Variables Control chart

Departemen Teknik Sistem dan Industri

ITS

Industrial Engineering ITS

 How to develop a control chart?
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Define the problem

Select a quality characteristic to be measured

Choose a subgroup to be sampled

Collect the data

Determine trial centreline

Determine trial control limits

Determining an alternative value for the standard

deviation
 Control Charts for x and R
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Notation for variables control charts

• n - size of the sample (sometimes called a subgroup) chosen at
a point in time
• m - number of samples selected
• x i = average of the observations in the i-th sample (where i = 1,
2, ..., m)

• x = grand average or “average of the averages (this value is

used as the center line of the control chart)
 Control Charts for x and R (2)
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Notation and values

• Ri = range of the values in the i-th sample
Ri = xmax – xmin

• R = average range for all m samples

•  is the true process mean
•  is the true process standard deviation
 Control Charts for x and R (3)
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Statistical Basis of the Charts

• Assume the quality characteristic of interest is normally
distributed with mean , and standard deviation, .
• If x1, x2, …, xn is a sample of size n, then he average of this
sample is
x1  x 2    x n
x
n
• x is normally distributed with mean, , and standard deviation,

x  / n
 Control Charts for x and R (4)
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• The probability is 1 -  that any sample mean will fall between


  Z / 2 x    Z / 2
n
and

  Z / 2 x    Z / 2
n
• The above can be used as upper and lower control limits on a
control chart for sample means, if the process parameters are
known.
 Control Charts for x and R (5)
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Control Limits for the x chart

x1  x 2    x m
x UCL  x  A2 R
m
Center Line  x
R
R1  R2    Rm LCL  x  A2 R
m

• A2 is found in Appendix VI for various values of n.

 Control Charts for x and R (6)
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Control Limits for the R chart

UCL  D4 R
Center Line  R
LCL  D3 R

• D3 and D4 are found in Appendix VI for various values of n.

 Control Charts for x and R (7)
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Estimating the Process Standard Deviation

• The random variable W = R/ is called relative range.
• The parameters of distribution of W are a function of the
sample size n.
• The mean of W is d2.
• The process standard deviation can be estimated using a
function of the sample average range.
R

 
d2

• This is an unbiased estimator of 

 Control Charts for x and R (8)
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R
• If we use x as an estimator of µ and as an estimator of ,
d2
then the parameter of the x chart are

If we define
 Control Charts for x and R (9)
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• Now consider the R chart. The center line will be R .

• To determine the control limits, we need an estimate of R .

Assuming that the quality characteristic is normally distributed,
can be found from the distribution of the relative range W =
R/ . The standard deviation of W, say d3 , is a known function
of n. Thus
R=W

• the standard deviation of R is R = d3 

 Control Charts for x and R (10)
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• Since  is unknown, we may estimate R by

• Consequently, the parameters of the R chart with usual three

sigma control limits are

• If we let
 Case Study 1
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A hard bake process is used in conjunction with photolithography in

semiconductor manufacturing. We wish to establish statistical control of
the flow width of the resist in this process using x and R charts. Twenty
five samples, each of size five wafers, have been taken when we think
the process is in control. The interval of time between samples or
subgroups is one hour. The flow width measurement data (in microns)
from the samples are shown in table 5.1
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Case Study 1
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Solution - Case Study 1

 Output Minitab - Case Study 1
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Phase II – Case Study 1

 Phase II – Case Study 1
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Revision of control limits and center lines

 Phase II – Case Study 1
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Output minitab
 Control limits, specification limits, and natural
tolerance limits
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• Control limits are functions of

the natural variability of the
process
• Natural tolerance limits
represent the natural
variability of the process
(usually set at 3-sigma from
the mean)
• Specification limits are
determined by
developers/designers.
• There is no mathematical
relationship between control
limits and specification limits.
 Rational Subgroups
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• X bar chart monitors the between sample variability

• R chart monitors the within sample variability.
• The estimate of  reflects only within sample variability, so it is not
correct to estimate  based on the usual quadratic estimator.
 Interpretation ofx and R chart
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