Quality Control

Project
They are the output of a manufacturing process in the automotive industry. The data contain 20
samples with 5 subgroups.

Data:

Measurementdataandsubgroupstatistics.Numericalexample
IDsamplei
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

MeasureX
0.0073
0.0106
0.0096
0.0080
0.0104
0.0071
0.0078
0.0087
0.0074
0.0081
0.0078
0.0089
0.0087
0.0084
0.0074
0.0069
0.0077
0.0076
0.0069
0.0063

0.0101
0.0083
0.0080
0.0076
0.0084
0.0052
0.0089
0.0094
0.0081
0.0065
0.0098
0.0090
0.0075
0.0083
0.0091
0.0093
0.0089
0.0069
0.0077
0.0071

0.0091
0.0076
0.0132
0.0090
0.0123
0.0101
0.0122
0.0120
0.0120
0.0105
0.0113
0.0111
0.0125
0.0101
0.0116
0.0090
0.0091
0.0062
0.0073
0.0078

0.0091
0.0074
0.0105
0.0099
0.0132
0.0123
0.0091
0.0102
0.0116
0.0125
0.0087
0.0122
0.0106
0.0140
0.0109
0.0084
0.0068
0.0077
0.0074
0.0063

M.xi /

Ri

si

0.0082
0.0080
0.0102
0.0094
0.0113
0.0084
0.0095
0.0101
0.0103
0.0102
0.0099
0.0107
0.0101
0.0101
0.0100
0.0085
0.0084
0.0070
0.0073
0.0073

0.0048
0.0047
0.0052
0.0047
0.0048
0.0071
0.0044
0.0033
0.0048
0.0071
0.0040
0.0037
0.0050
0.0057
0.0042
0.0024
0.0026
0.0015
0.0008
0.0025

0.0019
0.0017
0.0019
0.0019
0.0019
0.0028
0.0016
0.0012
0.0023
0.0029
0.0017
0.0017
0.0020
0.0023
0.0017
0.0010
0.0011
0.0006
0.0003
0.0011

0.009237

0.004155

0.0016832

0.0053
0.0059
0.0098
0.0123
0.0120
0.0073
0.0095
0.0099
0.0122
0.0136
0.0118
0.0126
0.0113
0.0097
0.0108
0.0090
0.0094
0.0067
0.0074
0.0088
Mean

Types Of Control Charts:

There are two types of control charts
1. Variable Control Charts (For Quantitative Data)
2. Attribute Control Charts (For Qualitative Data)

Control Charts for Variable Data:

Here we are going to discuss three types of the chat as fellow:
X
1.
- Chart
2. R- Chart
3. S- Chart

Chart: (Mean)

Its a simple
the

(Mean) chart, consist of upper and lower control limits and central line represent

value. When the points with in control limits then we can say that the process in control

otherwise out of control. Control chart is the best online monitoring process.

Control Limits:
CL=

UCL=
LCL=

CL= 0.009237
X

+ 3A2
- 3A2

UCL= 0.11666
LCL= 0.006808

Statistical Interpretation:
All the points with in the control limits which we define from the above formulas. On the behalf
of this graph can say that the process with in control and no assignable cause effecting the
process. As can see from 12 to 15 and 18 to 20 the graph showing some nonrandom pattern, this
means that there is some assignable cause is present.

R-Chart: (Range)

When the sample size fixed then use the R-Chart. R-Chart explain the variation. Means how
much variation present in the data. If the R-Charts points will out-side the control limits the
definitely X bar will be out of control.

Control Limits:
UCL= D4
CL=

UCL= 0.008905

LCL= D4

CL= 0.004211
R

LCL= 0

Statistical Interpretation:
As we can see all the points with in the control limits which define from the help of above
formulas. From the mean of R, it is very clear that very little variation present in the data. LCL is
0 because variation or here process cannot be negative so we assume here zero.

Estimation process Capability:

The

and R chart provide information about the performance or Process Capability of the

process. From the

process as

chart, we may estimate the mean flow width of the resist in the hard-bake

= 0.009237. The process standard deviation may be estimate,

R \

d2= 0.004211\2.326

0.0018104

Another way to express process capability is in term of Process Capability ratio (PCR) Cp,
which for a quality characteristics with both upper and lower specification limits.
Cp= USL-LCL\

S-Chart: (S.D)
When the sample size not fixed then use S-Chart. In simple words we can say that when the
sample size vary from sample to sample then the S-Chart is the appropriate technique for the
quality control process.
S-Chart

Control Limits:
UCL= B4
CL=

LCL= B3

UCL= 0.003555
CL= 0.001702

LCL= 0

Statistical Interpretation:
All the points with in the control limits. Limits define from the above formulas consist of upper
and lower control limits and central line. From the mean it is clear that not too much variation
present in the data. S.D cannot be negative that way assume that LCL equal to zero.

Control Charts Of Attribute Data:

There are several attribute charts for Quality control process as fellow:
1. P- Chart
2. C- Chart

3. U- chart
The p-Chart: (Proportion Of No. Defectives)
The p-chart is a control chart for monitoring the proportion of nonconforming products in
successive sub-groups of size n. An item of a generic subgroup is said to be nonconforming if it
possesses a specified characteristic. Given p1; p2; : : : ; pk , the subgroups proportions of
nonconforming product, the sampling randomvariable pi.
Day
21=10
22=10
23=10
24=10
25=10
26=10
27=10
28=10
29=10
30=10
31=10
1=11
2=11
3=11
4=11

Rejects Tested
32
25
21
23
13
14
15
17
19
21
15
16
21
9
25

Day

286
304
304
324
289
299
322
316
293
287
307
328
304
296
317

5=11
6=11
7=11
8=11
9=11
10=11
11=11
12=11
13=11
14=11
15=11
16=11
17=11
18=11
19=11

Rejects

Tested

21
14
13
21
23
13
23
15
14
15
19
22
23
24
27

281
310
313
293
305
317
323
304
304
324
289
299
318
313
302

The Fraction nonconforming is define as the ratio of the number of nonconforming items in a
population to the total number of items in that population. The items may have several quality
characteristics that are examined simultaneously by inspector. If the item does not conform to
standard on one or more of these characteristics, it is called as nonconforming.
The sample fraction nonconforming is define as the ratio of the number of nonconforming
units in the sample D to the sample size n; that is
p

= D \n
And

p (1 p )
n

p
=

P Chart of Rejected
1

0,11

UCL=0,1043

0,10

Proportion

0,09
0,08
0,07

_
P=0,0625

0,06
0,05
0,04
0,03

LCL=0,0207

0,02
1

10

13

16
Sample

19

22

25

28

Tests performed with unequal sample sizes

Rule Violations
Date

Violations for Points

21

Greater than +3 sigma

1 points violate control rules.

Control Limits:
P 3 p
UCL=
CL=

UCL= 0.1043

CL= 0.0625
P 3 p

LCL=

LCL= 0.0207

Statistical Interpretation:
As we can see that one is point is out of the upper control limit. Means some assignable cause
effecting the process. Need to take the action for remove the error. Exclude the 21 value from the
data and again make the chart and monitoring the process, thats called phase .

Revision of Control Limits and center line:

The effective use of any control chart will require periodic revision of control limits and center
lines. Its a phase operation.
P Chart of rejects
0,11
UCL=0,10217

0,10
0,09

Proportion

0,08
0,07

_
P=0,06089

0,06
0,05
0,04
0,03
0,02

LCL=0,01961
1

10

13

16
Sample

19

22

25

28

Tests performed with unequal sample sizes

Now all the points within the control limits. So we can say confidentially the process in control.

Run Test For P chart:

Run test for randomness,
Hypothesis:

Ho= Sequence follow the randomness

H1= Not follow the randomness
Level of significance:

0.05
C.R:
Reject Ho if p < 0.05

Runs Test: Rejected

Runs test for Rejected
Runs above and below K = 18,6552
The observed number of runs = 13
The expected number of runs = 15,3448
16 observations above K; 13 below
P-value = 0,370

Conclusion:
Here p value is 0.370 which is greater than 0.05, so we accept our null hypothesis. Means that
sequence is randomly.

The c-Chart:
The c-chart is a control chart used to track the number of nonconformities in special subgroups,
called inspection units. In general, an item can have any number of nonconformities. This is an
inspection unit, as a unit of output sampled and monitored for determination of nonconformities.
The classic example is a single printed circuit board. An inspection unit can be a batch, a
collection, of items. The monitoring activity of the inspection unit is useful in a continuous
production process. The number of nonconformities per inspection unit is called c.
The mean and the variance of the Poisson distribution, defined for the random variable number
of nonconformities units counted in an inspection unit.
Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Errors
10
11
6
9
12
12
14
9
5
0
1
2
1
11
9

Day
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Errors
8
7
1
2
3
5
1
11
9
14
1
9
1
8
12

Each specification point at which a specification is not satisfied results in a Defects

or nonconformity.

C Chart of Error
16
UCL=14,62

14

Sample Count

12
10
8

_
C=6,8

6
4
2
0

LCL=0
1

10

13

16
19
Sample

22

25

28

31

Control Limits:
c 3 c
UCL=
UCL= 14.62
c
CL=
CL= 6.8
c 3 c
LCL=
LCL= 0
Statistical interpretation:
As we can see all the points in the control limits. The products has fixed in control chart. LCL is
zero because probability cannot be negative. So we can say the process is in control.

Run Test For C chart:

Run test for randomness,
Hypothesis:

Ho= Sequence follow the randomness

H1= Not follow the randomness
Level of significance:

0.05
C.R:
Reject Ho if p < 0.05
Runs Test: Error
Runs test for Error
Runs above and below K = 6,8

The observed number of runs = 11

The expected number of runs = 15,7333
17 observations above K; 13 below
P-value = 0,073

Conclusion:
Here p value is 0.073 which is greater than 0.05, so we accept our null hypothesis. Means that
sequence is randomly.

The u-Chart:
If the subgroup does not coincide with the inspection unit and subgroups are made of different
numbers of inspection units, the number of nonconformities per unit Ui.

Errors/defectsinceramictiles.Numericalexample
Samplei
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

ci [nonconform. Size[ft ]
number]
14
47
21
6
16
27
21
22
43
17
32
14
9
16
19

7.1
3.3
5.9
5.2
5.6
8
8.9
5.6
6.1
4.2
8.4
6.8
4.4
5.2
7.8

ui

Samplei

ci [nonconform.
number]

Size[ft ]

1.972
14.242
3.559
1.154
2.857
3.375
2.360
3.929
7.049
4.048
3.810
2.059
2.045
3.077
2.436

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

25
32
41
13
0
14
16
17
18
26
14
23
35
42
31

9.8
8.8
7.1
3.3
6.8
4.4
5.6
8
8.9
5.3
3.1
6.2
4.8
13.5
5.9

ui
2.551
3.636
5.775
3.939
0.000
3.182
2.857
2.125
2.022
4.906
4.516
3.710
7.292
3.111
5.254

U Chart of nonconforming
7

1
1

Sample Count Per Unit

UCL=5,222

5
4

_
U=3,195

3
2

LCL=1,168

1
1

10

13

16
Sample

19

22

25

28

Control Limits:
U 3

U
k

UCL=
U
CL=
U 3

UCL= 5.222
CL= 3.195
U
k

LCL=

LCL= 1.168

Statistical Interpretation:
From the graph it is clear that the process is out of control, the red points showing the process is
out of control. The points out of control are 2, 4, 9, 18 and 29 exclude these points and make
Chart again.

Revision of control Limits and center line:

U Chart of nonconforming
5

Sample Count Per Unit

UCL=4,749
4

_
U=2,839

LCL=0,928
1

10

13

16
Sample

19

22

25

28

Statistical Interpretation:
Now all the points with in the control limits. So we can say the process in control, Its a phase .

Run Test For U chart:

Run test for randomness,
Hypothesis:

Ho= Sequence follow the randomness

H1= Not follow the randomness
Level of significance:

0.05
C.R:
Reject Ho if p < 0.05
Runs Test: nonconforming
Runs test for nonconforming
Runs above and below K = 22,4
The observed number of runs = 14
The expected number of runs = 15,4
12 observations above K; 18 below
P-value = 0,587

Conclusion:

Here p value is 0.587 which is greater than 0.05, so we accept our null hypothesis. Means that
sequence is randomly.