Professional Documents
Culture Documents
Quality Control
Outline
Inspection
Process variation (natural & assignable)
Type I and type II error
Process control
Control chart (variable and attribute)
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Learning Objectives
When you complete this supplement you
should be able to:
1. Understand the important of inspection in
quality control
2. Monitor and control the process
3. Develop various types of control chart (x-chart,
R-chart, p-chart and c-chart
4. Verify random & nonrandom pattern in control
chart
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Inspection
An appraisal activity that compares goods or services
to a standard
Involves examining items to see if an item is good or
defective
Detect a defective product
Inspection issues:
1. How much to inspect and how often
2. At what points in the process to inspect
3. Whether to inspect in a centralized or on-site location
4. Whether to inspect attributes or variables
Total Cost
Cost of
inspection
Cost of passing
defectives
Amount of Inspection
Optimal
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Centralized
• Specialized tests that may best be completed in
a lab
– More specialized testing equipment
– More favorable testing environment
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On-Site
Quicker decisions are rendered
Avoid introduction of extraneous factors
Quality at the source (near the line)
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Process Variability
Two basic questions concerning variability:
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Variation
• Variation PREDICTABLE
– Random (common cause) variation:
• Natural variation in the output of a process, created by
countless minor factors
• E.g: older machine, less sensitive
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Assignable Causes
Variations that can be traced to a specific reason
The objective is to discover when assignable
causes are present
• Eliminate the bad causes
• Incorporate the good causes
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Type of Errors
• Type I error
– Concluding a process is not in control when it actually is.
• Manufacturer’s Risk – manufacturer search for error
• Type II error
– Concluding a process is in control when it is not.
• Consumer’s Risk – manufacturer doesn’t realize error pass to
consumer
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PROCESS CONTROL
• Sampling and corrective action are only a part of the control
process
• Steps required for effective control:
– Define
– Measure
– Compare
– Evaluate
– Correct
– Monitor
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Process CONTROL
To measure the process, we take samples
and analyze the sample statistics following
these steps
Each of these
(a) Samples of the product, represents one
say five boxes of cereal sample of five
taken off the filling boxes of cereal
machine line, vary from
each other in weight # # 1:5
# # #
Frequency
# # # #
# # # # # # #
# # # # # # # # # #
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Process CONTROL
The solid line represents
the distribution
(b) After enough
samples are taken
from a stable
Frequency
process, they form a
pattern called a
distribution
Weight
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Process CONTROL
(d) If only natural
causes of variation
are present, the
output of a process
Frequency
Prediction
forms a distribution
that is stable over
time and is
predictable
Weight
?
?? ??
(e) If assignable causes are ? ?
? ?
present, the process ?
? ?
?
output is not stable over ??? ??
?
time and is not
Frequency
Prediction
predictable
Weight
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Process CONTROL
(a) In statistical
control and capable
of producing within
Frequency control limits
Size
(weight, length, speed, etc.)
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Managerial Considerations
• At what point in the process to use control charts
• What size samples to take
• What type of control chart to use
–Variables ?
–Attributes ?
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–X bar charts
– Range control charts
• Used to monitor the process dispersion
–R charts
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x i R i
x i 1
R i 1
k k
where where
x Average of sample means R Average of sample ranges
x i mean of sample i Ri Range of sample i
k number of samples
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LCLx x A2 R
where
A2 a control chart factor based on sample size, n
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(process mean is
shifting upward)
Sampling
Distribution
UCL
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UCL
Shift Not
X bar-Chart
Detected
lokasi puncak bukit
LCL
UCL
sama
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Plot X-Chart
6.30
UCL =6.25
6.20
6.10
6.00 6.02 6.00
5.98
5.94 5.93 CL =5.95
Ounces
5.90
5.84
5.80
5.70
LCL =5.65
5.60
5.50
1 2 3 4 5 6
Sample No.
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Plot R-Chart
1.20
1.11 UCL =1.09
1.00
0.80
Ounces
0.67
0.60
CL =0.52
0.46
0.40
0.34
0.27 0.24
0.20
LCL =0
0.00
1 2 3 4 5 6
Sample No.
34
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Correction: D3 = 0.3, D4 = 2
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p-chart
• Control chart used to monitor the proportion
of defectives in a process
c-chart
• Control chart used to monitor the number of
defects per unit
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Use a p-chart:
• When observations can be placed into two categories.
– Good or bad
– Pass or fail
– Operate or don’t operate
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Example p-chart
Sample of work of 20 clerks are shown. One
hundred records entered by each clerk were
examined and number of errors counted. The
fraction defective in each sample was
computed. Plot the control chart using three
standard deviation control limits.
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Calculation
Total Number of Error =
p=
Total No. of records examined
σ p^ = p (1 – p) =
n
UCLp = p + zσ p^
LCLp = p - zσ p^
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.11 –
.10 – UCLp = 0.10
.09 –
Fraction defective
.08 –
.07 –
.06 –
.05 –
.04 – p = 0.04
.03 –
.02 –
.01 – LCLp = 0.00
| | | | | | | | | |
.00 –
2 4 6 8 10 12 14 16 18 20
Sample number
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.11 –
.10 – UCLp = 0.10
.09 –
Fraction defective
.08 –
.07 –
.06 –
.05 –
.04 – p = 0.04
.03 –
.02 –
.01 – LCLp = 0.00
| | | | | | | | | |
.00 –
2 4 6 8 10 12 14 16 18 20
Sample number
43
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Use a c-chart:
• Use only when the number of occurrences per unit of measure can
be counted; non-occurrences cannot be counted.
– Scratches, chips, dents, or errors per item
– Cracks or faults per unit of distance
– Breaks or Tears per unit of area
– Bacteria or pollutants per unit of volume
– Calls, complaints, failures per unit of time
UCL c c z c
LCLc c z c
where c = mean number defective in the sample
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No.
complaints
4 – UCLc = 13.35
Number defective1
12 –
10 –
8 –
6 – c= 6
4 –
2 – LCLc = 0
0 – | | | | | | | | |
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Day
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Let’s Recap
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Okt 2016
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Mac 2017
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