4:

(Statistical process control, SPC)

. e-class
/
2010-2011.

. ..

4.1


.



.


.
,


.

100%
,
.


.


.
,
. :

(statistical process control, SPC).

(acceptance sampling).

(traditional statistical techniques).

2

() (SPC). ISO 9001 (2008)

. 8 ( )

.

4.2
(control chart)
.
,
.

.

:

,

( ISO 9001).

80
, ,
, ,
( )
3

 . ' ,


.
,
Dr. W. Shewhart
1920 Bell Laboratories
. ,
,
.
, , ,
(manufacturing). ,
(service sector)
.


.
, , ,
,
. ,
.

, (random causes) , ..

, .
, ,
, ,
(assignable causes).
,
. ,

, .. .
4


.

, (in statistical
control), (in control).
, (out of control).

,
( ).
.
,
.
,
, ,

().

.
( ) ,
. ,

.


,
,
.
, ..
,
.
, ,
.
.
5

 on line,
,


.

()

.
() .



.

,
, .


.
, . 3.
( X ) ()
, , :
n

X=

X
i =1

(4.1)

(X
i =1

X )2

n 1

(4.2)

,
.
6

 , . ,
.



. ,

.

(-3 - +3) . ,
,
99,73%.
3, 0,27%
(
).
,
. , 6
3,4 ( 6 sigma).
, (tolerance limits)
... (capability limits).
, , :


.

, .
(upper specification limit, USL)
(lower specification limit, LSL) .
. ,
99.7 %
, . ,

.
7


(capability index, Cp), :

Cp =

USL LSL
6

(4.3)

4.1: .

99,7% ()

Cp 1.

. 99,7%
, Cp 1
() . , Cp
1
99,7% .
Cp
1,2 - 1,4. 4.1
.
8


, ,
(.. ).

Cp

( X )
.
( C pk ) :
C pk =

min(USL X , X LSL)
6

(4.4)

C pk > 1 C pk > 1,33.

4.3.

() (control chart)

.

.
,
,
.

(sample statistic).
4.2
,
Shewart. :
) ,
.
) ()
,
,
:

(control charts for variables)

(.. , , , , ..).
( X -chart, R-chart)
(- chart).

(control charts for attributes)

(..
-). -p, -np, -c
-u (p-chart, np-chart, c-chart u-chart, ).

10

 4.2:

,
. , (center line, CL.)
(.. , )
. ,
.

(control linits) , (upper control limit,

UCL) , (lower control limit, LCL).
, ,
, .
,
,
.
, ,
.
.
,
.

, .
,
,
.
11

 4.5,

.

( 7 ),
,
.

.

, :
) t ,
) n,
) k.
k k .
3
. ,
.
.
,
,
(warning lines).
2
. 4.3

.

12

 4.3:

, .
(..

)
.
.
k n ,
t
.
.

.

.

.

4.4.

( )
( )
13

 ( ).
( X ) () (R)
.

() ,
4.2.

:

.
,
,

.

,
.

()
.

,
.

14




, ,
. ,
( X -chart) (R-chart)
(-chart) :
1.

() .

2.

3.

4.

5.

,

.

.
.
( X )
( ) .
() ( .. 4
5). :
(1) X ( X )
()
(2) ( X )
, x ,
(n). :
X =

(4.5)

X =

x
n

(4.6)
15

 (4.5) (4.6)
4.4.

4.4: .

. 99.7%
3 ()
( ). 3
.
( ) 0.0027, (3%
), , ,
, .
,
. ,
, - .
- ,
( ) .
,

.

.
()
.
16

 ,
.
,
.

.

/ ().
,

.

.
,

.
...
..
5 , ..
8 .., 9 .. .
,


.

5 .
,
,
.
17

 4
.


. 10 20
,
.
,
.
,

.
, ,

(), (R). ,
15 ,
( X ) (),
( X ) (R).
.


.

, ,
.

,
. ,
1 , 4
.

18



(data collection sheet).
,
,
.

()

()

4.5: .

19


, ( )
X R.
, ,
.
4.5 () ()
.
ASQ (American Society for Quality)

. , ,
. 4.6.

.


.
.


,
.

.
,
.

20

 4.6: ASQ (ASQ control chart data sheet)

[: ASQ]

21


k n.
k=20 n=5.
,
( X ) (R),
4.5().
( X ) :

X=

X 1 + X 2 + X 3 + ... + X n
=
k

X
k

(4.7)

( R ) :
R=

R1 + R2 + R3 + ... + Rn R
=
k
k

(4.8)

i
[ (4.2)] k .
X , R .

, ,
.

X R
.

.
X R
, .

22

.
,
.

25 . ,
.. ,
25.
,
, ,
.
10
, . .

.
.
(. ) X
,
.
99,7%
3 . ,
( ) ,
( X ) 3 X .
95,4 % 2
( X ) , ( X ) 2 X .
,
:

= X 3 X

=X

(4.10)

= X + 3 X

(4.11)

(4.9)

23

= R 3 R

(4.12)

= R

(4.13)

= R + 3 R

(4.14)

= X 3 X

(4.15)

= X

(4.16)

= X + 3 X

(4.17)

= 3

(4.18)

(4.19)

= + 3

(4.20)

.


4.5().

, ( R )
() ,
. :

R
d2

(4.21)

d2 4.1.
2 25 .
: 3 X =

3
n

(4.6)

(4.6) (4.20)
3 X =

3
R
d2 n

(4.22)

24

 (R),
3
2, , n 2 25
d2 n

, 4.1.

( X -chart), , :

= ( X ) A2 R

(4.23)

= X

(4.10)

= ( X ) + A2 R

(4.24)

(4.12), (4.13) (4.14),

:

= D3 R

(4.25)

= R

(4.13)

= D4W

(4.26)

D3 D4 n = 2-25 4.1.

. (4.15)-(4.20)
:
( X -chart):
_

= ( X ) A3

(4.27)

= X

(4.16)

= ( X ) + A3

(4.28)

(-chart):

= B3

(4.29)

(4.19)

= B4

(4.30)

25

n
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

4.1:
( X -, R- - )
/

d2

c4

2
3
D3
D4
B3
B4
1,880 2,659
0
3,267
0
3,266
1,128 0,798
1,023 1,954
0
2,574
0
2,568
1,693 0,886
0,729 1,628
0
2,282
0
2,266
2,059 0,921
0,577 1,427
0
2,114
0
2,089
2,326 0,940
0,483 1,287
0
2,004
0,030
1,970
2,534 0,951
0,419 1,182
0,076
1,924
0,118
1,882
2,704 0,959
0,373 1,099
0,136
1,864
0,184
1,815
2,847 0,965
0,337 1,032
0,184
1,816
0,239
1,761
2,970 0,969
0,308 0,975
0,223
1,777
0,284
1,716
3,078 0,723
0,285 0,927
0,256
1,744
0,322
1,678
3,173 0,975
0,266 0,886
0,283
1,717
0,354
1,646
3,258 0,978
0,249 0,850
0,307
1,693
0,382
1,619
3,336 0,979
0,235 0,817
0,328
1,672
0,407
1,593
3,407 0.981
0,223 0,789
0,347
1,653
0,428
1,572
3,472 0,982
0,212 0,763
0,363
1,637
0,448
1,552
3,532 0,983
0,203 0,739
0,378
1,622
0,466
1,534
3,588 0,984
0,194 0,718
0,391
1,608
0,482
1,518
3,640 0,985
0,187 0.698
0,403
1,597
0,496
1,504
3,689 0,986
0,180 0,680
0,415
1,585
0,510
1,490
3,735 0,987
0,173 0,663
0,425
1,575
0,523
1,477
3,778 0,988
0,167 0,647
0,434
1,566
0,535
1,465
3,819 0,988
0,162 0,633
0,443
1,557
0,545
1,455
3,858 0,989
0,157 0,619
0,451
1,548
0,556
1,444
3,895 0,989
0,153 0,606
0,459
1,541
0,564
1,436
3,931 0,990

26

(4.31)

c4

3, 3, c4 4 n = 2-25 4.1.
(4.27) (4.29)
, n < 6
, n < 5 .
R ,
, 4.1.
() ,
3 ( X )
.
(warning lines), .

. , , :
:

= X 2 X

(4.32)

= X + 2 X

(4.33)

= R 2 R

(4.34)

= R + 2 R

(4.35)

2, 3
4. . , 2/3

4.2 ,
. , ,
. , ,
27


.
() 0,
(4.21) (4.31):

0 =

0 =

R
d2

(4.21)

(4.31)

c4

(4.3)
Cp =

USL LSL
6 0

(4.3)

4.5.

,
,
.
,
, ,
.
, .
,
,
.
.
, ,
;
.

( X , R , )
28

 .
,
. ,

,
, ..
,
.


.

,
.

:
) ,
(..

),
) (..

) .


. ..
0 1 > 0.
k ,
-x.
.
4.7,
3 4 .

29

 4.7:

(run rules),
.
:
-

7 ( 8) (
),

10 11
,
2 3
,
4 5 ^

( ).

.

.
)

4.8: .

30

 4.8
.
( ) .
, :
-

,
,
(..
),
() .

,

:
- 6 (
),
- 10 8
( ).
) -

4.9: .

4.9
.


.
:

31

,
, ..,

4.10: .

4.10
, :
-

, , , ,
.

,
,
.
)

4.11:
.

32

 4.11

.
:
-

.
)

4.12
,
.
:

4.12:
.

,

.

,
33

 .
,
.


,
,

.


.


.

(SPC) 80%

(engineering analysis) 20% (statistics).

, ,
/ .
on-line
(real
time).
(. Microsoft Office Excell)
MINITAB (www.minitab.com)
SPC, CHARTrunner 2000
(www. pqsystems.com)

34

4.6.

( X ) (R)
, 4.3,
,

.

, :
(conforming)
(non-conforming).
,
X R , ,
.

/
( , , ..),
(control chart for attributes).
(control chart for variables)
.
,
, ..
, ,
.
(..
),
.
( ) () (
)
- ,
.
35

, ,
:
1.

2.

) / (
);
4
:
1. p ( - )
2. np ( - )
3. u ( - )
4. c ( - )

4.13.
. , 3
( )

. ,
, .

X R
, ,
. ,
,
X R .

,
.

.
( ) .
.

36

 4.13: .

4.6 () (p & np -charts)

,

() p.
,

.

, p
.
( ) p

. (
) .
( )
:

37

p
.

( ), 3 4.7.

.
,
.

,
.
(
3 ), . - ..
-
.
,
( ) ,
,
,
( )
. ,
38

 .
-np (np-chart).

(data collection sheet).

, ,
. ,
, -p
4.14.

4.14: .

,
,
.

.

39

 ( p )

p ( )
:
P=

np
=

n

(4.36)

( )
:
p=

(4.37)

( )
( )

.
:

= npq = np(1 p )

(4.38)

:
(4.39)

= np

, .

n.

npq

p =

npq
=
n

pq
=
n

p(1 p)

p(1 p)
=
n

(4.40)

:
( - p )

= p 3 p

= p 3

p (1 p )
n

(4.41)
(4.42)
40

= p

= p +3

(4.43)
p (1 p )
n

(4.44)

p p. p
(4.37).
,
.(4.42) (4.44). ,
( < 20 %)
_

, n
.
( - np )
np - p -
.

np .
:
= np 3 np

(4.45)

:
= np 3 np (1 p )

(4.46)

= np

(4.47)

= np + 3 np (1 p )

(4.48)

3
,

.

,
.

41

,

.
-p
, . ..
.
.

.
-p

, , .
-p,
.

.

4.6 () (u & c -charts)

,
. ,
, .
, .
(
) . :
, ,
, ..
,
,
(-u) (-c).
42

 -u

-u ,
.
p,
,
u.
, ,
-p.
:
_

OE = u + 3

(4.49)

n
_

= u

(4.50)

OE = u 3

(4.51)

(4.49) - (4.51) n
_

u :
_

u=

(4.52)

-c

c- ,
.
, c, (
, ,
. ..).
, Poisson.
:
_

= c + 3 c

(4.53)
43

= c
_

(4.54)

= c 3 c

(4.55)
_

(4.53) - (4.55) c ,

_

c=

(4.56)

- c :

,
.

4.7.

(
) .
:

,

-
.

.
44

Pareto

45

4.7

1

. 16 n=5 .
.1.
.1. : (mm)

4-5-06

8.10

0,492

0,498

0,501

0,496

0,505

10.50

0,500

0,506

0,495

0,504

0,500

12.15

0,497

0,500

0,499

0,507

0,502

13.45

0,505

0,509

0,504

0,500

0,497

15.00

0,506

0,502

0,500

0,510

0,501

7.50

0,498

0,494

0,501

0,503

0,501

9.10

0,502

0,500

0,499

0,503

0,504

11.15

0,503

0,496

0,500

0,504

0,503

12.50

0,497

0,493

0,500

0,501

0,500

10

13.45

0,490

0,507

0,498

0,500

0,495

8.50

0,500

0,499

0,503

0,497

0,498

12.20

0,500

0,499

0,503

0,496

0,494

11

5-5-06

6-5-06

12
13

13.00

0,496

0,501

0,500

0,500

0,495

14

14.00

0,500

0,501

0,500

0,503

0,502

15

15.00

0,500

0,502

0,500

0,502

0,499

12.45

0,498

0,500

0,496

0,497

0,499

16

7-5-06

8-5-06

.1,
, .2, ( X ),
(R) (). 16
X , R ,
:

X=
R=

X
n

8, 0031
= 0,50019
16

R = 0,140 = 0, 00875
n

16

0, 0496
= 0, 0031
16

46

 .2 : ( X ), (R) ()
.1.

(R)

()

0,4984

0,013

0,0044

0,5010

0,011

0,0037

0,5010

0,010

0,0035

0,5030

0,012

0,0041

0,5038

0,010

0,0037

0,4994

0,009

0,0032

0,5015

0,005

0,0019

0,5012

0,008

0,0030

0,4982

0,008

0,0030

10

0,4980

0,017

0,0057

11

0,4994

0,006

0,0022

12

0,4984

0,009

0,0030

13

0,4984

0,006

0,0022

14

0,5012

0,003

0,0014

15

0,5022

0,009

0,0032

16

0,4980

0,004

0,0014

8,0031

0,140

0,0496

( X , R ).

4.4
:

X A2 R

(4.23) & (4.24)

4.1, n=5, 2 2=0,577

:
= 0,50019 0,577(0,00875) = 0,495
= 0,50019 + 0,577(0,00875) = 0,505
1().

:
= D3 R

(4.25)

= D4 R

(4.26)

47

 4.1, n=5 D3=0 D4=2,114

:
= 0
= 2,114 (0,00875) = 0,0185
.1().

:
= B3

(4.29)

= B4

(4.30)

4.1, n=5 3=0 4=2,089

:
= 0
= 2,089(0,0031) = 0,0065
.1().

: .1
,
.
: ) )
.

.

48

 .1: 1

49

( .3)
(gram)
400 gram. 400 15 gram.

.3
( X ) ( R ), 20
. :

X=

X
n

R=

7896, 6
= 394,83
20

R = 386 = 19,3
n

20

.3 : (gram)

50

X A2 R

(4.23) & (4.24)

4.1 n=5 2 0,577

:
= 394,83 0,577(19,3) = 383,70
= 394,83 + 0,577(19,3) = 406,00

:
= D3 R

(4.25)

= D4 R

(4.26)

4.1. n=5 D3=0 D4=2,114

:
= 0
= 2,114(19,3) = 40,80

( X ) (R),
.3
.2() ().

,
.

, 80%
.

51

 .2: 2

52

 3
()
.
.4
.4:

(p)

/ 2

1280

154

0,120

1378

128

0,093

1194

106

0,089

1266

117

0,092

1294

132

0,102

793

68

0,088

996

102

0,102

10

1217

126

0,104

11

1312

152

0,116

12

876

74

0,084

13

1128

117

0,104

14

1243

135

0,109

15

1403

164

0,117

16

1374

149

0,108

17

1236

154

0,126

18

1308

146

0,112

19

1223

131

0,107

20

904

88

0,097

21

1401

159

0,113

22

1346

143

0,106

23

1107

109

0,098

24

814

97

0,119

25

1203

137

0,114

26

1112

154

0,138

28

1002

94

0,094

29

1275

136

0,107

30

1166

144

0,123

31

1357

163

0,120

33.208

3.579

p,
4.13.

53


( )
(4.37):

p=

=

=

3579
= 0,1078
33208

( p ) (4.38).
: 3 = 3. p (1 p ) = 3. (0,1078)(0,8922) = 3. 0, 0962 = 0,9306
:
(4.42) (4.44) .
( , Omachonu & Ross, 2004, p. 300)
.. .

(=
). .5. .
..
(4.42) (4.44). , 1 3 ..
:

O.E. = 0,1078

0,1278 x0,8922
= 0,1078 0, 0260
1280

p
.3.
, ,
100p p.
.5:. .4.

3 =

p (1 p )
n

p 3 p

p + 3 p

, 2

1280

154

0,120

0,0260

0,0817

0,1338

1378

128

0,093

0,0251

0,0827

0,1329

1194

106

0,089

0,0269

0,0809

0,1347

1266

117

0,092

0,0262

0,0816

0,1340

1294

132

0,102

0,0259

0,0819

0,1337

793

68

0,088

0,0330

0,0748

0,1408

54

996

102

0,102

0,0295

0,0783

0,1373

10

1217

126

0,104

0,0267

0,0811

0,1345

11

1312

152

0,116

0,0257

0,0821

0,1335

12

876

74

0,084

0,0314

0,0764

0,1392

13

1128

117

0,104

0,0277

0,0801

0,1355

14

1243

135

0,109

0,0264

0,0814

0,1342

15

1403

164

0,117

0,0248

0,0830

0,1326

16

1374

149

0,108

0,0251

0,0827

0,1329

17

1236

154

0,126

0,0265

0,0813

0,1343

18

1308

146

0,112

0,0257

0,0821

0,1335

19

1223

131

0,107

0,0266

0,0812

0,1344

20

904

88

0,097

0,0310

0,0768

0,1388

21

1401

159

0,113

0,0270

0,0808

0,1348

22

1346

143

0,106

0,0254

0,0824

0,1332

23

1107

109

0,098

0,0280

0,0798

0,1358

24

814

97

0,119

0,0326

0,0752

0,1404

25

1203

137

0,114

0,0268

0,0810

0,1346

26

1112

154

0,138

0,0279

0,0799

0,1357

28

1002

94

0,094

0,0294

0,0784

0,1372

29

1275

136

0,107

0,0261

0,0817

0,1339

30

1166

144

0,123

0,0273

0,805

0,1351

0,0253

0,825

0,1331

31

1357

163

0,120

33.208

3.579

.3.,
,

.

.3 ( p) 3

55

 4
SPC
. 25
. ()
20 kg 1 kg.
.

.


X = (4.4) X =

x
n

(4.5)

.. 3 .. X 3 X
:
= X + 3
= X 3

x
n

x
n

= 20 + 3x

1
= 20, 6 kg
25

= 20 3 x

1
= 19.4 kg
25

5

25
.
.

10

12

19

11

16

11

26

20

14

12

13

21

10

19

13

22

22

11

14

25

23

15

15

15

24

28

16

25

11

17

21

18

14

56

c.

25 350.

_

c=

350
=
= 14
g 25

:
_

= c + 3 c = 14 + 3 14 = 25, 22
= c 3 c = 14 3 14 = 2, 77
.4 .

,
11 24
. , 6
16 21
.

.4 ( c) 5 .

57

, ., , 2 ., . ,
2009.

, .. , ., ISO 9000:2000, . , 2002.

, ., , , 2000.

, .., , , ,
1986.

, ., , 2 ., Interbooks, 2005.

, . ., , . ,
2010.

, .., , . , 2001.

, ., , 2 ., . , 2002.

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ASM International, 1992.

Box, G., Jenkins, G.M. and Reinsel G., Time Series Analysis: Forecasting and
Control, 3rd ed., Prentice Hall, 1994.

Chandra, M.J., Statistical Quality Control, CRC Press, 2001.

Grant, E.L. and Leavenworth, R.W., Statistical Quality Control, 7th ed, McGrawHill, 1996.

Juran, J.M. and Godfrey, A.B. (eds), Jurans quality handbook, 5th ed., McGrawHill, 1998.

Kutz, M. (ed.), Mechanical engineers handbook - Vol 3: Manufacturing and

Management, 3rd ed., John Wiley & Sons, 2006.

Montgomery, D., Statistical Process Control, 5th ed., ASQ Press, 2004.

Oakland, J.S., Statistical Process Control, 6th ed., Elsevier, 2008.

Omachonu, V.K. and Ross, J.E., Principles of total quality, 3rd ed., CRC Press,
2004.

Shewhart, W.A., Economic Control of Quality from the Viewpoint of Manufactured

Product, Van Nostrand, 1931 (Republished 1980, ASQC Quality Press).

Wheeler, D.J. and Chambers, D.S., Understanding Statistical Process Control, 2nd
ed., SPC Press, 1982.

58

 (Internet)

http://www.asq.org
American Society for Quality (ASQ)
http://www.qualitytrainingportal.com/resources/spc/index.htm
K (resource center) SPC
http://statpages.org/javasta2.html
K
SPC

59