Pp10a

Quality Control
Chapter 10Acceptance Sampling

Systems
PowerPoint presentation to accompany
Besterfield
Quality Control, 8e
PowerPoints created by Rosida

Coowar
Besterfield: Quality Control, 8th ed..
2009 Pearson Education, Upper Saddle River, NJ 07458.

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Outline
Lot-by-lot acceptance sampling plans for
attributes
Acceptance sampling plans for continuous
production
Acceptance sampling plans for variables

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Learning Objectives
When you have completed this chapter you
should be able to:
Determine the sampling plan using ANSI/ASQ
Z1.4.
Know the switching rules for ANSI/ASQ Z1.4.
Categorize the various sampling plan
systems in terms of lot-by-lot, continuous

production, attributes or variables.

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Learning Objectives-contd.
should be able to:
Describe the various sampling plan systems
and know their function (advantages,

disadvantages, purpose etc.).
Determine the sampling plan using the Dodge
Romig Tables
Construct the OC Curve for a chain sampling
plan.

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Learning Objectives-contd.
should be able to:
Be able to use the Shainin Lot Plot Method.
Determine the sampling plan ANSI/ASQ S1
Determine whether a lot is accepted or
rejected using ANSI/ASQ Z1.9

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Lot-by-Lot Acceptance
Sampling Plans for Attributes
Devised in 1942 at Bell Labs
Later became MIL-STD-105E
ISO-2859
ANSI/ASQ Z1.4
Wording & terminology changes
Additional tables added

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ANSI/ASQ Z1.4
This standard is applicable to:
End items
Components and raw materials
Operations
Materials in process
Supplies in storage
Maintenance operations
Data or records

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ANSI/ASQ Z1.4
Intended to be used for a continuing
series of lots, but may be designed

for isolated lots.
Standard provides for single, double,
and multiple sampling plans.

Provision is also provided for
normal, tightened, or reduced

inspection.
Plan is specified by the AQL, and
sample-size code.

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ANSI/ASQ Z1.4
Normal inspection is used at the start of
inspection with changes being a function

of recent quality history.
Tightened inspection:
Generally used when producers recent
quality history has deteriorated.

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ANSI/ASQ Z1.4
Reduced inspection:
Used when the producers recent
quality history has been exceptionally

good.
Decision concerning what type of plan to
use is left to the responsible authority.

Nonconformities are classified such as
critical, major

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ANSI/ASQ Z1.4

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Sample Size Code Letters

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Comparison of Inspection
levels

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ANSI/ASQ Z1.4
AQL
The AQL is the most important part of the
standard since the AQL and sample size

dictate the plan used.
AQL is defined as the maximum percent
nonconforming that can be considered

satisfactory as a process average.
Satisfactory = Producers risk,
Usually 0.05

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ANSI/ASQ Z1.4
AQL
AQL is specified by contract or
responsible authority.
AQL may be determine from
historical data, empirical
judgment, engineering
information, experimentation,
producers capability,
consumers requirements.

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ANSI/ASQ Z1.4
AQL
AQL is specified by contract or responsible
authority.
AQL may be determine from historical
data, empirical judgment, engineering

information, experimentation, producers
capability, consumers requirements.
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ANSI/ASQ Z1.4
Sample Size
Determined by lot size and
inspection level
Use of sample-size code
Inspection level is determined by
the responsible authority.
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ANSI/ASQ Z1.4
Sample Size
Different levels of inspection provide
approximately the same protection

to the producer, but different
protections to the consumer.
Plan provides for special levels to
be used where relatively small

sample sizes are necessary and
large sampling risks must be
tolerated. (S-1, S-2, S-3, S-4)
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ANSI/ASQ Z1.4
Implementation
Determine lot size

Determine inspection level
Find sample-size code letter in table
Determine AQL
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ANSI/ASQ Z1.4
Implementation contd.
Determine type of sampling plan

Find sampling plan in appropriate
table
Start with normal inspection and
change to tightened or reduced

based on switching rules
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AQL
What an AQL means is that as long as a
supplier maintains his/her process
average (% defective) at the assigned
AQL or lower, there is a very high
probability that shipments from that
supplier, when inspected using ASQ Z1.4
sampling plans, will be accepted.
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AQL
By the same token, there is a very high
probability that shipments, when
inspected using ASQ Z1.4 sampling plans,
will be rejected if a supplier's process
average (% defective) remains higher
than the assigned AQL.
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ANSI/ASQ Z1.4
Single sampling plans
Start by identification of AQL, lot size,
inspection level, and type of sampling

plan.
Locate appropriate plan parameters
in tables.
Double and Multiple Sampling
Similar procedures as single sampling

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ANSI/ASQ Z1.4
Normal, Tightened, and Reduced Inspection
Start with normal inspection
Switching Procedures
Normal to tightened
Institute when 2 out of 5 consecutive lots not
accepted on original inspection

Tightened to normal
Institute when 5 consecutive lots accepted
If not, then discontinue inspection under this
plan
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ANSI/ASQ Z1.4
Normal to reduced
Institute when: (all of the following)
Preceding 10 lots on normal inspection
have been accepted

Total nonconforming in preceding 10
samples is less than number identified in

Table 10-5.
Production is at a steady rate
Reduced inspection is considered
desirable by responsible authority

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ANSI/ASQ Z1.4
Reduced to normal
Institute when: (any of the following)
A lot is not accepted
Sampling procedure terminates with
neither acceptance or rejection criteria

have been met
Production is irregular or delayed
Other conditions
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ANSI/ASQ Z1.4
Standard is designed for use where units of
product are produced in a continuing series of

lots or batches.
If a sampling plan is desirable for a lot or
batch of an isolated nature, it should be

chosen based on the Limiting Quality (LQ) and
consumers risk, b.
These tables are included in the standard,
but not the textbook.

Or use ANSI/ASQ Standard Q3
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ANSI/ASQ Standard Q3
Standard is used for inspection of
isolated lots by attributes.

Provides indexed tables by Limiting
Quality, LQ.
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Two Schemes:
1. Used for lots that are isolated or

mixed or that have an unknown history
as far as all parties know.
Lot size and LQ must be known.
Nominal values of the LQ are
based on b=0.10
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Two Schemes:
2. Used when a vendor is producing a

continuous stream of lots and sends
one or a few to a customer who will
consider them as isolated lots.
Occurs frequently when purchasing
small quantities of raw materials.
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Dodge-Romig Tables
A set of inspection tables for lot-by-lot
acceptance sampling by attributes.

Tables are based on Limiting Quality (LQ)
and Average Outgoing Quality Limit (AOQL).

Tables for single and double sampling
Advantage that the plan provides a
minimum amount of inspection for a given

inspection procedure.
Desirable for in-house inspection
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Dodge-Romig Tables
Limiting Quality LQ
Based
on the probability that a particular

lot, which has percent nonconforming
equal to the LQ, will be accepted.
Probability
is the consumers risk, =
0.10
LQ
plans give assurance that

individual lots of poor quality will
rarely be accepted.
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Dodge-Romig Tables
Observations about the LQ tables:
As the lot size increases, the
relative sample size decreases.

The tables extend until the process
average is one-half of the LQ.

As the process average increases,
a corresponding increase occurs in

the amount inspected.
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Dodge-Romig Tables
Average Outgoing Quality Limit AOQL
Applicable when the inspected lot is a
convenient subdivision of a flow of

product for materials handling purposes
(non-homogeneous)
AOQL plan limits the amount of poor
outgoing quality on an average basis,

but gives no assurance on individual
lots.
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Dodge-Romig Tables
Process average
Obtained by the same techniques as for p-
charts
First 25 lots the average percent
nonconforming is obtained
Type of nonconformance
Dodge-Romig tables do not provide for
different categories or tightened inspection

Different LQ or AOQL values may be used
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Chain Sampling Inspection Plan

A special type of lot-by-lot acceptance
sampling plan for attributes designated as

Chain Sampling Plan ChSP-1.
Applicable to quality characteristics which
involve destructive or costly tests.

Use of small sample sizes
Acceptance number, c=0
Poor shape of OC curve at the
producers risk
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Chain Sampling Inspection

Plan
Chain sampling uses the cumulative
results of several samples

Determination of the value of i, the
number of previous samples, is

determined by analysis of the OC
curves for a given sample size.
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Plan
Procedure:
For each lot, select a sample of
size n and test each for

conformance to specifications.
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Plan
Procedure:
If the sample has 0 nonconforming
units, accept the lot; if the sample has

2 or more nonconforming units, do not
accept the lot; and if the sample has 1
nonconforming unit, it may be
accepted provided that there are 0
nonconforming units in the previous
i samples of size n.
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Chain Sampling Diagram

Current Lot
i previous lots
n=5
c=0
Secondto-Last
Lot
Last Lot
Accept if 0 Nonconforming Units

Zero Nonconforming Units in i
&
in n =5 or if 1 Nonconforming UnitPrevious Lots
Figure 10-4 Chain Sampling Diagram
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Plan
Conditions for use of the Chain Sampling
Plan:
1. The lot should be one of
continuing series of product that

is sampled in substantially the
order of production
2. The consumer can normally
expect the lots to be essentially

the same quality.
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Plan
Conditions for use of the Chain Sampling
Plan:
3. The consumer has confidence in the
producer not to occasionally send an

unacceptable lot that would have
the optimum chance of acceptance.
4. The quality characteristic is one that
involves destructive or costly tests.

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Sequential Sampling
Used for costly or destructive tests
Subgroup size of 1 item by item plan
Sequential sampling is similar to multiple
sampling, except sequential sampling can, in

theory, continue indefinitely.
In practice, the plan is truncated after the
number inspected is equal to three times the

number inspected by a corresponding single
sampling plan.
Based on the Sequential Probability Ratio Test
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Sequential Sampling Plan
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Sequential Sampling Plan
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Skip Lot Sampling

Designated SkSP-1 and based on AOQL.
A single sampling plan for minimizing
inspection costs when there is a

continuing supply of lots of raw
materials, component parts,
subassemblies, and finished parts from
the same source.
Applicable to chemical and physical
characteristics that require laboratory

analysis.
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Procedure for SkSP-1 Plans

Begin by inspecting every lot
When i consecutive lots are
found to be conforming
Discontinue inspection of every lot
Inspect a fraction, f, of the lots
In a random manner
When an inspected lot is found
nonconforming
Figure 10-7 Procedure SkSP-1 plans

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ANSI/ASQ S1
Provides procedures to reduce the
inspection effort when the

suppliers quality is superior.
A skip-lot scheme used in
conjunction with attribute lot-by-lot

plans given in ASQ Z1.4
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ANSI/ASQ S1
Requirements to use ANSI/ASQ S1
1. Have a documented system for controlling
product quality and design changes

2. Have instituted a system that is capable of
detecting and correcting changes that

might adversely affect quality.
3. Not have experienced an organizational
change that might adversely affect quality
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ANSI/ASQ S1
Additional requirements of the product:
Be of stable design
Have been manufactured on a continuous
basis for at least 6 months unless agreed

to a longer period.
Have been on normal and reduced
inspection during the qualification period.

Have maintained a quality level at or less
than the AQL for at least 6 months.

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ANSI/ASQ S1
Other:
The previous 10 or more consecutive lots
have been accepted

The min cumulative sample size for the last
10 or more consecutive lots have been met.

The acceptance numbers for the last 2 lots
have been met
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Sampling for Continuous

Production
Acceptance sampling for continuous
production implies that manufacturing

operations do not create lots as part
of the normal part of the production
process.
Parts are produced by a
continuous process on a
conveyor or similar system.
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Production
Plans for continuous production consist of
alternating sequences of sampling

inspection and screening (100%) inspection.
Plans begin with 100% inspection and
convert to sampling after a stated

number of items are free of
nonconformities.
Sampling continues until a stated number
of nonconforming units are found, at

which time 100% inspection in reinstated.
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Production
Applicable to attribute, nondestructive
inspection of moving product.

Inspection should be easy and rapid
Process must be capable of
manufacturing homogeneous product
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Production
Developed by Dodge
CSP-1, CSP-2, CSP-3

Later, MIL-STD-1235B
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Production
CSP-1
Begins with 100% inspection of the
product in the order of production

until a certain number of successive
units are free of nonconformities.
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Production
CSP-1
Sampling inspection is then instituted
Samples are selected in such a
manner as to minimize any bias

If a nonconformity occurs, sampling is
discontinued and 100% inspection

begins.
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CSP-1 and CSP-F Plans

Start
The Screening Crew Inspects 100% of the Units
When i Consecutive Units Are Found Free of
Nonconformities Concerned,
The Screening Crew is Released from 100% Inspection

and the Sampling Inspector Inspects a Fraction, f, of
the Units, Where the Sample Units are Selected in a
Random Manner.
When the Sampling Inspector Finds One of the
Nonconformities Concerned,
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MIL-STD-1235B
Standard is composed of five different
continuous sampling plans.

Designated by code letters
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MIL-STD-1235B
Inspection is by attributes for
nonconforming units using three classes

of severity:
Critical
Major
Minor
Each of the plans incorporates a
provision for discontinuance of inspection

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Acceptance Sampling Plans

for Variables
Shainin Lot Plot
ANSI/ASQ Z1.9-2003
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for Variables
Shainin Lot Plot
Random sample of 10 subgroups of 5
each
Find average and range
Construct a histogram
Calculate Xdouble bar, R bar
Calculate ULL and LLL
Compare to lot plots in Figure 10-15
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for Variables
ANSI/ASQ Z1.9-2003 Sampling
Procedures and Tables for
Inspection by Variables for Percent
Nonconforming is an acceptance
sampling system to be used on a
continuing stream of lots for
Acceptance Quality Limit (AQL)
specified.
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for Variables
ANSI/ASQ Z1.9-2003 provides
tightened, normal, and reduced plans
to be used on measurements which are
normally distributed. Variation may be
measured by sample standard
deviation, sample range, or known
standard deviation. It is applicable only
when the normality of the
measurements is assured.
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Quality Control

Chapter 10Acceptance Sampling

PowerPoints created by Rosida

2009 Pearson Education, Upper Saddle River, NJ 07458.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

systems in terms of lot-by-lot, continuous

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

and know their function (advantages,

2009 Pearson Education, Upper Saddle River, NJ 07458.

rejected using ANSI/ASQ Z1.9

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Intended to be used for a continuing

series of lots, but may be designed

and multiple sampling plans.

normal, tightened, or reduced

2009 Pearson Education, Upper Saddle River, NJ 07458.

inspection with changes being a function

quality history has deteriorated.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

quality history has been exceptionally

use is left to the responsible authority.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Sample Size Code Letters

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

standard since the AQL and sample size

nonconforming that can be considered

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

data, empirical judgment, engineering

2009 Pearson Education, Upper Saddle River, NJ 07458.

the responsible authority.

2009 Pearson Education, Upper Saddle River, NJ 07458.

approximately the same protection

be used where relatively small

2009 Pearson Education, Upper Saddle River, NJ 07458.

Determine lot size

2009 Pearson Education, Upper Saddle River, NJ 07458.

Determine type of sampling plan

change to tightened or reduced

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

Start by identification of AQL, lot size,

inspection level, and type of sampling

Similar procedures as single sampling

2009 Pearson Education, Upper Saddle River, NJ 07458.

accepted on original inspection

2009 Pearson Education, Upper Saddle River, NJ 07458.

have been accepted