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Production Sample Size Considerations - JDS G223 X2 Clause 7.2.2.

John Deere requests that the supplier use a sampling plan for measurement data that insures no more than one days produ
undetected. Use the spreadsheet titled Sample Size & Control Limit Design on JD Supply Network. The Average Product
would be less than or equal to one days consumption at John Deere. See Statistical Process Control Scheme Design, by
Journal of Quality Technology, Vol. 27, No. 3, July 1995.

For example, assume it is economical for a supplier to check no more than 2% of production for control purposes. The proce
mean of 100 mm with a standard deviation of 0.1 mm, and a Cpk equal to 1.33. John Deere consumes 250 pieces per day.
detect a one sigma process shift before producing 250 pieces.

To use the Sample Size & Control Limit Design spreadsheet for control limits and sampling frequency, enter in cell B3 the va
shift, and enter 2% in B4 which is the sampling rate. The spreadsheet tells us to measure 6 pieces every 294 pieces, and s
at:
100 (1.667)( )/(6) = 100(1.667)(0.1)/ 6 = 100 0.07mm.

If the process sigma changes by one unit, the control chart will indicate a significant change before 239 parts are produced f
are fewer than 250 the plan provides the protection that John Deere requires.
Introductory Explanation
Optimum control scheme based on:
Subgroup size, n
Sampling frequency, r
Control limit, k
Average Production Length1 is the criterion for evaluation
Average Production Length is the total amount of production between a shift in the process mean and signal of the shift.

The goal of a control scheme is to detect a shift in the process mean after as few items as possible are produced while mini
alarms.
APL is a direct measure of how well the control scheme works.

Traditionally, a sample size, n, of 4 or 5 and control limits, k, at +/- 3 standard errors are recommended. These could be con
Rational subgroups are recommended.
Subgroup size and frequency are selected to minimize the opportunity for assignable causes to occur within the subgroup w
opportunity for variability to occur between samples.
Error probabilities and operating characteristic curves further the analysis of the schemes effectivity.
Type I and II ( and risks) and Average Run Length are often employed.
The desire is to have a large ARL when the process is in control and a small ARL when the process has shifted an unaccept
Specific values for sampling frequency are rarely suggested and quantitative methods of selecting the frequency are seldom

Refer to power point slides titled "SPC Control Design" on JD Supply Net, by Jim Stevenson Master Process Pro at JD Wate
understanding.
Protection Code: 1234

no more than one days production would go


etwork. The Average Production Length to detection
Control Scheme Design, by Keats, Miskulin & Runger,

or control purposes. The process is known to have a


onsumes 250 pieces per day. Therefore, we want to

quency, enter in cell B3 the value of 1 for the sigma


eces every 294 pieces, and set the control chart limits

efore 239 parts are produced for John Deere. Since 239

ean and signal of the shift.

sible are produced while minimizing the number of false

mended. These could be considered standard.

o occur within the subgroup while maximizing the

ctivity.

ocess has shifted an unacceptable amount.


ting the frequency are seldom used.

Master Process Pro at JD Waterloo Works for additional

Source: Keats, J. B., Miskulin, J. D. and Runger, G. C. (1995). Statistical Process Control scheme design, Journal of Quality Technology, 27(3), pp. 214-225.
Specify:

1.35
25.0%
3000

d = sigma shift of mean


r = sampling rate = percent of production sampled.
APLo = in control production pieces
Decision:

Check a subgroup of 6 pieces every 18 pieces. Set control limits on Xbar


at 2.653 sigma/sqrt(6) units. The expected number of pieces made before
a chart signal is 26.

Please enter value from 0.0 - 5.0


Please enter value from 0.0% - 100.0%
>0
Specify d, r and APLo. The blue graph line, APLd,
indicates the number of units produced before the
control chart signals a shift of d sigma units. Change
d, r and APLo to get the desired APLd production
quantity.

Subgroup Size and Control Factor


10000
9000
APLd, 8000
Parts Until Signal

APLd

k, Control Chart Factor

7000
6000
5000
4000
3000
2000
1000
0
Subgroup Size, n

27(3), pp. 214-225.

e graph line, APLd,


roduced before the
sigma units. Change
d APLd production

Source: Keats, J. B., Miskulin, J. D. and Runger, G. C. (1995). Statistical Process Control scheme design, Journal of Quality
Technology, 27(3), pp. 214-225.
Specify:
d = sigma shift of mean
1.35
r = sampling rate = sample per DPS
0.25
APLo = in control production pieces
3000
Decision:
Check a subgroup of 6 pieces every
18 pieces. Set control limits on
Xbar at 2.653 sigma units.
Result:
k = Xbar chart factor
n = subgroup size
h = sampling interval
nmax = maximum subgroup size
APLd = number of pieces produced
when the process mean is shifted d
sigma units.

2.653
6
18
1000

26

Conclusion:
6 <-Optimum ->
Subgroup
APLd
1
125
2
56
3
37
4
30
5
27
6
26
7
26
8
27
9
29
10
31
15
45
20
60
25
75
30
90
35
105
40
120
45
135
50
150
60
180
70
210
80
240
90
270
100
300
125
375
150
450

2.653
k
3.209
3.004
2.878
2.787
2.714
2.653
2.600
2.554
2.513
2.476
2.328
2.219
2.131
2.058
1.994
1.938
1.887
1.841
1.760
1.689
1.626
1.570
1.518
1.405
1.309

175
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400

525
600
750
900
1050
1200
1350
1500
1650
1800
1950
2100
2250
2400
2550
2700
2850
3000
3300
3600
3900
4200
4500
4800
5100
5400
5700
6000
6300
6600
6900
7200

1.225
1.150
1.020
0.908
0.810
0.722
0.641
0.566
0.496
0.431
0.369
0.310
0.253
0.199
0.147
0.097
0.048
0.000
-0.092
-0.180
-0.265
-0.349
-0.431
-0.512
-0.593
-0.674
-0.757
-0.842
-0.929
-1.020
-1.117
-1.221

e design, Journal of Quality

r
1
5%
n

11
1
3
5
7
9

10
20
50

Subgroup Size and Control Factor


APLd

APLd, Parts Until Signal

k, Control Chart Factor

Subgroup Size, n

1%

r
2%

3%

4%

5%