Lecture 7&8

Types of Process Data

Two types of process data:

1. Variable: continuous data. Things we can measure. Example includes length, weight, time, temperature,
diameter, etc.
2. Attribute: discrete data. Things we count. Examples include number or percent defective items in a lot,
number of defects per item etc.

Types of Control Charts: the classification of control charts depend upon the type of data.

1. Variable charts: are meant for variable type of data. X bar and R Chart, X bar and sigma chart, chart for the
individual units
2. Attribute chats : are meant for attribute type of data. p chart, np chart, c chart, u chart, U chart

Control charts for the variable type of data (X bar and R charts)

In the x bar chart the sample means are plotted in order to control the mean value of a variable. In R chart, the sample
ranges are plotted in order to control the variability of a variable

Centre line, upper control limit, lower control limit for x bar and R charts are calculated. The formulae used are as
following:

= mean of the ith sample

n = sample size,

Xi = ith data

Ri = range of ith sample

Xmax(i) = maximum value of the data in ith sample

Xmin (i) = minimum value of the data in ith sample

= mean of g samples

(Centre Line for X bar chart)

= mean of mean of g samples

g = number of samples
sx = standard deviation of samples

= = estimate of standard deviation of population

d2 = parameter depends on sample size n

(Upper control limit for X bar chart)

A2 = = parameter depends on sample size

value of A2 can be directly obtained from the standard tables

(Lower control limit for X bar chart)

where (Upper control limit for R chart)

where (Lower control limit for R chart)

Example:

Mean values and ranges of data from 20 samples (sample size = 4) are shown in the table below:

Mean Mean Mean Mean Mean

S.N of Range S.N of Range S.N of Range S.N of Range S.N of Range
Sample Sample Sample Sample Sample
1 10 4 5 9 5 9 10 4 13 12 4 17 12 4
2 15 4 6 11 6 10 11 6 14 12 3 18 15 3
3 12 5 7 11 4 11 12 5 15 11 3 19 11 3
4 11 4 8 9 4 12 13 4 16 15 4 20 10 4

Sum of mean of 20 samples = = 232

Average of mean values of 20 samples = = 11.6 (Center Line of X bar Chart)

Average of Ranges of 20 samples = = 4.15 (Center Line of R Chart)

Upper Control Limit of X bar chart = 11.6 + A2 4.15 (A2 = 0.729 for sample size 4)

= 14.63
Lower Control Limit of X bar chart = 11.6 - A2 4.15 (A2 = 0.729 for sample size 4)

= 8.57

Upper Control Limit of R chart = D3 4.15 (D3 = 2.282 for sample size 4)

= 9.47 9.5

Lower Control Limit of R chart = D4 4.15 (D4 = 0 for sample size 4)

X-Bar Chart

Sample data at S.N 2, 16, and 18 are slightly above the UCL. Efforts must be made to find the special causes and
revised limits are advised to calculate after deleting these data.

R Chart

All the data are within the LCL and UCL in R Chart. Hence variability of the process data is not an issue to worry.

Control charts for Attribute type data (p, c, u charts)

p-charts calculates the percent defective in sample. p-charts are used when observations can be placed in two
categories such as yes or no, good or bad, pass or fail etc.

c-charts counts the number of defects in an item. c-charts are used only when the number of occurrence per unit of
measure can be counted such as number of scratches, cracks etc.

u-chart counts the number of defect per sample. The u chart is used when it is not possible to have a sample size of a
fixed size.
For attribute control charts, the estimate of the variability of the process is a function of the process average.

Centre line, upper control limit, lower control limit for c, p, and u charts are calculated. The formulae used are as
following:

p-chart formulae

= centre line of p chart

Where n is the sample size. Sample size in p chart must be

Sometimes LCL in p chart becomes negative, in such cases LCL should be taken as 0

c-chart formulae

= centre line of c chart

u-chart formulae

ci =number of defects in ith sample

k = number of samples

ni = size of ith samples

Example: p-chart

Data for defective CDs from 20 samples (sample size = 100) are shown in the table below:

No. of Proportion No. of Proportion

Sample Sample
Defective Defective = Defective Defective =
No. No.
CDs = x x/sample size CDs = x x/sample size
1 4 .04 11 6 .06
2 3 .03 12 5 .05
3 3 .03 13 4 .04
4 5 .05 14 5 .05
5 6 .06 15 4 .04
6 5 .05 16 7 .07
7 2 .02 17 6 .06
 8 3 .03 18 8 .08
9 5 .05 19 6 .06
10 6 .06 20 8 .08

CL =

p-Chart

Sample data at S.N 16 , 18, and 20 are above the UCL. Efforts must be made to find the special causes and revised
limits are advised to calculate after deleting these data. There is important observation that is clearly visible from the
data points that there is an increasing trend in the average proportion defectives beyond sample number15 also, data
show cyclic pattern. Process appears to be out of control and also there is a strong evidence that data are not from
independent source.

Example: c-chart

Data for defects on TV set from 20 samples (sample size = 10) are shown in the table below:

Sample No. of Sample No. of Sample No. of Sample No. of

No. Defects No. Defects No. Defects No. Defects
1 5 6 4 11 6 16 5
2 4 7 5 12 5 17 4
3 5 8 6 13 4 18 6
4 6 9 8 14 7 19 6
5 4 10 7 15 6 20 6

CL =
 c-Chart

None of the sample is out of the LCL and UCL. But the chart shows cyclic trend.

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