Acceptance Sampling - Besterfield

Quality Control
Chapter 9- Lot-by-Lot
Acceptance Sampling
By Attributes
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Besterfield
Quality Control, 8e
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Coowar
Besterfield: Quality Control, 8th ed..
2009 Pearson Education, Upper Saddle River, NJ 07458.

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Outline
Fundamental Aspects
Statistical Aspects
Sampling Plan Design

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Learning Objectives
When you have completed this chapter you
should be able to:
Know the advantages and disadvantages of
sampling; the types of sampling plans and

selection factors; criteria for formation of lots;
criteria for sampling selection; and decisions
regarding rejected lots.
Determine the OC Curve for a single sampling
plan.

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Learning Objectives-contd.
should be able to:
Determine the equations needed to graph the
OC Curve for a double sampling plan.

Know the properties of OC Curves.
Know the consumer-producer relationships of
risk, AQL, and LQ.

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Learning Objectives-contd.
should be able to:
Determine the AOQ curve and the AOQL for a
single sampling plan.

Determine single sampling plans for stipulated
producers risk and for stipulated consumers

risk.

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Fundamental Aspects
Acceptance Sampling is a form of
inspection applied to lots or
batches of items before or after a
process to judge conformance to
predetermined standards.

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Acceptance Sampling
Acceptance Sampling is very useful when:
Large numbers of items must be
processed in a short amount of time.

The cost of passing defectives is low.
Fatigue/boredom is caused by inspecting
large numbers of items.

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Acceptance Sampling
Acceptance Sampling is very useful when:
Destructive testing is required

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Acceptance Sampling
Three important aspects of sampling:

Involves random sampling of the
entire lot
Accept and Reject Lots (does not
improve the quality) Lot

Sentencing
Audit Tool
Three approaches to lot sentencing:
Accept with no inspection
100% inspection
Acceptance Sampling

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Acceptance Sampling
Advantages
Less expensive
Reduced damage
Reduces the amount of inspection
error
Disadvantages
Risk of accepting bad lots and
rejecting good lots

Less information generated
Requires planning and
documentation

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Sampling Plans
Sampling Plans specify the lot size, sample
size, number of samples and
acceptance/rejection criteria.
Sampling plans involve:
Single sampling
Double sampling
Multiple sampling
Lot
Random
sample

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Sampling Plans
Single Sampling Plan
N = lot size
n = sample size
C=acceptance number
If c or less non-conforming units are found
in the sample, the lot is accepted, else it is
rejected.

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Single Sampling Plan

A single sampling plan is one where:
A representative sample of n items is
drawn
from a lot size of N items
Each item in the sample is examined
and classified as good/defective
If the number of defective exceeds a
specified rejection number (c) the whole lot
is rejected; otherwise the whole lot is
accepted

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Double Sampling Plan

A Double Sampling Plan allows to take a
second sample if the results of the original
sample are inconclusive.
Specifies the lot size, size of the initial sample,
the
accept/reject/inconclusive criteria for the
initial sample
(N, n1, c1 (Ac), r1(Re))
Specifies the size of the second sample and the
acceptance rejection criteria based on the total
number of defective observed in both the first
and second sample (n2,c2,r2)

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Lot
Accept Lot
First Random
sample
First sample inconclusive,

take second sample
Reject Lot
C1
r1
Compare number of defective found in the first random sample to C1
and r1 and make appropriate decision.

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Lot
First Random sample
Second Random sample
Accept Lot
Reject Lot
C2
Compare the total number of defective in both lots to C2 and make
the appropriate decision

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A Multiple Sampling Plan is similar to the

double sampling plan in that successive
trials are made, each of which has
acceptance, rejection and inconclusive
options.
Which Plan you choose depends on:
Cost and time
Number of samples needed and
number of items in each sample

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Lot Formation
Considerations before inspection:
Lots should be homogeneous
Larger lots are more preferable than
smaller lots
Lots should be conformable to the
materials-handling systems used in
both the vendor and consumer
facilities

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Random Sampling
Units selected for inspection should
be chosen at random
If random samples are not used, bias
can be introduced
If judgment methods are used to
select the sample, the statistical
basis of the acceptance-sampling
procedure is lost

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Statistical Aspects
The Operating Characteristic

Curve:
Measures the performance of an
acceptance sampling plan

Plots the probability of accepting the
lot versus the lot fraction defective
Shows the probability that a lot
submitted with a certain fraction
defective will be either accepted or
rejected

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Acceptable Quality Level

(AQL)
The AQL is a percent defective that is
the base line requirement for the
quality of the producer's product. The
producer would like to design a
sampling plan such that there is a
high probability of accepting a lot
that has a defect level less than or
equal to the AQL.

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Lot Tolerance Percent

Defective
The Lot Tolerance Percent Defective
LTPD or LQ is a designated high
defect level that would be
unacceptable to the consumer. The
consumer would like the sampling
plan to have a low probability of
accepting a lot with a defect level as
high as the LTPD.

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Type I Error (Producers Risk)

This is the probability, for a given
(n,c) sampling plan, of rejecting a lot
that has a defect level equal to the
AQL. The producer suffers when this
occurs, because a lot with acceptable
quality was rejected. The symbol is
commonly used for the Type I error
and typical values for range from 0.2
to 0.01.

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Type II Error (Consumers

Risk)
This is the probability, for a given
(n,c) sampling plan, of accepting a
lot with a defect level equal to the
LTPD. The consumer suffers when
this occurs, because a lot with
unacceptable quality was accepted.
The symbol is commonly used for
the Type II error and typical values
range from 0.2 to 0.01.

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Operating Characteristic
Curve
This curve plots the probability of
accepting the lot (Y-axis) versus the
lot fraction or percent defectives (Xaxis). The OC curve is the primary
tool for displaying and investigating
the properties of a Lot Acceptance
Sampling Plan.

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OC Curves
There are two types of OC curves:
Type A
Gives the probability of
acceptance of an individual lot
coming from finite production
Type B
Gives the probability of
acceptance for lots coming from
a continuous production

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OCCs for Single Sampling

Plans
Probability of accepting lot
An Operating Characteristic Curve (OCC) is a

probability curve for a sampling plan that shows the
probabilities of accepting lots with various lot
1 levels (% defectives).
quality
Under this sampling plan, if the lot has 3% defective
. the
probability of accepting the lot is 90%
. the
probability of rejecting the lot is 10%
0.9
0.8
0.7
0.6
0.5
0.4
If the lot has 20% defective

. it has a small probability (5%) of being accepted
. the probability of rejecting the lot is 95%
0.3
0.2
0.1
0
0
.05
.10
.15
.20
Lot quality (% defective)

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OCC, AQL and Producers Risk

1
Producers Risk = probability acceptable lot is rejected
0.9
0.8
0.7
0.6
0.5
AQL - percentage level of defects at

which a customer is willing to accept
0.4
0.3
0.2
0.1
0
0
.05
.10
.15
.20
Acceptable Lot

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OCC, LTPD and Consumers Risk

1
0.9
0.8
0.7
LTPD - upper limit on the percentage

of defectives that a customer is
willing to accept.
0.6
0.5
0.4
0.3
0.2
0.1
Consumers Risk = probability unacceptable is accepted
0
0
.05
.10
.15
.20
Unacceptable Lot

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OCC for Double Sampling Plan

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Inspect a sample
of 150 from lot
of 2400
If 4 or more
If 1 or less
Nonconforming units
Nonconforming
units accept lots andIf 2 or 3 nonconforming the lot is not accepted
and stop
stop
units, inspect a second
sample of 200
If 5 or less
Nonconforming units
On both samples,
Accept the lot
If 6 or more
Nonconforming units
On both samples
The lot is not accepted
Figure 9-5 Graphical description of the double sampling plan: N=2400,n1=150,c

r1=4, n2=200, c2=5, and r2=6

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OCC for a Multiple Sampling Plan

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Average Outgoing Quality

(AOQ)
A common procedure, when
sampling and testing is nondestructive, is to 100% inspect
rejected lots and replace all
defectives with good units. In this
case, all rejected lots are made
perfect and the only defects left are
those in lots that were accepted.

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Average Outgoing Quality

The Average Outgoing Quality (AOQ) is the
average of rejected lots (100% inspection)
and accepted lots ( a sample of items
inspected)
N -n
AOQ = Pac * p(
) where
N
Pac = Probability of accepting a lot
p = Fraction defective
n = sample size
N = Lot size

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AOQ and Acceptance Sampling

11 lots
15 lots
2% nonconforming N=3000 2% nonconforming
Producer
n=89
Consumer
c=2
4 lots
2% nonconforming
4 lots
0% nonconforming
Figure 9-15 How acceptance Sampling works


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AOQ and Acceptance

Sampling
Total Number
11 lots-
Number
Nonconformi
ng
11(3000)=33,000
33,000(0.02)=660
4(3000)
(0.98)=11,760
44,760
660
2%
Nonconforming
4 lots0%
Nonconforming
Percent Nonconforming (AOQ) =

660/44,760 X 100 =1.47%
Figure 9-15 contd.


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Average Quality of Inspected

Lots
Typically the term (N-n)/N is very close to 1;
therefore, the equation most often used is:
AOQ = Pac * p where

Pac = Probability of accepting a lot
p = Fraction defective

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Average Outgoing Quality Level

A plot of the AOQ (Y-axis) versus the
incoming lot p (X-axis) will start at 0

for p = 0, and return to 0 for p = 1
(where every lot is 100% inspected
and rectified). In between, it will
rise to a maximum. This maximum,
which is the worst possible long
term AOQ, is called the Average
Outgoing Quality Level AOQL.

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Average Total Inspection

(ATI)
When rejected lots are 100%
inspected, it is easy to calculate the
ATI if lots come consistently with a
defect level of p. For a LASP (n,c)
with a probability pa of accepting a
lot with defect level p, we have:
ATI = n + (1 - pa) (N - n)
where N is the lot size.

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Average Sample Number

(ASN)
For a single sampling (n,c) we know each
and every lot has a sample of size n
taken and inspected or tested. For
double, multiple and sequential plans,
the amount of sampling varies
depending on the number of defects
observed.

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Average Sample Number

(ASN)
For any given double, multiple or
sequential plan, a long term ASN
can be calculated assuming all
lots come in with a defect level
of p. A plot of the ASN, versus
the incoming defect level p,
describes the sampling
efficiency of a given plan
scheme.
ASN = n1 + n2 (1 P1) for a double
sampling plan.

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Suppose is known and the AQL is
also known then :
Sampling
plan with stipulated

producers risk
Sampling plan with stipulated
consumers risk
Sampling plan with stipulated
producers and consumers risk
can be designed.

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Stipulated Producers Risk
= 0.05
AQL = 1.2%
Pa=0.95
P0.95= 0.012
Assume values for C, find np0.95 for
this c value, calculate n

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Stipulated Consumers Risk
= 0.10
LQ = 6.0%
Pa=0.10
P0.10= 0.060
Assume values for C, find np0.95 for
this c value, calculate n

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Stipulated Producers and
Consumers risk
= 0.10
= 0.10
AQL=0.9
LQ= 7.8
Find the ratio of P0.10/P0.95. From
table 9-4 C is between 1 and 2. Find
n for c =1 and n for c =2 .

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Have 4 plans.
Select plan based on:
Lowest
sampling size
Greatest sampling size
Plan exactly meets consumers
stipulation and is as close as
possible to producers stipulation
Plan exactly meets producers
stipulation and is as close as
possible to consumers stipulation

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Acceptance Sampling - Besterfield

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Quality Control

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.

sampling; the types of sampling plans and

2009 Pearson Education, Upper Saddle River, NJ 07458.

OC Curve for a double sampling plan.

risk, AQL, and LQ.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

single sampling plan.

producers risk and for stipulated consumers

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.

processed in a short amount of time.

large numbers of items.

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.

Three important aspects of sampling:

improve the quality) Lot

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

rejecting good lots

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.

Single Sampling Plan

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Double Sampling Plan

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Double Sampling Plan

First sample inconclusive,

2009 Pearson Education, Upper Saddle River, NJ 07458.

Double Sampling Plan

First Random sample

Second Random sample

2009 Pearson Education, Upper Saddle River, NJ 07458.

Double Sampling Plan

A Multiple Sampling Plan is similar to the

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.

The Operating Characteristic

Measures the performance of an

acceptance sampling plan

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Acceptable Quality Level

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Lot Tolerance Percent