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INTRODUCTION
This chapter covers three types of acceptance sampling plans; a. lot-by-lot acceptance sampling for attributes b. Continuous production acceptance sampling for attributes c. Acceptance sampling for variables. This chapter it is helpful to distinguish among: a. An individual sampling plan that states the lot size, sample size or sizes, and the acceptance criteria. b. A sampling plan scheme that is a combination of sampling plan with switching rules and possibly a provision for discontinuance c. A sampling system that is a collection of sampling schemes
LEARNING OBJECTIVES
The objectives of this unit are to : 1. Define an individual sampling plan that states the lot size, sample size or sizes, and the acceptance criteria. 2. Use a sampling plan scheme that is a combination of sampling plan with switching rules and possibly a provision for discontinuance.
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7.1
The standard is applicable, but not limited to attribute inspection of the folowing; end items, components and raw materials, operations, materials in process, supplies in storage, data or records, etc. Sampling plans of this standard are intended to be used for a continuing series of lots, but plans may be designed for isolated lots by consulting the OC curve to determine the plan with desired protection. The standard provides for three types of sampling; single, double, and multiple. For each sampling plan, provision is made for normal, tightened or reduced inspection. In this chapter, we only focused on he single sampling plan.
Figure 7.1: Comparison of Normal (N), Tightened (T) and Reduced (R) inspection. Tightened inspection is used when the producers recent quality history has deteriorated. Acceptance requirements under tightened inspection are more stringent than under normal inspection. Reduced inspection is used when the producers recent quality history has been exceptionally good. Figure X, illustrates the differences among the OC curves for Normal (N), Tightened (T), and Reduced (R), inspection. The number inspected under reduced inspection is less than under normal inspection. The decision as to the type of plan to use (single, double, or multiple) is left to the responsible authority. Normal inspection is used at the start of inspection with changes to tightened or reduced inspection being a function of recent quality performance.
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Product is submitted in homogeneous lots with the manner of presentation and identification designated or approved by the responsible authority (consumer). Samples are selected at random without regard to their quality. Non-accepted lots are resubmitted after all nonconforming units are removed or nonconformities corrected. The responsible authority will determine whether reinspection should include all types or classes of nonconformities or the particular types or classes of nonconformities that caused initial non acceptance.
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The decision on the inspection level is also a function of the type of product. For inexpensive items, for destructive testing, or for harmful testing, inspection level II should be considered. When subsequent production costs are high or when the items are complex and expensive, inspection level III may be applicable. The consumer should change the inspection level as conditions warrant. Four additional special levels (S-1, S-2, S-3, and S-4) are given in Table 7.1 and may be used where relatively small sample sizes are necessary and large sampling risks can or must be tolerated.
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Table 7.1 does not immediately provide the sample size based on the lot size and inspection level but does give a sample-size code letter. The AQL and the sample-size code letter index the desired sampling plan. Implementation The steps required to use the plan are as follows: 1. Determine the lot size (usually the responsibility of materials management) 2. Determine the inspection level (usually level II it can be changed if conditions warrant). 3. Enter table and find sample-size code letter. 4. Determine the AQL 5. Determine the type of sampling plan (single, double, or multiple) 6. Enter the appropriate table to find the sampling plan 7. Start with normal inspection and change to tightened or reduced based on switching rules. Example problems for single sampling plans are given in subsequent sections.
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example, if a single sample tightened plan (Table 7.3) is indexed by an AQL of 4.0% and a code letter D, the code letter changes to F and the sample size changes from 8 to 20. If the vertical arrow points down, it means that the sample size is too small to make a decision; if the vertical arrow points up, it means that a decision can be made with a smaller sample size. In some cases, the sample size will exceed the lot size and, in those cases, 100% inspection is required.
Normal, Tightened, and Reduced Inspection Unless otherwise directed by the responsible authority, inspection starts with the normal inspection condition. Normal, tightened, or reduced inspection will continue unchanged for each class of nonconformities or nonconforming units, or until the switching procedures given below require a change. Normal to tightened. When normal inspection is in effect, tightened inspection shall be instituted when 2 out of 5 consecutive lots or batches have not been accepted on original inspection (i.e., ignoring resubmitted lots). Tightened to normal. When tightened inspection is in effect, normal inspection shall be instituted when 5 consecutive lots or batches are accepted on original inspection.
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Table 7.2: Single Sampling Plans for Normal Inspection (Table II-A of ANSI/ASQ Z1.4-1993)
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Table 7.3: Single Sampling Plansfor Tightened Inspection (Table II-A of ANSI/ASQ Z1.41993)
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Table 7.4: Single Sampling Plans for Reduced Inspection (Table II-A of ANSI/ASQ Z1.41993)
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Normal to reduced. When normal inspection is in effect, reduced inspection shall be instituted provided all following conditions are satisfied. 1. The preceding 10 lots or batches have been on normal inspection and all of the lots have been accepted on original inspection. 2. The total number of nonconforming units (nonconformities) in the samples from the preceding 10 lots or batches is equal to or less than the applicable number given in Table 7.5. For example, if the total number inspected for the past 10 lots or batches is 600 and the AQL is 2.5%, the limit number is 7. Therefore, to qualify for reduced inspection, the number nonconforming in the 600 inspected must be equal or less than 7. In some cases, more than 10 lots or batches are necessary to obtain a sufficient number of sample units for a particular AQL, as indicated by the note of Table 7.5. This condition is optional. 3. Production is at steady rate. In other words, no difficulties, such as machine breakdowns, material shortages, or labor problems, have occurred recently. 4. Reduced inspection is considered desirable by the responsible authority (consumer). The consumer must decide if the savings from fewer inspections warrant the additional record-keeping and inspector training expenses. Reduced to normal. When reduced inspection is in effect, normal inspection shall be instituted provided any of the four conditions below are satisfied on original inspection. 1. A lot or batch is not accepted 2. When the sampling procedure terminates with neither acceptance nor rejection criteria having been met, the lot or batch is accepted, but normal inspection is reinstated starting with the next lot. 3. Production is irregular or delayed 4. Other conditions, such as customer desire, warrant that normal inspection will be instituted. If 5 consecutive lots or batches remain on tightened inspection, then inspection should be discontinued pending action to improve the quality of submitted material.
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Table 7.5: Limit Numbers for Reduced Inspection (Table VIII of ANSI/ASQ Z1.4-1993)
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7.2
ANSI/ASQ Z1.4-1993, which is appropriate for a continuous stream of lots. This standard indexes tables by Limiting Quality (LQ) values and is applicable to type A or type B lots or batches. These concepts were discussed in the last chapter. The LQ values are determined by the same techniques used to determine AQL values. There are two schemes. One scheme, given in Table 7.6, is designed to be used for lots that are isolated or mixed or that have an unknown history as far as both vendor and vendee know. To use the table that lot size and LQ value must be known. Table 7.6: Single Sampling Plans Indexed by Nominal Limiting Quality (LQ)
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Example 1 Given a lot size of 295 and an LQ value of 3.15%, determine the sampling plan. From Table 7.6 the solution is n Ac = 80 =0
The nominal values of the LQ are based on = 0.10. Because we are working with whole numbers, the actual LQ values will vary slightly from the nominal. Note the LQ is given as a percent. The second scheme is used when a vendor is producing a continuous stream of lots and sends one or few to a customer who will consider them as isolated lots. This situation would frequently occur in the purchase of small quantities of a raw material. Tables are given for LQ values of 0.5, 0.8, 1.25, 2.0, 3.15, 5.0, 8.0, 12.5, 20.0, and 32.0%. Only the table for 3.15% is reproduced, as Table 7.7. The tables list the process quality in terms of AQL (as used in ANSI/ASQ Z1.4-1993), which are equivalent to the LQ for different lot sizes. Example 2 Given a lot size of 295, Inspection Level II, and an LQ value of 3.15%, where the isolated lot is from a vendor with a continuous stream of product, determine the sampling plan. From Table 7.7 the solution is n Ac = 125 =1
Note that the information in the last 5 columns can be used to plot the OC curves. Also note that the information in Table 7.7 comes from ANSI/ASQ Z1.4. The only difference is the indexing by LQ values in order to make it easier to use.
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Table 7.7: Single Sampling Plans for Nominal Limiting Quality 3.15%
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SUMMARY
In this chapter we have studied that 1. There are 2 standard can be used; ANSI/ASQ Z1.4-1993 and ANSI/ASQ Standard Q31988. 2. Each sampling plan must have the lot size, sample size or sizes, and the acceptance criteria. 3. There are switching rules as guidance for a sampling plan scheme that is a combination of sampling plan.
REFERENCES
1. 2. 3. Dale H. Besterfield, (2004), Quality Control, 7th Edition, Prentice Hall. Douglas C. Montgomery, (2005),Introduction to Statistical Quality Control, 5th Edition, John Wiley and Sons. Frank M. Gryna, Richard C.H. Chua, Joseph A. Defeo, (2007), Jurans Quality Planning and Analysis, 5th Edition, Mc Graw-Hill.
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