Acceptance Sampling: Purpose of Lot Inspection

Purpose of Lot Inspection
Acceptance Sampling
u Not
used to estimate lot quality Quality Control Tool be used as an audit tool
Reject/Accept decision only

u Not a u Should
incoming supply meets specifications output from a process meets specifications

WOOD/STAT 335 Quality Improvement
Lot Inspection
3 Methods u Do Not Inspect u 100% Inspection u Acceptance Sampling
Why Use Acceptance Sampling?

u Destructive
Testing
u Cost of inspection is high u 100%
inspection not feasible from a time standpoint u Vendor has good performance, but some checking should be done u When there are liability issues
Advantages & Disadvantages

Advantages u Less expensive u Less handling & damage u Reduces inspection error u Lot rejection motivates supplier u Can do destructive tests Disadvantages u Risk of accepting bad, rejecting good u Less information is known about the product u Requires planning & documentation of the sampling procedure
Types of Sampling Plans

u Type of Measurement
Attributes - go/no go Variables - measured quantity

u Sampling Schemes
Single Sampling Double Sampling Multiple Sampling
Wood 335 Quality Improvement Course Notes Dr. Thomas Maness
#10 Acceptance Sampling November, 2001 Page1
Lot Formation
u Should be homogeneous
Single Sampling Plans

Terminology
N= n= c= d= Lot Size Sample Size Allowed number of defects Observed number of defects
same machines, operators, etc, makes problem detection easier

u Larger
lots preferred
u Handling systems should be designed to
facilitate sampling u Samples must be random
Procedure
From a homogeneous lot of size N, take a random sample of n items. If the number of defects found in the sample (d) exceeds the allowable number defective (c) - reject the lot. Otherwise accept the lot.
Procedure
Procedure - Important Points

Measure of Performance
Operating Characteristics Curve u Plots Pa vs. p
Pa - Probability of Accepting the Lot p - Fraction Defective in the Lot
Calculating Pa
Pa = P{d c} = n! p d (1 p ) d !( n d )! d =0
c n d
Example
Sample of Furniture Parts
N = Lot Size is sufficiently large to use binomial n = 89 c= 2 d = Observed from Sample
When sampling from large lots and the binomial can be used.
Data for OC Curve

p 0.000 0.005 0.010 0.010 0.015 0.020 0.025 0.030 0.035 0.040 0.045 0.050 0.055 0.060 0.065 0.070 0.075 0.080 0.085 0.090 0.095 0.100 Pa 1.0000 0.9897 0.9397 0.9397 0.8502 0.7366 0.6153 0.4985 0.3936 0.3042 0.2307 0.1721 0.1265 0.0919 0.0659 0.0468 0.0329 0.0230 0.0159 0.0109 0.0074 0.0050
Resulting OC Curve
OC Curve
1.000 0.900
n = 89 c=2
n! Pa = p1d 1 p1d d =0 d !(n d )! =

or Pa = binomdist(c,n,p,true )
2
n d
0.800 0.700 0.600 Pa
89! p d 1 p d d =0 d !(89 d ) !
89 d
0.500 0.400 0.300 0.200 0.100 0.000 0.000 0.020 0.040 0.060 Lot Fraction Defective 0.080 0.100 0.120
Perfect Sampling Plan

100% Inspection What would the OC Curve Look Like?
Perfect Sampling Plan

Perfect Plan OC Curve - 100% Inspection
1.000 0.900 0.800 0.700 0.600 Pa 0.500 0.400 0.300 0.200 0.100 0.000 0.000 0.020 0.040 0.060 Lot Fraction Defective 0.080 0.100 0.120
Types of Curves
u Type A OC Curve
Type A and B OC Curves

Lot Size = 200
Type A & B OC Curves for n = 89, c = 2

1.0000 0.9000 0.8000 0.7000 0.6000 Pa 0.5000 0.4000 0.3000 0.2000 0.1000 0.0000 0.000 0.020 0.040 0.060 Fraction Defective (p) 0.080 0.100 0.120 Type B Type A
Probabilities for an individual lot Use the hypergeometric distribution Always lies below the Type A Curve
u Type B OC Curve
For a large lot, or a stream of lots Binomial is correct distribution
Type A and B OC Curves

Lot Size = 1000
Points on the OC Curve

u AQL - Acceptable
Type A & B OC Curves for n = 89, c = 2

1.0000 0.9000 0.8000 0.7000 0.6000 Pa 0.5000 0.4000 0.3000 0.2000 0.1000 0.0000 0.000 0.020 0.040 0.060 Fraction Defective (p) 0.080 0.100 0.120 Type B Type A
Quality Level
poorest quality consumer would accept as a process average

u LTPD - Lot
Tolerance Percent Defective
poorest quality consumer would accept in a given lot this is higher than the AQL also know as:
RQL - Rejectable Quality Level LQL - Limiting Quality Level
Resulting OC Curve
OC Curve
1.000 0.900 0.800 0.700 0.600 Pa 0.500 0.400 0.300 0.200 0.100 0.000 0.000
Designing a Sampling Plan

Want an OC Curve Passing Through 2 Points u Where Pa = 1 , for lots with P1 Defective u Where Pa = , for Lots with P2 Defective
This gives us 2 equations and 2 unknowns
AQL 0.020
0.040
Lot Fraction Defective
0.060 LTPD
0.080
0.100
0.120
Designing a Sampling Plan

n! 1 = p1d (1 p1d ) d = 0 d !( n d ) ! n! d = p d 1 p2 ) (n d )! 2 ( d =0 d !
c c n d
Resulting OC Curve
OC Curve
1.000 0.900 0.800 0.700 0.600 Pa 0.500 0.400 0.300
Will reject a lot better than P1 with probability
n d
Solve these 2 equations for n and c
0.200 0.100 0.000 0.000
Will accept a lot worse than P2 with probability
P1
0.020
0.040
2 Lot Fraction Defective
0.060 P
0.080
0.100
0.120
Ways to Solve the Equations

u Nomograph
Rectifying Inspection
Approach
Incoming Lots P0 Rejected Lots Inspection Accepted Lots Outgoing Lots
u Tabular Approach
Duncans Dodge-Romig Tables Military Standards
Fraction Defective 0
Incoming Lots P0
Rejected Lots Inspection Accepted Lots
Outgoing Lots
Incoming Lots P0
Outgoing Lots
Fraction Defective P0
Measures of Effectiveness
u Average
Outgoing Quality
Incoming Lots P0
Outgoing Lots p1 < p0
Average Fraction Defective of Outgoing Lots

u Average
Outgoing Quality Limit
Maximum Fraction Defective of Outgoing Lots

u Average
Total Inspection
Average Number of Samples Taken
Average Outgoing Quality

Outgoing Quality u if lot accepted, outgoing quality is same as incoming quality, p
Incoming Lots P0 Rejected Lots Inspection Accepted Lots
Fraction Defective P0 Fraction Defective 0

Outgoing Quality u if lot accepted, outgoing quality is same as incoming quality, p u if lot rejected, all defects are fixed, outgoing quality p = 0
Incoming Lots P0 Rejected Lots Inspection Accepted Lots
Fraction Defective P0 Fraction Defective 0

In general,

In general,
AOQ = Pa * p + (1 Pa ) * 0
AOQ = Pa * p + (1 Pa ) * 0
Accepted Lots
Rejected Lots

Leaving,

Leaving,
AOQ = Pa * p
AOQ = Pa * p
However, you must correct for the sample taken since defects in the sample will be fixed or replaced.

Final AOQ equation:
AOQ Curve
AOQL Curve
0.0180 0.0160
Outgoing Fraction Defective
P p( N n ) AOQ = a N
0.0140
n = 89, c = 2
0.0120
0.0100 n = 89, c = 1 0.0080
0.0060
0.0040
n = 89, c = 0
0.0020
0.0000 0.000 0.020 0.040 0.060 0.080 0.100 0.120
Incoming Lot Fraction Defective
Average Outgoing Quality Limit

Maximum AOQ Possible u As lot quality worsens, you are more likely to reject the lot. u When the lot is rejected, it is rectified. u Therefore, at some point outgoing quality starts to improve.
Average Outgoing Quality Limit

AOQL Curve
0.0180 0.0160
0.0140
n = 89, c = 2
Outgoing Fraction Defective
0.0120
0.0100 n = 89, c = 1 0.0080
0.0060
0.0040
n = 89, c = 0
0.0020
0.0000 0.000 0.020 0.040 0.060 0.080 0.100 0.120
Incoming Lot Fraction Defective
Average Total Inspection

Inspection u always must inspect n units for the sample

Inspection u always must inspect n units for the sample u must detail rejected lots, inspecting N units
Incoming Lots P0 Inspect n units Rejected Lots
Incoming Lots P0
Inspect n units
Rejected Lots
Accepted Lots
Accepted Lots

In general,

In general,
ATI = n + (1 Pa )( N n)
ATI = n + (1 Pa )( N n)
Accepted Lots
Rejected Lots

12000.0
Double Sampling
Idea Behind Double Sampling u Take 1st Sample
If decision is clear, accept or reject the lot
u If
10000.0
8000.0
n = 89, c = 0
n = 89, c = 1
n = 89, c = 2
not, Take 2nd Sample
6000.0
4000.0
2000.0
0.0 0.000 0.020 0.040 0.060 0.080 0.100 0.120
Lot Fraction Defective
Double Sampling
Idea Behind Double Sampling u Take 1st Sample
If decision is clear, accept or reject the lot
u If
Incoming Lots P0
Double Sampling
Terminology
n1 c1 n2 c2 sample size on 1st sample acceptance number on 1st sample sample size on 2nd sample acceptance number on both samples
not, Take 2nd Sample

Inspect n1 units Rejected Lots Inspect n2 units Rejected Lots
Accepted Lots
Accepted Lots
Double Sampling
Procedure
Incoming Lots P0 If d1 > c2 reject Inspect n1 units If d1 c1 accept Inspect n2 units If d1+d2 c2 accept If d1+d2 > c2 reject
First Sample
Inspect n1 units
Incoming Lots P0 If d1 > c2 reject Inspect n1 units If d1 c1 accept
Accept the lot if no more than c 1 defects occur in 1st sample.
First Sample
Inspect n1 units
Incoming Lots P0 If d1 > c2 reject Inspect n1 units If d1 c1 accept
Double Sampling
Otherwise, Proceed to 2nd Sample
Reject the lot if more than the total allowable number of defects (c2) occur in 1st sample.
Double Sampling
Procedure
Double Sampling
Procedure
Accept the lot if no more than c 2 defects occur in both samples.
Reject the lot if more than c 2 defects occur in both samples.
OC Curve for Double Sampling

Pa = PaI + PaII
Example
Consider the Double Sampling Plan: n1 = 50 c1 = 1 n2 = 100 c2 p =3 = .05
Accepted on 1st Sample
Accepted on 2nd Sample
Example, continued
Pa for first sample is the probability of observing no more than 1 defect on first sample.
Example, continued
Pa for first sample is the probability of observing no more than 1 defect on first sample. Pa (first) = binomdist(c1, n1, p, TRUE) = 0.279
PaI =
d1 = 0 1
50! d (50 d )! p (1 p)
1 d1 1
50 d1
Example, continued
Pa for second sample is the probability of observing no more than 3 total defects on both samples, given that you observed d 1 defects on the first. Pa (second) = Prob(d 1=2) * Prob(d 2<=1) + Prob(d 1=3) * Prob(d 2=0) = 0.01 + 0.001
Example, continued
Pa for both samples is the sum of Pa (first) and Pa(second). Pa (both) = Pa (First) + Pa (Second) = 0.279 + 0.011 = 0.290
All points on the OC Curve are calculated the same way.
Average Sample Number

In Double Sampling, number of samples taken is variable. ASN = = Where: PI = + P(lot is accepted on first sample) P(lot is rejected on first sample) n1 PI + (n1+n 2) (1-PI ) n1 + n2 (1- PI )

In Double Sampling, number of samples taken is variable. ASN = = Where: PI = + P(lot is accepted on first sample) P(lot is rejected on first sample) n1 PI + (n1+n 2) (1-PI ) n1 + n2 (1- PI )
Prob. of making any decision on the 1st sample

In Double Sampling, number of samples taken is variable. ASN = = 50 + 100 (1- 0.519 ) 98
Curtailment
Usually, the decision is made as soon as the number of defects found exceeds d2. This is called a curtailed sample. ASN curve for a curtailed Double Sample always lies below the Single Sampling Plan.
On average, 98 samples are taken with this plan
AOQ - Double Sampling

With Rectifying Inspection:
ATI - Double Sampling

With Rectifying Inspection:
AOQ =
[P
I a
( N n1 ) + PaII ( N n1 n2 ) p N
ATI = n1PaI + ( n1 + n2 ) PaII + N (1 Pa )

Acceptance Sampling: Purpose of Lot Inspection

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Acceptance Sampling: Purpose of Lot Inspection

Uploaded by

Copyright:

Available Formats

Purpose of Lot Inspection

Reject/Accept decision only

incoming supply meets specifications output from a process meets specifications

Why Use Acceptance Sampling?

u Cost of inspection is high u 100%

Advantages & Disadvantages

Types of Sampling Plans

Attributes - go/no go Variables - measured quantity

Single Sampling Double Sampling Multiple Sampling

Wood 335 Quality Improvement Course Notes Dr. Thomas Maness

#10 Acceptance Sampling November, 2001 Page1

Single Sampling Plans

same machines, operators, etc, makes problem detection easier

u Handling systems should be designed to

facilitate sampling u Samples must be random

Procedure - Important Points

Wood 335 Quality Improvement Course Notes Dr. Thomas Maness

#10 Acceptance Sampling November, 2001 Page2

Data for OC Curve

n! Pa = p1d 1 p1d d =0 d !(n d )! =

0.800 0.700 0.600 Pa

Perfect Sampling Plan

Perfect Sampling Plan

Wood 335 Quality Improvement Course Notes Dr. Thomas Maness

#10 Acceptance Sampling November, 2001 Page3

Type A and B OC Curves

Type A & B OC Curves for n = 89, c = 2

For a large lot, or a stream of lots Binomial is correct distribution

Type A and B OC Curves

Points on the OC Curve

Type A & B OC Curves for n = 89, c = 2

poorest quality consumer would accept as a process average

Tolerance Percent Defective

Designing a Sampling Plan

This gives us 2 equations and 2 unknowns

Lot Fraction Defective

Wood 335 Quality Improvement Course Notes Dr. Thomas Maness

#10 Acceptance Sampling November, 2001 Page4

Designing a Sampling Plan

Will reject a lot better than P1 with probability

Solve these 2 equations for n and c

0.200 0.100 0.000 0.000

Will accept a lot worse than P2 with probability

2 Lot Fraction Defective

Ways to Solve the Equations

Duncans Dodge-Romig Tables Military Standards

Rejected Lots Inspection Accepted Lots

Rejected Lots Inspection Accepted Lots

Wood 335 Quality Improvement Course Notes Dr. Thomas Maness

#10 Acceptance Sampling November, 2001 Page5

Rejected Lots Inspection Accepted Lots

Outgoing Lots p1 < p0

Average Fraction Defective of Outgoing Lots

Outgoing Quality Limit

Maximum Fraction Defective of Outgoing Lots

Average Number of Samples Taken

Average Outgoing Quality

Average Outgoing Quality

Outgoing Lots p1 < p0

Outgoing Lots p1 < p0

Average Outgoing Quality

Average Outgoing Quality

Wood 335 Quality Improvement Course Notes Dr. Thomas Maness