name of the database from which SPC will retrieve data In the Database user field type a name for the user when logging into the ODBC data source In the Password field type a password for the user when logging into the ODBC data source Click El to browse for the T
88. m and it is assumed that users have a working knowledge of both software products Please refer to the documentation that originally came with your software for questions about CIMPLICITY and Microsoft Windows l 2 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E SPC Features The SPC option comes complete with a host of exciting features Major features include Live data viewing from ActiveX containers such as CimView screens and Internet Explorer Easy scalability from a simple workstation to Client Server configurations Generation of CIMPLICITY HMI alarms for out of control conditions This means in addition to displaying out of control conditions on SPC charts you can display alarms for them in the Alarm Viewer log them to an Alarm Log Printer and log them via the Database Logger Centralized configuration that allows for the creation and maintenance of all the various characteristics and specification limits for your process even though your charts may cross over several CimView screens on your HMI system XBar R X Individual XBar S and Histogram charts for variable quality characteristics p nP c and u charts for attribute quality characteristics Pareto charts for defect analysis Tabular reports that let you view numeric data in table format High quality printing directly from the SPC ActiveX control Both logged and runtime Point data collection Access to changing values for sample sizes control li
89. me side of the center line The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 8 one Std deu Control Test 3 N consecutive subgroups in a row all increasing or decreasing This test checks to see if N subgroups in a row are increasing in value or decreasing in value The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 6 4 32 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Control Test 4 N subgroups in a row alternating up and down This test checks to see if N subgroups in a row are alternately increasing in value then decreasing in value The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 14 one Std deu Control Test 5 M out of N subgroups in a row in Zone A or beyond same side of center This test checks to see if M out of N subgroups in a row on the same side of the center line are in Zone A or beyond The Mth subgroup that meets the test criteria will be marked with a red asterisk For example if M 2 and N 3 GFK 1413E Configuring SPC Data 4 33 Control Test 6 M out of N subgroups in a row in Zone B or beyond same side of center This test checks to see if M out of N subgroups in a row on the same side of the center line are in Zone B or beyond The Mth subgrou
90. me time on the SPC Control Properties dialog box as shown in the figure above Figure is for instructive purposes only Configuring SPC Charts 5 9 Pareto Group Check boxes and enter data using the definitions for options as follows Show fixed number of bars check box and enter the number of bars to be displayed on the Pareto chart If you have more defect codes than bars only the bars for the most frequently occurring defects will display Clear check box to display a bar for each defect code defined for this product Show bar of remaining defects check box to display the total number of other defects on a separate bar marked Other Clear the check box to disable option Report Properties You can configure the data to be displayed on your report in the SPC Control Properties dialog box Several options for adding information are available using the Report tab see figure 14 7 To set report properties 1 Click the Report tab 2 Check boxes to display options on your report or clear boxes to disable options SPC Control Properties Click to select Fields dl bei ime meL masa es id Check boxes to display data on your 4 Subgroup I CL RCL Unselect All report Clear boxes M Bar vale a UCL M RS UCL EEE to disable option M R S value A vale the check boxes Cancel Apply Help i Tip Alternately use the Select All button to check all of the options or the Unselect All button to disable
91. ming and control tests to be performed on the data Caution If you enter specific values during configuration and an inconsistency is detected SPC will display an error message You cannot save the configured data until the error is corrected Note If you use Points for general characteristics on limits rather than specific values SPC will alert the user when the values become specific at runtime If SPC detects configuration inconsistencies it will display an SPC_ADMIN_ALARM in the Alarm Viewer See SPC Administration Alarms Configuring SPC Data 4 39 Adding a New Attribute Quality Characteristic 144 To add an Attribute Quality Characteristic do one of the following Method I File menu 1 Expand the Products folder and select the product 2 Click File on the menu bar 3 Select New 4 Select Attribute Quality Characteristic from the pullout menu Method 2 Popup menu 1 Expand the Products folder and select the product 2 Right click and select New Attribute Quality Characteristic from the popup menu Result Using both methods the Attribute Quality Characteristic Properties dialog box opens with the General tab displayed see figure New Attribute Quality Characteristic example of right click method 2 Right click 1 Expand the on the product 3 Select New main Products to display Attribute Quality folder popup menu Characteristic y SpeCigl SPC Configuration file Edt Miew Tools Help Att
92. mits and auto recalculation during runtime Manual data entry through a dialog in the SPC ActiveX control Calculated data stored in a database via ODBC that lets you use standard database tools for such things as exporting data reporting and maintenance SPC Components The SPC option consists of the following three components SPC Data Collector Process that runs in the background and collects data performs analysis alarms out of control conditions and writes calculated data to the database based on your configuration A new enhanced feature of SPC is the ability to analyze attribute data and store the resulting data in a database for further processing SPC Group Configuration Graphical User Interface that enables you to configure the quality characteristics and defect categories to be analyzed The latest addition to the Interface is the ability to configure attribute characteristics SPC ActiveX Control ActiveX control that can be embedded in an ActiveX container such as a CimEdit CimView screen or Internet Explorer This enables you to view the data analyzed by the SPC Data Collector through various charts and reports Also you can perform such functions as manually entering data printing displaying charts and setting up an ODBC data source GFK 1413E Introducing Statistical Process Control 1 3 Upgrade Old SPC Charts 1 4 You will be required to upgrade your existing SPC charts 1f they meet one of the following cond
93. n XBar R chart displays the average of each sample in the set its center line is calculated as Nit Xo Ka m X where X 1 through Xm are the averages of each sample and m is the number of samples This grand average becomes the center line of the XBar chart XBar R Chart Control Limits To construct the upper control limit UCL and lower control limit LCL for the XBar R chart we need to know the standard deviation of the data This can be estimated with the range method In a sample of size n the range is the difference between the smallest and largest observations In other words R X max X min GFK 1413E C 1 If R7 through Rn is the range of m samples then the average range is Rit R24 Rm m R The formulas used for calculating the upper and lower control limits for the XBar chart are UCL x A R LCL x A R Where A2 is a tabulated value based on the sample size See the XBar Chart Factors for Control Limits table in Appendix A for values of A2 for sample sizes ranging from 1 to 25 If the sample size is greater than 25 the formulas are UCL X 38 LCL X 3S where is the standard deviation for the chart R Chart Center Line For the R chart the formula for calculating the center line 1s Rit R24 Rm m R R Chart Control Limits The formulas used for calculating the upper and lower control limits for the R chart are UCL RDs LCL RD where D4 and D3 are tabulated values
94. n in the Limits tab of the Properties dialog box Also you can use the Force Auto Recalc feature to set the Point values for control limits 11 7 To specify Points for control limits 1 Click the Limits tab 2 Click the Points radio button see figure 3 Enter the a different Point for the UCL CL and LCL control limits as follows Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 4 If you want to use the current control limits elsewhere in your project or download them to a device indicate the floating point array Point of three 3 elements in the Setpoint ID field The Point contains three elements for all values to be set in the following order LCL CL UCL Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point 5 Indicate the Upper Spec Limit for control criteria Attributes Limits Properties Points Control limits C Values Eont Auto recalculation acu ES en a El gt o fora aa Setpoint ID CSET_ARRAYS Popup Force Auto Recalc CFORCE_BOOL En Browse Specification limits Upper Spec Limit E 4 52 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di To use auto recalculation to set Point values In the Force auto recalc field indicate the Boolean Point ID that has been created to override the value control lim
95. ng Points to Specify Sampling parameters 4 13 Using Values to Specify Sampling parameters 4 15 V Variable Logged collection 4 19 Point Collection 4 17 Variable Control Test 1 Beyond upper lower limits 4 32 2 Same side of center line 4 32 3 Consecutive subgroups in a row 4 32 4 Alternating up and down 4 33 5 In a row in beyond A 4 33 6 In a row in beyond B 4 34 7 In a row in C 4 34 8 In a row beyond C 4 35 Variable QC Data Manual data entry SPC ActiveX control 6 3 Variable Quality Characteristic Adding 4 12 Variable Quality Characteristic Properties Collection SPC configuration 4 16 General SPC configuration 4 12 Limits SPC configuration 4 21 GFK 1413E W Web Page Creating SPC charts 5 11 X Xbar R chart Center line calculation C 1 XBar R chart Control limit calculations C 1 XBar R Chart Description 2 5 XBar R Chart Calculations C 1 XBar R chart factors for control limits A 1 Xbar S chart Center line calculation D 1 XBar S chart Control limit calculations D 2 XBar S Chart Description 2 5 XBar S Chart Calculations D 1 XBar S chart factors for control limits A 2 X Individual chart Center line calculation B 1 Control limit calculations B 1 X Individual Chart Description 2 4 X Individual Chart Calculations B 1 GFK 1413E Index
96. nstant sample size u chart measures the number of nonconforming items per inspection unit subgroups which can have varying sample sizes It is similar to c chart except that the number of nonconforming units is expressed on a per unit basis 11 Step Five Add and Configure Defect Categories Specify the defects that are to be tracked for each product For each defect indicate the following information Defect Description Scope for example if you want to use the same data source for multiple defects Collection characteristics Measurement SPC generates Pareto charts by default Note If you already know the control limits for a process simply enter them If not for example because the process is new use SPC auto recalculation to calculate control limits for variables and attributes When you are satisfied with the calculated limits enter the calculated limits and disable SPC auto recalculation GFK 1413E Configuring SPC Data 4 3 SPC Document Software configuration for SPC begins with opening and configuring an SPC document The SPC document is the container for one or more products that you will add and configure When the document is active every included product will be tracked unless you deactivate tracking for one or more of the products at the product level See Defining Product Properties Opening a New Document 144 To open an SPC document 1 Open your project in the Workbench 2 Double
97. ntainer for all of the products that are to be grouped together The products variables attributes and defects are stored here in a directory structure similar to Windows Explorer The properties that you specify for your document will impact all of its included products For example the designated ODBC data source will store data calculated from the SPC Data Collector for all the products included in the document Step Two Add and Configure Products The product is the main container for the type of data that you will choose to collect and analyze Initially you will provide a name description and resource ID for your product Step Three Add and Configure Variable Quality Characteristics Specify the variables you want to measure for each product For each variable indicate the following information Description for example Widget_Length Collection characteristics Limits Alarms Calculation Type For each variable that you add a histogram is automatically generated by SPC In addition you can select between the following chart types XBar R chart set to view the range between the highest and lowest point in a sample This range is relatively efficient for small subgroup sample sizes especially below 9 Although it provides you with a spread it does not give you a clear indication of where the points fall relative to your control limits XBar S chart sets to review the average of the standard deviations
98. ntrol check that triggered the alarm The value of the sample that triggered the alarm GFK 1413E Configuring SPC Data 4 29 3 Inthe Setpoint ID field indicate a Point to be set when an SPC alarm occurs as follows Click E to browse for an existing Point in the Select a Point dialog box or Click to designate a New Point Variable Quality Characteristics Properties VAR SDEVICE FAILOVER af TI al Check to enable alarming xl Check boxes to activate control tests and indicate test criteria 4 Check the Alarm enabled box to activate alarming for the variable clear to disable option 5 Proceed to next section Criteria for Variable Control Tests for complete instructions and information about each of the available control test options 4 30 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Criteria for Variable Control Tests GFK 1413E SPC plots the averages of the samples you define on XBar charts in the XBar R and XBar S chart sets It is the XBar charts that display the zone in which these averages fall At runtime each subgroup that meets one or more of the selected test criteria will be displayed with a special character the default is a red asterisk The following zones are used in these tests Zone C is the area up to one standard deviation from the center line Zone B is the area between one and two standard deviations from the center line Zone A is the area between two and
99. o meaningful information use information to change your process and increase quality monitor your process on a continuous basis react to runtime information maintain consistent quality levels SPC is built on and fully integrated with the CIMPLICITY HMI family of products As with all CIMPLICITY products SPC runs in a Windows based environment enabling flexibility for multiple users and a familiar platform that decreases the learning curve GFK 1413E 1 1 About the CIMPLICITY HMI SPC Option The CIMPLICITY HMI SPC option provides you with the industry standard set of statistical tools that enable you to analyze data and convert it into useful information CIMPLICITY HMI SPC is capable of collecting and analyzing data 24 hours a day providing critical information about potential quality problems using the alarming feature This enables you to make improvements to your quality program and allows you to monitor changes and verify results CIMPLICITY HMI SPC provides you with the following types of charts and printed reports for analyzing your process data Variable Attribute Characteristics Characteristics Defects Bar R p Pareto XBar S nP X Individual C Histogram u Based on Microsoft s design standards CIMPLICITY SPC charts are designed as OCX control objects so that they are easily added to your CimView screens Note This manual is not intended to provide instruction on CIMPLICITY HMI or your Windows operating syste
100. ol Limit SPC will display the following error message The upper control limit must be greater than the center line and the center line must be greater than the lower control limit Note If you use Points for general characteristics on limits rather than specific values SPC will alert the user when the values become specific at runtime If SPC detects configuration inconsistencies it will display an SPC_ADMIN_ALARM in the Alarm Viewer See SPC Administration Alarms GFK 1413E Configuring SPC Data 4 21 100 kh bh SPC Auto Recalculation Feature One of the many advantages SPC offers is its ability to automatically calculate the control limits for a process This particularly comes in handy if your process is new and you want the SPC program to generate control limits SPC offers two options to automatically recalculate control limits Auto recalculation is used in place of Values or Points Once the control limits are automatically calculated select either Values or Points for the life of the process Force Auto Recalc is used in addition to Values or Points This option provides the flexibility to reset control limits during runtime As a result when you send an application to production you can have SPC recalculate the control limits so that they are accurate for the process Once the control limits are automatically calculated disable the Force Auto Recalc option Important The Quality Control rules you have always
101. ollowing chart types XBar R nP XBar S c E p E u The SPC exclusion process evolves as follows 1 During runtime when an SPC chart is on screen the operator selects Exclusion Mode An X appears at the top left of CimView indicating that Exclusion Mode is active 2 The operator selects the samples to exclude 3 SPC automatically performs a recalculation based on the exclusions and updates the control limits displayed on the chart J4 Totoggle SPC Exclusion Mode On Off SPC comes with two methods to toggle Exclusion Mode On Off Both methods are accessed through CimView when an SPC chart is on screen Method I Popup menu 1 Right click on an SPC chart that is display on an SPC CimView screen 2 Select Exclusion Mode from the popup menu see figure Result Exclusion Mode is checked on the popup menu signifying the feature is active Update Manual Data Entry Print Exclusion Mode Exclusion Mode Properties Use Ambient Properties About SPC 4 36 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E ddy Method 2 Double click 1 Double click the SPC chart to display the SPC Control Properties dialog box 2 Click the Chart tab 3 Check the Exclusion Mode box SPC Control Properties Color Type Barr Chart zl Foreground Y Black Max to display 25 Background O white r Update interval 00 00 02 Chart Yellow Chart title Title widget Length
102. on the toolbar Result The mouse pointer changes to a bracket A GFK 1413E 5 1 5 2 2 Position the bracket on the CimEdit screen and click to fix the position of the chart Result The Insert Object dialog box opens see figure Insert Object ActiveX Object From file Acrobat Control hor Actives lo Achyvebar Class a ActveMovwielontral Object AB Actives etup TextCtl Object 4 ActivexPlugin Object a CIMPLICITY AMY Control Gor CIMPLICITY HDA Viewer Editor Control Select ts 3 CIMPLICITY Recipe Control SPC Control CIMPLICITY SPC Control and then Al CIMPLICITY Trend Control Add Control Cancel Help Click OK 3 Select CIMPLICITY SPC Control from the ActiveX list 4 Click OK Result A new SPC Control is placed at the position you selected in your CimEdit screen The SPC control initially is empty and displays a message for editing the control CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Configuring SPC Chart Properties GFK 1413E diy Configure SPC chart Properties using the CIMPLICITY SPC Control Properties dialog box To open the CIMPLICITY SPC Control Properties dialog box Method I Quickest Double click on the chart Method 2 Edit menu 1 Click Edit on the menu bar 2 Select CIMPLICITY SPC Control Object 3 Select Properties from the pullout menu Method 3 Popup menu 1 Select the chart 2 Right click and select Properties from the po
103. or above or below the central line Sigma The Greek letter O used to designate a standard deviation Special Cause A source of variation that is intermittent and often unpredictable Sometimes called an assignable cause it is signaled by a point beyond the control limits a run or other non random pattern of points within the control limits Standard Deviation A measure of the spread of the process output Subgroup A subgroup is a set of one or more observations that are used to calculate a point on an SPC chart Another term for a subgroup is a sample Variable Data Variable data consists of measurable parameters such as weight temperature or length Variable Quality Characteristic For CIMPLICITY SPC a Variable Quality Characteristic is a measurable parameter such as weight temperature or length Other terms for Variable Quality Characteristic are Variable QC or variable data Glossary lil Introducing Statistical Process Control Welcome to Statistical Process Control Welcome to Statistical Process Control SPC CIMPLICITY s state of the art option for supporting a successful quality control program SPC enhances your ability to manage a quality control program by addressing the four major phases of quality control Measurement Analysis Improvement Control CIMPLICITY SPC supports your quality control program by enabling you to collect substantial amounts of accurate data convert data int
104. p that meets the test criteria will be marked with a red asterisk For example if M 4 and N 5 Control Test 7 N subgroups in a row in Zone C above or below center This test checks to see if N subgroups in a row lie in Zone C on either side of the center line The Nth subgroup and all the following subgroups that meet the test criteria will be marked with a red asterisk For example if N 15 4 34 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Control Test 8 N subgroups in a row beyond Zone C above or below center This test checks to see if N subgroups in a row lie beyond Zone C on either side of the center line The Nth subgroup and all following subgroups that meet the test criteria will be marked with a red asterisk For example if N 8 GFK 1413E Configuring SPC Data 4 35 SPC Control Test Exclusion Mode A process must be in control when you determine the control limits for your process However when you calculate the control limits there may be some variation due to special causes such as samples being taken when your machines are warming up When there is this kind of variation SPC exclusion mode allows you to manually select samples for exclusion from control limit calculation har Important When calculating control limits variation must be due to common causes only Variation cannot be attributable to special causes or control limits are not valid SPC Exclusion Mode is enabled on the f
105. pup menu Result Using any of the above methods the CIMPLICITY SPC Control Properties dialog box will open Configuring SPC Charts 5 3 General Properties Define the appearance of your SPC chart in the General tab of the SPC Control Properties dialog box see figure 144 To define SPC general properties 1 Type in the qualified path to the project and SPC document containing the data to be displayed in the chart Alternately click the Browse button to search for the project and SPC document 2 Select the Product to be charted from the drop down list 3 Inthe Batch ID field enter the text that identifies the batch process to be examined The chart will display only those points where the content of the Batch Point ID matches this identifier 1a Type in or select the project from the drop down list 1 Type in or click Browse to select the project amp SPC document that contains the data to be displayed 3 teh a SL Grip Ba Wena EPI Corro Properties Fini SPECOHRIGTE ST r E Baraa chat Lines e Buchi Report i 2 Select the Product from the drop down list 3 Optionally enter the amd text ID for the batch to C GPa rod recent ale Tare spar be examined f Sida GS Gaie TIAN End date fining 5 Designate the duration for data collection by clicking the appropriate radio button and entering data in t
106. put on which attribute data can be collected Average The sum of values divided by the number or sample size of values This is usually designated by a bar over the symbol for the values being averaged The most common averages in SPC are X The average of values within a subgroup X The average of subgroup averages also called the process average R The average of subgroup ranges Central Line The line on the control chart that represents the average value of the items being plotted Characteristic A distinguishing feature of a process on which variable data can be collected Control Chart A graphic representation of a characteristic of a process It shows the plotted values of data for the characteristic a central line and one or two control limits Control Limit A line or lines on a control chart used as a basis for judging the stability of a process Control limits are calculated from process data Defect Data Defect data consists of a defect code and a count of the number of units that contain that defect It is possible for a unit to contain more than one defect Defect data is displayed in a Pareto chart which ranks the defects by number of occurrences Defect Quality Characteristic For CIMPLICITY SPC a Defect Quality Characteristic defines the collection of defect categories be used for defect data for a Pareto chart Other terms for Defect Quality Characteristic are Defect QC or defect data Document
107. quired limits While CIMPLICITY HMI s normal alarm functions detect when individual Points actually exceed limits SPC analysis can provide early warning by detecting undesirable systematic variations in your process This can help you pinpoint process machine operator or material problems so that actions can be taken to diagnose and resolve the problem CIMPLICITY SPC uses an SPC ActiveX control that supports XBar R XBar S X Individual and Histogram charts for analyzing variable data p nP c and u charts for analyzing attribute data Pareto charts for analyzing defect data The data is retrieved from ODBC logging analyzed according to the standard SPC calculations for the chart and displayed graphically by populating configured charts with the result This ActiveX control can be used in CimEdit CimView screens or other applications like Internet Explorer that supports ActiveX controls The SPC variable charts display values between 4 sigma 4 O and 4 sigma 40 Data outside of this range is not displayed but it is still used in the chart calculations 2 1 2 2 Suggested Readings This manual shows you how to use the SPC option available for CIMPLICITY HMI To acquire additional information about SPC please consult one of the many SPC publications that are currently available Suggested publications are Easy as SPC Perry Johnson Inc 1986 Statistical Quality Control Handbook Western Electric Co Inc
108. r Click gt to designate a New Point 5 Indicate the Upper Spec Limit for control criteria Attributes Limits Properties Values Values C Points Auto recalculation UCL CL 13 5 LEL 11 5 Setpoint ID CSET_ARRAYS Popup Force Auto Recalc CFORCE_BOOL T Browse Specification limits Upper Spec Limit E CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E di To use auto recalculation to set control limit values In the Force auto recalc field indicate the Boolean Point ID that has been created to override the value control limits at runtime This feature can be configured to be turned on or off at runtime Point On When the Point is on set to TRUE auto recalculation is activated and the chart s control limits are recalculated Pre set values are ignored Point Off When the Point is off set to FALSE auto recalculation is deactivated and the last calculated values are used Pre set values are ignored until the data collector is restarted or dynamically refreshed Do one of the following see figure Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Note Whenever the Force Auto Recalc Point is set to either TRUE or FALSE the data collector will drop the current sample and start fresh Configuring SPC Data 4 51 Points Control Limits In order to use Points to set control limit criteria use the Points optio
109. ribute Quality Characteristics Properties ATT General E _ Limits Alarm GE DAY Defect Folder New Variable Quality Characters a a 7 Yew Attribute Quality Characteristic sl IE E AAA Calculation type IF CHART Cut Ctrl Data setpoint ID E Copy Ctrl Mn Paste o Result The Attribute Quality Delete Characteristic Properties dialog Rename box displays on the General tab Properties 4 40 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Specifying an Attribute s General Characteristics Begin configuring a new attribute by defining its general characteristics in the General tab of the Attributes Quality Characteristics Properties dialog box J4 To specify general characteristics 1 Click the General tab see figure 2 Check Active box to activate data collection for the attribute clear box to disable option The Document and Product must also be active for collection 3 Type a Description for the attribute that will be displayed in the directory 4 Select from among p nP c and u chart sets from the Calculation type drop down list 5 If you want to use the current p nP c or u values elsewhere in your project or download them to a device indicate the floating Point in the Setpoint ID field as follows Click El to browse for an existing Point in the Select a Point dialog box or Click 2 to designate a New Point Note Of the four available chart types only one c
110. s of your chart and also customize the look of their titles and labels in the SPC Control Properties dialog box see figure J4 To set X and Y axis properties 1 Click the Axis tab 2 Check boxes to show lines on your chart or clear boxes to hide lines Lines display as follows Show X axis title Displays the X axis title Show X axis labels Displays X axis labels Show Y axis title Displays Y axis title Show Y axis labels Displays Y axis labels 3 Click Font Title to display the Font dialog box Adjust the font style and size of your X and Y axis titles using the available options 4 Click Label Font to display the Font dialog box Adjust the font style and size of your X and Y axis labels using the available options Adjust the font style and size of your titles and Check boxes to show labels using the X and Y axis titles and scroll lists labels Clear boxes to hide titles and labels SAC Control Properti Ed Hait Microsoft Sans Se Electi Strikeout Select a TrueType font so that text will display correctly Note For both the Title and Labels be sure to select a TrueType font Other fonts may not display the text correctly on your chart CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Bar Chart Properties Histograms only Check box to display configured Upper amp Lower Genera Chat T ra specification limits di If you are configuring a Histogram or
111. set in the following order XBar LCL XBar CL XBar UCL R S LCL R S CL R S UCL Do one of the following Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Indicate the Specification limits for Histogram analysis as follows Lower type the Lower Specification Limit LSL Upper type the Upper Specification Limit USL Configuring SPC Data 4 25 J3 To use auto recalculation to set Point values Inthe Force auto recalc field indicate the Boolean Point ID that has been created to override the value control limits at runtime This feature can be configured to be turned on or off at runtime Point On When the Point is on set to TRUE auto recalculation is activated and the XBar R S control limits are recalculated The data collector will set the control Points specified in the dialog box fields to the calculated values Point Off When the Point is off set to FALSE auto recalculation is deactivated and the last calculated values are used until the control Points are updated Do one of the following see figure Click E to browse for an existing Point in the Select a Point dialog box or Click gt to designate a New Point Variable Quality Characteristics Properties YAR General Collection Limite Alarm Control limits C Values 6 Points Auto recalculation Bar UCL xEAR_UCL A gt sueca As_UCL BIB Bar C xBAR_CL Jo msc As_cL HE
112. sing the Auto Recalculation or Force Auto Recalculation option Once you determine that SPC has automatically collected enough data to calculate the correct control limits disable the automatic collection option The calculated control limits are then used for the life of the process Remember that the control limits produced by auto recalculation are valid only when your process 1s in control If you calculate them while your process is going out of control then the limits will be incorrect Configuring SPC Data 4 49 4 50 dl Control Limits for Specific Values You can use your own criteria to set control limits using the Values option in the Limits tab of the Properties dialog box Also you can use the Force Auto Recalc feature to override limit values set in the dialog box To specify values for control limits 1 Click the Limits tab 2 Click the Values radio button see figure 3 Enter the values for the p nP c or u chart s control limits as follows UCL Upper control limit CL Center line LCL Lower control limit 4 If you want to use the current control limits elsewhere in your project or download them to a device indicate the floating point array Point of three 3 elements in the Setpoint ID field The Point contains three elements for all values to be set in the following order LCL CL UCL Do one of the following Click E to browse for an existing Point in the Select a Point dialog box o
113. standard deviations then the average standard deviation 1s gt r aa S e 2 m The formulas used for calculating the upper and lower control limits for the XBar chart are UCL x As LCL x As Where A3 is a tabulated value based on the sample size See the XBar Chart Factors for Control Limits table in Appendix A for values of A3 for sample sizes ranging from 1 to 29 If the sample size is greater than 25 the formulas are UCL X 38 LCL X 38 where is the standard deviation for the chart S Chart Center Line For the S chart the formula for calculating the center line is Sy Sy TS S m S Chart Control Limits The formulas used for calculating the upper and lower control limits for the S chart are UCL sBa LCL sB3 where B3 and B4 are tabulated values based on the sample size See the Range Chart Factors for Control Limits table in Appendix A for values of B3 and B4 for sample sizes ranging from 1 to 25 If the sample size is greater than 25 the formulas are UCL 5 3S LCL s 35S where is the standard deviation for the chart CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Appendix E Histogram Chart Calculations Histogram Chart Calculations The Histogram shows you the distribution the central tendancy and the scatter or variability of the sample data This chart also displays the calculated process capability for the data There are two process capability measur
114. ta Collector is to use the EU value s for the Point Clear if the SPC Data Collector should use the raw value s for the Point 4 44 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Logged Collection for an Attribute You can choose to use data logged for the attribute in the ODBC database table that is updated by CIMPLICITY HMI Specify logged collection options using the Attribute Quality Characteristic Properties dialog box J17 To specify Logged for data collection 1 Click the Collection tab 2 Click the Logged radio button 3 Use the ODBC data source drop down list to select the name of the database from which SPC will retrieve data 4 In the Database user field type a name for the user when logging into the ODBC data source Attributes Collection Properties Logged Attribute Quality Characteristics Properties ATT General Collection Limits Alarm CIMPLICITY Alarm Logging aia are im l oggirig Point Logged C None CIMPLICITY Logging Tracker DDEC data CIMBDY CIMPLICITY Point Logging CIMPLICITY SPC Database user Sandi O Password ET Table ID Tai at si Column IE coit E Match Columnl D eaz at sis El Match Value o Batch ColumalL batchcol o Po Sampling Automatic data collection Subgroups ize M Manual entry allowed Cancel Help 5 Inthe Password field type a password for the user when logging into the ODBC data source 6 Click El to browse for the Tab
115. the ODBC data source 7 Inthe Password field type a password for logging into the ODBC data source Note SPC creates and uses a default data source called CIMPLICITY SPC This default data source is an Access mdb file called SPC mdb It is stored in the ARC subdirectory of where you installed CIMPLICITY Usually C CIMPLICITY HMI ARC CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Products After you define the basic parameters for your document you can add the products that will be included in the group To do this create a folder for each product The Product folder will be a subfolder of the main Products folder Adding a New Product GFK 1413E di Add a new product to SPC by creating a new product folder see figure below To create a Product folder Method 1 File menu 1 Click File on the menu bar 2 Select New 3 Select Product from the pullout menu Method 2 Popup menu 1 Select the Products folder 2 Right click and select New Product from the popup menu Result Using either method the Product Properties dialog box opens Configuring SPC Data 4 9 Defining Product Properties The Product Properties dialog box is where you identify each product that is added to the document by designating the following see figure Data collection activate or deactivate Product name Description Resource ID 41 To specify Product properties 1 The Active box is checked
116. ting the sample is now excluded see figure Example of Excluding Bad Data From SPC Charts A E Std deu la Four samples 1a are beyond Zone A The reason is explainable 1b An X indicates that SPC is in Exclusion Mode 1b To exlude the samples 2a Click each dot Each dot changes to an X or 2b Hold down the left mouse button Draw a box around the samples 3 Four Xs 3 represent the samples that are excluded from calculation Application Engineering Note The GetControlLimits ActiveX method provides access to the control limits displayed on the chart 4 38 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Attribute Quality Characteristics GFK 1413E dl de In additional to defining variable quality characteristics you now have the option of the defining attribute quality characteristics for your product SPC uses information that you enter in the Attribute Quality Characteristics Properties dialog box to configure in detail p nP c and u chart sets Use the Attribute Quality Characteristics Properties dialog box to create and define characteristics as follows General characteristics including the name of the characteristic whether or not data 1s to be collected for the attribute whether you want to use a p nP c or u chart set Collection characteristics specifies the data collection method Limits sets control and specification limits Alarms indicates alar
117. tion limits Alarms indicates alarming and control tests to be performed on the data Caution If you enter specific values during configuration and an inconsistency is detected SPC will display an error message You cannot save the configured data until the error is corrected Example You select Values to enter a variable s control limits and enter 25 for an Upper Control Limit and 50 for a Lower Control Limit SPC will display the following error message The upper control limit must be greater than the center line and the center line must be greater than the lower control limit Note If you use Points for general characteristics on limits rather than specific values SPC will alert the user when the values become specific at runtime If SPC detects configuration inconsistencies it will display an SPC_ADMIN_ALARM in the Alarm Viewer See SPC Administration Alarms Configuring SPC Data 4 Adding a New Variable Quality Characteristic J1 To add a Variable Quality Characteristic do one of the following Method 1 File menu 1 Expand the Products folder and select the product 2 Click File on the menu bar 3 Select New 4 Select Variable Quality Characteristic from the pullout menu Method 2 Popup menu 1 Expand the Products folder and select the product 2 Right click and select New Variable Quality Characteristic from the popup menu Result Using either method the Variable Quality Character
118. trol limits are out of sequence R S control limits are out of sequence Sample size is invalid Se ae Te eS Gap size is invalid Configuring SPC Data 4 73 Document Tools The SPC document provides you with three major tools for storing and locating specific information as follows Document Tree directory Configure Display Attributes Find Function Document Tree SPC organizes data in a hierarchy that logically emulates the steps you take to configure the application 1 The Products folder is the primary folder and the top level of the directory hierarchy 2 Defined Product folders represent the next sublevel in the hierarchy Contained within the Product subfolder are Variable and Attribute quality characteristics that you configure for your product 3 Defined Defect folders represent the third level in the hierarchy Contained within the Defect subfolder are Defect categories that you configure for your product The Main Tree The directory structure in an SPC document is illustrated below 1 Highest level in hierarchy primary folder that contains all 2 Products product folders and their sub ae ROD 8 DEF El A O level items 2 second level in hierarchy folder for your defined Hroduct that contains variables attributes and defect folders 3 Third level in hierarchy defect folder contains all of the configured defect categories 4 74 CIMPLICITY SPC Operation Manual D
119. tton see figure Result The Manual entry allowed box is checked by default to enable manual data entry Variable Quality Characteristics Properties YAR 4 20 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E Setting Limits for Variable Quality Characteristics Once you have defined the variable s general characteristics and collection methods you are ready to set control limits for your XBar R or XBar S chart sets in the Variable Quality Characteristics Properties dialog box Included are Control limits and Specification limits Control Limits for a Variable In order to set control limits for your chart sets SPC provides you with several different options If you know the limits that you want to set you can use Points or Values If the process is new and you would like to have limits calculated automatically for you you can use the auto recalculation features Whatever your preference SPC provides you with an option You can specify values for control limits by entering values or using auto recalculation You can enter values as specific values Points Caution If you enter specific values during configuration and SPC detects an inconsistency it will display an error message and will not allow you to save the configuration until you correct the error Example You select Values to enter a variable s control limits and enter 25 for an Upper Control Limit and 50 for a Lower Contr
120. up Select the components you want to install clear the components you do not want to install Components HMI Server Base 126158 EI Server Redundanc Application Options O26 E H SPC Charts L Communications OK I System Sentry Tracker 3688 K L Trending C Tracker Display 1203 K JO WebView C Syster Utilities OK O Alarm Management LCI Demo FBSB4 K I Dexcom Toolkit C Point Management Description The Statistical Process Control option allows users to collect quality data and make control charts Space Required 5026 K Space Available 6926 2 KB Back Cancel 3 Click Next Check the Application Options box Check the SPC Charts box Clear all other boxes in the Components group GFK 1413E Introducing Statistical Process Control 1 5 10 Click Next to proceed with installation 11 Restart your computer once the SPC option has been installed 144 To configure SPC 1 Configure an ODBC data source A default Microsoft Access database called CIMPLICITY SPC is automatically created when you install SPC You only need to change or reconfigure this if you want to use a data source other than Microsoft Access 2 Configure SPC data collection as follows a Open your project in the Workbench b Click Project on the menu bar c Select Properties to open the Project Properties dialog box d Check the SPC Charts and Database Logger boxes in the Options group e Click OK Result The Database Logger and
121. use Points for general characteristics on limits rather than specific values SPC will alert the user when the values become specific at runtime If SPC detects configuration inconsistencies it will display an SPC_ADMIN_ALARM in the Alarm Viewer See SPC Administration Alarms 4 48 CIMPLICITY SPC Operation Manual December 2000 GFK 1413E GFK 1413E kh bh SPC Auto Recalculation Feature One of the many advantages SPC offers is its ability to automatically calculate the control limits for a process This is an excellent feature when your process is new and you want the SPC program to generate control limits SPC offers two options to automatically recalculate control limits Auto recalculation is used in place of Values or Points Once the control limits are automatically calculated select either Values or Points for the life of the process Force Auto Recalc is used in addition to Values or Points This option provides the flexibility to reset control limits during runtime As a result when you send an application to production you can have SPC recalculate the control limits so that they are accurate for the process Once the control limits are automatically calculated deactivate the Force Auto Recalc option Important The Quality Control rules you have always followed for control limits still apply to both SPC automatic recalculation options as follows When your process 1s new or in optimum condition calculate the limits u

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