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Acceptance Sampling
Acceptance Sampling
20!
f (2) 0.05 2 (1 0.05) ( 20 2 ) 0.1887
2!(20 2)!
P( acceptance of lot)=0.3585 + 0.3774 = 0.1887 = 0.9246
Assuming
1) No inspection errors
2) Cost to replace a defective found in inspection is borne by the producer or is small
compared to the damage or inconvenience caused by the defective
Economic comparison of inspection alternatives:
100% inspection is justified in case of equipment where the cost of finding and correcting
defective increases rapidly for each major stage that the product moves to from production to the
customer.
An electronic component may cost $1 at incoming inspection, $10 at the PCB stage, $100 at the
system level and $1000 in the field. In such a case it is worthwhile to spend more on inspection
at initial stage rather than spending much more at a later stage.
It also needs to be noted that Neither sampling nor 100% inspection can guarantee that every
defective item in a lot will be found.
Sampling involves a risk that the sample will not adequately reflect the conditions of the lot. The
Type I error discussed earlier is also called Producers risk or also as risk. The Type II error is
also known as Consumers risk or risk.
Double-sampling plans
One of the following decisions, based on the information in the initial sample, is
made
1. Accept the lot
2. Reject the lot
3. Take a second sample
If a second sample is taken, information in both the samples is used to
decide acceptance or rejection
Multiple sampling-plans
Extension of Double-sampling plan, more than two samples may be required
Ultimate extension of sampling is Sequential sampling
Module 21
Single sampling plans for attributes
Example 2:
N=10000 , n = 89 and c=2
The probability of acceptance for different values of p, fraction defective are shown in the
following table.
The OC curve is shown in the figure below.
The and risks referred to earlier are shown on the OC curve as below.
The following figure shows the effect of sample size on the OC curves. It is noted that the
discriminatory power of the sampling plan increases with sample size.
Type-B OC curve is constructed with the assumption that the sample is taken from a large
lot or from a stream of lots selected at random from a process.
Binomial distribution is the exact probability distribution for calculating the probability
of acceptance.
Type-A OC curve is used to calculate probability of acceptance for an isolated lot of finite
size.
The exact sampling distribution of the number of defective items in the sample is the
hypergeometric distribution.
As the size of the lot increases, the lot size has a decreasing impact on the OC curve.
If the lot size is at least 10 times the sample size, the two types of curves are almost same.
Type-A OC curve always lies below the Type-B OC curve.
OC curve for single-sampling with c=0: The curves are shown in the figure below
Sampling plans with c=0 have OC curves that are complex through out their range.
Probability of acceptance drops very rapidly even for small values of lot fraction
defective.
This is hard on the vendor and some times uneconomical for the consumer.
From slide 14, for n=89, AQL=1%, Pa=0.78 for c=1 and Pa=0.41 for c=0
The Poisson distribution yields a good approximation when n is at least 16, N at least 10
times n and p is less than 0.1.
The Poisson distribution as applied to acceptance sampling is
e np (np)r
P(r )
r! in sample of n.
where, P(r) is the probability of exactly r defectives
Module 22
Rectifying inspection
Corrective action required after rejection of lots.
Generally, rejected lots are 100% inspected, with defective items removed for rework or
replaced by good items.
Such sampling programs are called Rectifying Inspection Programs
Average Outgoing Quality (AOQ) is the quality in the lot that results from the application
of rectifying inspection.
If the lots are from a process with p fraction defective, then In lots of size N, ,
1. n items contain no defectives as defectives are replaced
2. N-n items contain no defectives if the lot is rejected
3. N-n items contain p(N-n) defectives if the lot is accepted
Expected number of defectives is Pa(N-n)
Therefore, AOQ = Pap(N-n)/N
If N is large relative to n, Approximately, AOQ= Pap
The curve that plots AOQ against incoming quality, p is called AOQ curve
From the AOQ curve, we note that average outgoing quality is good both for good and
very bad incoming qualities.
The maximum ordinate on the curve represents the worst possible average quality that
results from the rectifying plan.
This point is called the Average Outgoing Quality Limit (AOQL)
AOQL is an average level of quality, across a large stream of lots and it does not give
assurance that an isolated lot will have quality no worse than AOQL.
If the lot has no defectives, the amount of inspection per lot =n
If all are defectives, the amount of inspection per lot = N
If the lot quality is 0<p<1, then the Average Total Inspection (ATI) per lot will be
ATI = n + (1 Pa)(N n)
Double Sampling Plan
Decision of acceptance or rejection based on two samples
A lot may be accepted if the sample is good enough or may be rejected if the sample is
bad enough
If the first sample is neither good enough nor bad enough, decision is based on evidence
of first and second sample combined.
This is shown in the following .
OC Curve of a double sampling plan:
Example 3:
Draw the OC curve of the single-sampling given with sample size 300 and acceptance number 5.
We first fix tentative probabilities of acceptance (Pa)
Consider the table shown below
n np P Pa Pap
300 0.98
300 0.95
300 0.70
300 0.50
300 0.20
300 0.05
300 0.02
Search the cumulative Poisson distribution table under c=5 column for a value close to the
required Pa value and note the corresponding np value . For this np calculate the corresponding
p. Complete the table and draw the required curve.
n np P Pa Pap
=AOQ
300 2.0 0.0067 0.983 0.0065
300 2.6 0.0087 0.951 0.00827
300 4.4 0.0147 0.70 0.0106
300 5.6 0.0187 0.512 0.00957
300 7.8 0.025 0.210 0.00526
300 10.5 0.035 0.05 0.00175
300 12.0 0.04 0.02 0.0008
From the above table the OC curve can be constructed which is given in the following
Example 4:
In a double sampling plan, N=5000, n1=100, c1=0, n2=100, c2=1
(a) Use Poissons table to compute the probability of acceptance of a 1% defective lot.
(b) assume that a lot rejected by this sampling plan will be 100% inspected. What will be the
AOQ if the submitted product is 1% defective? Considering the inspection of both
rejected lots, what will be the avarage number of articles inspected per lot if the
submitted product is 1% defective?
No of defective articles = 5000x0.01=50 No of non-defective articles= 5000-50=4950
(a) n1p=100x0.01=1
From Poissons table, PI(0)=0.368
Accept the lot if
I) Zero defective in the first sample
II) One defective in the first sample and zero defective in the second sample
PI(1)= 0.736-0.368=0.368
For the second sample, N=5000-100=4900,
No of defectives=49
P=49/4900=0.01, n2p=100x0.01=1
PII(0)=0.368
Therefore, probability of acceptance,
Pa=PI(0) + PI(1)xPII(0)
= 0.368+0.368x0.368=0.5034
(b) AOQ=Paxp=0.5034x0.01=0.005034 or 0.5034 %
Average no of articles inspected =PI(0)n1+PI(1)(n1+n2) + (1-Pa)N
i.e. 0.368 x100+0.368x0.368x200+ (1-0.5034)5000=2547
Module 23
Multiple Sampling Plans
A multiple sampling plan is an extension of double sampling plan more than two
samples are required
If at any stage the number of defective items is less than or equal to the corresponding
acceptance number, the lot is accepted.
If at any stage the number of defective items is greater than or equal to the corresponding
rejection number, the lot is rejected.
These plans generally involve less total inspection compared to single or double sampling plans
guaranteeing the same protection, but usually require higher administrative costs and higher
caliber inspection personnel
Sample Sample size Combined samples
First n1 n1 c1 r1
Second n2 n1+n2 c2 r2
Third n3 n1+n2+n3 c3 r3
Fourth n4 n1+n2+n3+n4 c4 r4
Rejection Acceptance
The equations for the two limit lines for specified values of p1, 1-, p2, and are
And
Numerical example:
Design a sequential sampling plan for the following specifications:
= 0.05, p1 = 0.1
= 0.2, p2 = 0.3