CPK

Measure Phase
Process Capability
Process Capability
Welcome to Measure
Process Discovery
Six Sigma Statistics
Measurement System Analysis
Process Capability
Continuous Capability
Concept of Stability
Attribute Capability
Wrap Up & Action Items
OSSS LSS Green Belt v11.0 XL - Measure Phase 2 © Open Source Six Sigma, LLC
Understanding Process Capability
Process Capability:
• The inherent ability of a process to meet the expectations of the

customer without any additional efforts.
• Provides insight as to whether the process has a :

– Centering Issue (relative to specification limits)
– Variation Issue
– A combination of Centering and Variation
– Inappropriate specification limits
• Allows for a baseline metric for improvement.
*Efforts: Time, Money, Manpower, Technology, and Manipulation
Capability as a Statistical Problem
Our Statistical Problem: What is the probability of our

process producing a defect ?
Define a Practical
Problem
Create a
Statistical Problem
Correct the
Statistical Problem
Apply the Correction

to the Practical
Problem
Capability Analysis
The X’s The Y’s

(Inputs)
Y = f(X) (Process Function) Variation – “Voice of
(Outputs)
the Process”
Frequency
Op i Verified Op i + 1
? Data for
Y1…Yn
X1
Y1 10.16
10.11
10.16 9.87
X2 Off-Line 10.05
10.11 9.99
10.16
9.87 10.11
Analysis Scrap 10.33
10.05 10.12
9.99 10.05
Correction 10.44
10.33 10.43
10.12 10.33
X3 Y2 9.86
10.44 10.21
10.43 10.44
10.01
10.21 9.86
9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5
10.07
9.86
10.29
10.07 10.15
10.01 10.07
10.36
10.29 10.44
10.15 10.29
10.03
10.44 10.36
X4 10.36
10.33
10.03
10.15
10.33
Yes No Y3 10.15
X5 Correctable
?
Requirements – “Voice
Critical X(s): Data - VOP of the Customer”
Any variable(s) 10.16
10.11 9.87 10.16
LSL = 9.96 USL = 10.44
10.05 9.99 10.11
which exerts an 10.33
10.44
10.12
10.43
10.21
10.05
10.33
9.86 10.44
undue influence on 10.07
10.29
10.01
10.15
9.86
10.07
10.44
the important 10.36
10.03
10.33
10.29
10.36
outputs (CTQ’s) of a 10.15
Defects
process Defects
Capability Analysis Numerically -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 +6
9.70 9.80 9.90 10.0 10.1 10.2 10.3 10.4 10.5 10.6
Compares the VOP to the VOC Percent Composition
Process Output Categories
Incapable Off target

LSL
Average
USL LSL Average
USL
Target Target
Capable and
on target
Average
LSL USL
Target
Problem Solving Options – Shift the Mean
This involves finding the variables that will shift the process
over to the target. This is usually the easiest option.
USL
LSL
Shift
Problem Solving Options – Reduce Variation
This is typically not so easy to accomplish and occurs often in

Six Sigma projects.
LSL USL
Problem Solving Options – Shift Mean & Reduce Variation
This occurs often in Six Sigma projects.
USL
LSL Shift & Reduce
Problem Solving Options
Obviously this implies making them wider, not narrower.

Customers usually do not go for this option but if they do…it’s
the easiest!
LSL USL USL

Move Spec
Capability Studies
Capability Studies:
• Are intended to be regular, periodic, estimations of a process’s
ability to meet its requirements.
• Can be conducted on both Discrete and Continuous Data.
• Are most meaningful when conducted on stable, predictable
processes.
• Are commonly reported as Sigma Level which is optimal (short term)
performance.
• Require a thorough understanding of the following:
– Customer’s or business’s specification limits
– Nature of long-term vs. short-term data
– Mean and Standard Deviation of the process
– Assessment of the Normality of the data (Continuous Data only)
– Procedure for determining Sigma level
Steps to Capability
Select Output for

Improvement
#1 Verify Customer
Requirements
#2 Validate
Specification
Limits
#3 Collect Sample
Data
#4 Determine
Data Type
(LT or ST)
#5 Check data
for normality
#6 Calculate
Z-Score, PPM,
Yield, Capability
Cp, Cpk, Pp, Ppk
#7
Verifying the Specifications
Questions to consider:
• What is the source of the specifications?

– Customer requirements (VOC)
– Business requirements (target, benchmark)
– Compliance requirements (regulations)
– Design requirements (blueprint, system)
• Are they current? Likely to change?
• Are they understood and agreed upon?

– Operational definitions
– Deployed to the work force
Data Collection
Capability Studies should include “all” observations (100% sampling) for a specified period.
Short-term data: Long-term data:
•Collected across a narrow •Is collected across a broader inference
inference space. space.
•Daily, weekly; for one shift, •Monthly, quarterly; across multiple
machine, operator, etc. shifts, machines, operators, etc
•Is potentially free of special cause •Subject to both common and special
variation. causes of variation.
•Often reflects the optimal •More representative of process
performance level. performance over a period of time.
•Typically consists of 30 – 50 data •Typically consists of at least 100 – 200
points. data points.
Lot 1 Lot 5
Fill Quantity
Lot 3
Lot 2
Lot 4
Short-term studies
Long-term study
Baseline Performance
Process Baseline: The

average, long-term performance
level of a process when all input
variables are unconstrained. Long-term
baseline
Short Term
4
Performance
` 3
2
1
LSL TARGET USL
Components of Variation
Even stable processes will drift and shift over time by as much as 1.5
Standard Deviations on the average.
Long Term
Overall Variation
Short Term
Between Group Variation
Short Term
Within Group Variation
Sum of the Squares Formulas
SS total = SS between + SS within
Precision
Shift (short-term capability)
x
x x
x
x x
x x x
x x
x
x x x Time
x x
x x x x
x x x
x
Stability
A Stable Process is consistent over time. Time Series Plots and

Control Charts are the typical graphs used to determine stability.
At this point in the Measure Phase there is no reason to assume the

process is stable.
Tic toc…
tic toc…
Measures of Capability
Mathematically Cpk and Ppk are the same and Cp and Pp are the
same.
The only difference is the source of the data, Short-term and Long-term,
respectively.
Hope
– Cp and Pp
• What is Possible if your process is perfectly Centered
• The Best your process can be
• Process Potential (Entitlement)
Reality
– Cpk and Ppk
• The Reality of your process performance
• How the process is actually running
• Process Capability relative to specification limits
Capability Formulas
Six times the sample

Standard Deviation
Sample Mean
Three times the sample

Standard Deviation
Note: Consider the “K” value the penalty for being off center LSL – Lower specification limit
USL – Upper specification limit
SigmaXL® Example
Open worksheet “Camshaft”. Create a Normal Probability Plot and

Descriptive Statistics of Suppliers 1 and 2.
By looking at the “P-values”

the data look to be Normal
since P is greater than .05
SigmaXL® Example
Create a Capability Analysis for both suppliers, assume long-term data.

Note the subgroup size for this example is 5.
LSL=598 USL=602
Supplier 1 SigmaXL® Example
SigmaXL® Example
SigmaXL® has a calculator to allow you to quickly find the sigma

level for a process.
SigmsXL>Templates and Calculators> Basic Process Capability Templates>Process Sigma Level - Continuous
For long term sigma level use the

long term StDev. For short term use
the short term StDev.
SigmaXL® Example
Supplier 2
Long Term
Continuous Variable Caveats
Capability indices assume Normally Distributed data.

Always perform a Normality test before assessing Capability.
Capability Steps
Select Output for

Improvement We can follow the steps for
calculating capability for
#1 Verify Customer
Requirements
Continuous Data until we
reach the question about
#2 Validate
Specification data Normality…
Limits
#3 Collect Sample
Data
#4 Determine
Data Type
(LT or ST)
#5 Check data
for Normality
#6 Calculate
Z-Score, PPM,
Yield, Capability
Cp, Cpk, Pp, Ppk
#7
Attribute Capability Steps
Select Output for

Improvement
Notice the difference when
#1 Verify Customer
we come to step 5…
Requirements
Validate
#2 Specification
Limits
#3 Collect Sample
Data
#4
Calculate
DPU
#5
Find Z-Score
#6 Convert Z-Score
to Cp & Cpk
#7
Z Scores
Z Score is a measure of the distance in Standard Deviations of a

sample from the Mean.
The Z Score effectively transforms the actual data into standard normal
units. By referring to a standard Z table you can estimate the area
under the Normal curve.
– Given an average of 50 with a Standard Deviation of 3 what is
the proportion beyond the upper spec limit of 54?
50
54
Z Table
Attribute data is always long-term in the shifted condition since it requires so

many samples to get a good estimate with reasonable confidence.
Short-term Capability is typically reported, so a shifting method will be

employed to estimate short-term Capability.
You Want to Estimate : ZST ZLT

Short Term Long Term Sigma Short-Term Long-Term
Your Data Is : Capability Capability Level DPMO DPMO
1 158655.3 691462.5
Short Term Subtract
ZST Capability 1.5 2 22750.1 308537.5
Long Term Add 3 1350.0 66807.2

ZLT Capability 1.5 4 31.7 6209.7
5 0.3 232.7
6 0.0 3.4
By viewing these formulas you can see there is a relationship between them.
If we divide our Z short-term by 3 we can determine our Cpk and if we divide

our Z long-term by 3 we can determine our Ppk.
Attribute Capability Example
A customer service group is interested in estimating the Capability of

their call center.
A total of 20,000 calls came in during the month but 2,500 of them
“dropped” before they were answered (the caller hung up).
Results of the call center data set:

Samples = 20,000
Defects = 2,666
They hung up….!
Attribute Capability Example
1. Calculate DPU
2. Look up DPU value on the Z-Table
3. Find Z-Score
4. Convert Z Score to Cpk, Ppk
Example:
Look up ZLT
ZLT = 1.11
Convert ZLT to ZST = 1.11+1.5 = 2.61
1. Calculate DPU
2. Look up DPU value on the Z-Table
3. Find Z Score
4. Convert Z Score to Cpk, Ppk
Example:
Look up ZLT
ZLT = 1.11
Convert ZLT to ZST = 1.11+1.5 = 2.61
2
.87
Summary
At this point, you should be able to:
• Estimate Capability for Continuous Data
• Estimate Capability for Attribute Data
• Describe the impact of Non-normal Data on the analysis

presented in this module for Continuous Capability
The Certified Lean Six Sigma Green Belt Assessment
The Certified Lean Six Sigma Green Belt (CLSSGB) tests are
useful for assessing Green Belt’s knowledge of Lean Six
Sigma. The CLSSGB can be used in preparation for the ASQ
or IASSC Certified Six Sigma Green Belt (CSSGB) exam or
for any number of other certifications, including private
company certifications.
The Lean Six Sigma Green Belt Course Manual
Open Source Six Sigma Course Manuals are professionally

designed and formatted manuals used by Belt’s during
training and for reference guides afterwards. The OSSS
manuals complement the OSSS Training Materials and
consist of slide content, instructional notes data sets
and templates.
Get the latest products at…
www.OpenSourceSixSigma.com
OSSS LSS Green Belt v11.0 XL - Measure Phase © Open Source Six Sigma, LLC

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Measure Phase

Six Sigma Statistics

Measurement System Analysis

Wrap Up & Action Items

• The inherent ability of a process to meet the expectations of the

• Provides insight as to whether the process has a :

• Allows for a baseline metric for improvement.

*Efforts: Time, Money, Manpower, Technology, and Manipulation

Our Statistical Problem: What is the probability of our

Apply the Correction

The X’s The Y’s

outputs (CTQ’s) of a 10.15

Capability Analysis Numerically -6 -5 -4 -3 -2 -1 +1 +2 +3 +4 +5 +6

Incapable Off target

This is typically not so easy to accomplish and occurs often in

This occurs often in Six Sigma projects.

Obviously this implies making them wider, not narrower.

LSL USL USL

Select Output for

• What is the source of the specifications?

• Are they current? Likely to change?

• Are they understood and agreed upon?

Process Baseline: The

SS total = SS between + SS within

A Stable Process is consistent over time. Time Series Plots and

At this point in the Measure Phase there is no reason to assume the

Six times the sample

Three times the sample

Open worksheet “Camshaft”. Create a Normal Probability Plot and

By looking at the “P-values”

Create a Capability Analysis for both suppliers, assume long-term data.

SigmaXL® has a calculator to allow you to quickly find the sigma

For long term sigma level use the

Capability indices assume Normally Distributed data.

Select Output for

Select Output for

Z Score is a measure of the distance in Standard Deviations of a

Attribute data is always long-term in the shifted condition since it requires so

Short-term Capability is typically reported, so a shifting method will be

You Want to Estimate : ZST ZLT

Long Term Add 3 1350.0 66807.2

If we divide our Z short-term by 3 we can determine our Cpk and if we divide

A customer service group is interested in estimating the Capability of

Results of the call center data set:

They hung up….!

At this point, you should be able to:

• Estimate Capability for Continuous Data

• Estimate Capability for Attribute Data

• Describe the impact of Non-normal Data on the analysis

The Lean Six Sigma Green Belt Course Manual

Open Source Six Sigma Course Manuals are professionally

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