Control Chart Selection for Crimping Operations for RJ 45 Plugs

G

gautham.nk

#1
I need help in selecting Control chart type for Crimping operations that we are doing for RJ 45 Plugs. We have identified this as a critical process parameter that needs to be controlled and monitored over a period of time.

There are eight points of contact on each plug and the specifications set around the plugs are 6 +/- .08.

I did try with a moving average chart but it did not make sense in taking the average of these eight points as they are not exactly in a plain surface. The heights of teeth follow a U –shaped projection after crimping.
Please see the below data that I had measure for a small interval.
Parts
1st trail
Avg
6
6.041
6.048
6.044
6.4
6.023
6.04
6.046
6.028
6.084
3
6.009
6.028
6.013
6.012
6.001
6.01
6.013
6
6.011
4
5.989
6.001
5.998
6
5.983
6.002
5.994
5.979
5.993
9
6.001
6.004
6.002
5.995
5.988
6
5.998
5.991
5.997
1
6.042
6.053
6.046
6.041
6.035
6.048
6.059
6.047
6.046
7
6.038
6.055
6.027
6.07
6.025
6.033
6.05
6.033
6.041
8
6.017
6.038
6.04
6.042
6.034
6.05
6.046
6.026
6.037
2
6.043
6.055
6.051
6.045
6.038
6.052
6.06
6.04
6.048
5
6.045
6.062
6.05
6.038
6.045
6.056
6.075
6.055
6.053
10
6.006
6.039
6.022
6.021
6.018
6.052
6.042
6.042
6.030


Based on the above data if can one could direct that would be great.

Thanks in advance.

:thanx:
 
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Steve Prevette

Deming Disciple
Staff member
Super Moderator
#2
Re: Control Chart Selection

Are these data for one of the eight points, or are all eight points mixed together?

Also, there seem to be some odd results. Most of the entries are to three decimal places around 6.0. But then there are some integer entries, such as 6, 3, 6, 4. Do these denote batches or data entries?
 
G

gautham.nk

#3
Hello Steve,

Thanks for the early reply.

Data is from 8 different points on the RJ45 Plug.

The Odd Number posted are the random part numbers picked and measured. Sorry I was trying to paste the data from excel and it seems to have gone wrong. I am trying to repaste data and also attach the file with readings on it

Parts1st trailAvg66.0416.0486.0446.46.0236.046.0466.0286.08436.0096.0286.0136.0126.0016.016.01366.01145.9896.0015.99865.9836.0025.9945.9795.99396.0016.0046.0025.9955.98865.9985.9915.99716.0426.0536.0466.0416.0356.0486.0596.0476.04676.0386.0556.0276.076.0256.0336.056.0336.04186.0176.0386.046.0426.0346.056.0466.0266.03726.0436.0556.0516.0456.0386.0526.066.046.04856.0456.0626.056.0386.0456.0566.0756.0556.053106.0066.0396.0226.0216.0186.0526.0426.0426.030
 

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I

iamtroll

#4
It might help if you submitted in an Excel file or even a Word file so that the numbers could be more easily manipulated. It would also help to carefully identify part numbers, run order and any multiple tooling input. :)Kind of a lot but it can help in analysis.

If I understand the crimp height characteristic, you will have between part variation and within a part variation. You could also have an additional variation input is you are also using multiple tools to crimp with or worse yet, progressive tooling. All of this makes for a challenging analysis since the liklihood of the process being even near normal is very low. Not knowing a lot about your tooling and process, the first step I would take is to analyze the within a part variation amd between tool variation (if there are multiple tools). This will tell you how a lot about your tooling so that you can determine whether or not your tooling is capable of producing withing spec. That's Capable with a large "C". This is not a real capability study, but you have data so you can at least get a feel for what is going on.
 
G

gautham.nk

#5
Hello IAMTROLL,

Thanks for the reply.

I have attched the results in an excel file.

The results obsereved are from one crimping machine and there is no tool to tool variation here. As you said there is variation from part to part and within each part.

:thanx:
 

Attachments

Steve Prevette

Deming Disciple
Staff member
Super Moderator
#6
I took part 10 as an example. First thing to do is simply plot the dots. I put a grand average and control limits through the data using moving range. The data are unstable - and several things can be seen:

The first result done by any operator on any trial is the lowest value, except for operator 3's 2nd trial.

Operator 1's 6th 7th and 8th attempts were of a pattern different thant the 2nd through 5th attempts.

Operator 2 seemed the most consistent, and assuming 6 is the target value, better than operators 1 and 3.

For Operators 2 and 3, the second trial resulted in lower values than the first.

Next step would be to subdivide into smaller groups of data to see which sets are consistent with each other.
 

Attachments

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