Series A

TQM Training Module on

Control Charts
Doc. No. A-05.02.20180522
Revision 02; 22nd May 2018
Authors: Shubham Sourav

For further clarifications, write to shubham.sourav@jsw.in © Total Quality Management, JSW Group
 TQM Training Series: 6 series with 66 training modules
This is a training module on Control Charts (A-05)
Series-A Series-C Series-D Series-F
Basic Problem Solving Tools Quality Management Basics Productivity & Efficiency Tools Advanced Statistical Tools
A-01 Flow Charts C-01 Quality Mgmt. Basics D-01 Value Stream Mapping (VSM) F-01 Sampling & Distribution
A-02 Cause & Effects Diagram C-02 Basic Statistics D-02 Time & Motion Study F-02 Hypothesis Testing
A-03 Stratification C-03 Statistical Process Control D-03 SMED F-03 Regression
A-04 Scatter Diagram C-04 KPI Drill Down D-04 Wrench Time Analysis F-04 Basics of DoE
A-05 Control Charts C-05 KPI Benchmarking D-05 Queuing Theory F-05 Factorial DoE
A-06 Check Sheets C-06 Strategic Analysis Tools D-06 Inventory Management F-06 Principal Component Analysis
A-07 Histogram C-07 Policy Management D-07 Linear Programming Problem F-07 Cluster Analysis
C-08 Policy Diagnosis F-08 Conjoint Analysis
A-08 Pareto Charts D-08 Game Theory
C-09 Daily Management F-09 Discriminant Analysis
A-09 Graphs D-09 OEE
C-10 Daily Mgmt. in Maintenance F-10 Factor Analysis
D-10 PERT & CPM
C-11 Cross Functional Mgmt.
Series-B F-11 Response Surface Method
C-12 Quality Assurance Basics
Basic Management Tools F-12 Taguchi DoE
C-13 MSA
B-01 Brainstorming F-13 Weibull Analysis
C-14 PFD, FMEA, Control Plan Series-E
B-02 Affinity Diagram Decision-making Tools
C-15 Cost of Poor Quality (COPQ)
B-03 Arrow Diagram C-16 Improvement Fundamentals E-01 Quality Function Deployment
B-04 Tree Diagram C-17 4i Methodology E-02 Fault Tree Analysis
B-05 PDPC C-18 5S E-03 AHP & Paired Analysis
B-06 Matrix Diagram C-19 Quality Circles E-04 Pugh Matrix
B-07 Matrix Data Analysis C-20 QC Story Approach E-05 Time Series Analysis
B-08 Relation Diagram C-21 Kaizen, OPL, Poka Yoke
Flow of the training Document

1 Introduction to Control Chart

Steps of Control Chart

2 Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

Control Chart: Introduction

 Statistical Process Control (SPC) emphasizes

on controlling the process not the product.
Control charts is the basic tool of SPC.

Sample characteristic
 The basic purpose of Control charts is to
monitor process variation; is a graph used to
study how a process behaves over a period
of time. Data is plotted in timely order.

 A control chart always has a central line for the

average, an upper line for the upper control
limit and a lower line for the lower control
limit.
Sample number or time

 Control lines are determined from historical data. By

comparing current data to these lines, you can draw Control charts can be
conclusions about whether the process variation is plotted for both Variable
consistent (in control) or is unpredictable (out of and Attribute type of
control, affected by special causes of variation). data
Control Chart: History

• The control chart was invented by Walter A.

Shewhart at Bell Labs in 1920s while working Common Causes Special Cause
for the reliability of telephony transmission
systems.
• He analysed different processes and concluded

Sample characteristic
that all manufacturing processes display
variation. He identified two components of
variation:
Central Line
– A Steady component which appears to be
inherent to the process and called this as
Chance causes / Common Cause & it
cannot be economically removed until basic
changes are made in the process
– An Intermittent component, called this as
Assignable cause / Special Cause, which Sample number or time
can be predicted and economically removed
‘Common causes’ and ‘Special causes’
variations
 Even in best designed production processes, certain amount of variability exists. Also
known as “background noise”, variability is a cumulative effect of many small and
unavoidable causes.
 When variation is relatively small, it is considered acceptable. In Statistical Process Control,
this natural variability is often called a “stable system of Chance causes / Common
causes.” A process that is operating with only chance causes of variation (inherent part of
process) is said to be in control.
 Other kinds of variability may arise from three major sources - incorrect operation,
incorrect design, or defective inputs. Such variability is generally large when chance
causes, and it usually represents an unacceptable level of process performance. These are
called Assignable causes / Special Causes. A process that is operating in the presence
of assignable causes is said to be out of control.
 Purpose of SPC is to quickly detect occurrence of assignable / special causes or process
shifts so that investigation and corrective action may be undertaken before any
nonconformity occurs. The control chart is an online process-monitoring technique
widely used for this purpose.
‘Common causes’ and ‘Special causes’ variations

Comparison Common Causes / Chance Special Causes / Assignable

criteria Causes Causes

Poor design, Poor maintenance, Machine malfunction, Operator

Generic types of Lack of clearly defined SOPs, error, Defective raw material,
variations Vibration in industrial processes, Power surges, Automation
etc. failures, etc.

Nature / source System deficiencies Process failure

Scattered, unstable &
Process behavior Stable and predictable
unpredictable

Type of
Requires fundamental changes In-process corrections and ROI is
Improvement
and ROI is low high
actions required

Responsibility of
Management Operator / supervisor
action
Approx. % in total 85%-95% are of this type 5% - 15% are of this type
Control Chart: Control Limits

Theatrical Normal Curve Actual Process Curve

The fundamental relationships in developing
control charts are as follows:
The center (or central) line is the mean of the
process. UCL

No. of Standard Deviations from the Mean

+3σ
The upper control limit (UCL) is the mean plus 3
standard deviations.
The lower control limit (LCL) is the mean minus 3 +2
σ
standard deviations.
+1
So, the limits are: Μean ±3σ σ
The reason for using 3 standard deviations is based Mea
on the assumption that the process output is n
normally distributed.
-
If the process is in control, there is a very small 1σ
probability of an observation falling outside of the -
control limits. This probability increases as the 2σ
process deviates from the in - Control State. - 3σ
LCL
Types of Control Charts

Control Charts

Attribute
Variable
Control
Control Charts
Charts

Defects -
No. of measurements in Defectives – Contain
each subgroup Total Defects in individual single/ multiple defects
/ all Items

More than Subgroup Subgroup Subgroup Subgroup

One 4 to 8 sample size sample size sample size sample size
8 Constant Different Constant Different

Individual Average & Average & Defects Proportion

Standard Defects No. of
& Moving Range per of
Deviation per Unit Defectives
Range Chart Subgroup Defectives
Chart (X-Bar, R Chart C - Chart np - Chart
(X-Bar, S) U- Chart P - Chart
(X-MR) Chart)
Flow of the training Document

1 Introduction to Control Chart

Steps of Control Chart

2 Construction

3 Examples from our Plant

4 Making Control Chart in MS-

Excel
Steps of making a control chart

Step 1 Identify the parameter to be studied for variation

 Decide the process characteristic / parameter which you want to
study,
Example : ‘Si’ content in hot metal, hot metal temperature, Coil
thickness, Defects in each coil etc.
Steps of making a control chart

Step 2 Data Collection

 As per AIAG(Automotive Industry Action Group), minimum number of data points
required to analyze the process for variation is 100
 The data related to process parameter is collected in the in the form of subgroups
which contain one / more samples.
 Subgroup size: Size of the subgroup depends on the process under study. If
variation in the process is relatively small, then large subgroup size (sample size
more than 8 in each subgroup) needed to detect the process shift. If process has
a large variation then small subgroup sample size (sample size less than 8 in
each subgroup) is sufficient to detect the process shift.
 Subgroup frequency: The subgroups are taken sequentially in time, ie once in
hour / shift / day etc. frequency of subgroup has to be decided in such a way
that, it can reflect the potential opportunity for a process change.
Steps of making a control chart

Step 3 Determine the type of control chart to be used

 Determine the type of data,

Data can be of two types:
Variable data
Variable data are measured on a continuous scale and also can be measured in
fractions or decimals
example: time, weight, distance or temperature.
Attributes Data
Attribute data are counted and cannot have fractions or decimals. Attribute
data arise when you are determining only the presence or absence of
something: success or failure, accept or reject, correct or not correct.
example, a report can have four defects , but it cannot have four and a half
defects.
 Select the appropriate control chart based on whether parameter
under study is variable or attribute, subgroup sample size &
considering whether subgroup sample size is constant or different.
Steps of making a control chart

Step 4 Calculate the control statistics & sample control limits

 The control statistics such as Mean, Range, Standard Deviation are to
be calculated for the collected data.
 Using these control characteristics, and control chart formulae,
calculate sample limits such as, Central Line (CL), Upper Control Limit
(UCL) & Lower Control Limit (LCL)
Steps of making a control chart

Step 5 Plotting the sample limits & data on the chart

 Plot the calculated sample limits on the chart, plot the subgroup data,
connect the points and visualize the patterns & trends.

Subgroup data
Sample characteristic

Central Line

Sample number or time

Steps of making a control chart

Step 6 Find and address the special causes

 Look for out of control points , ie points outside the control limits (UCL / LCL),
those variations are due to special causes.
 Conduct a process analysis to determine the root causes of special causes,
with the help of process log.
 Improve the process by taking suitable corrections / corrective actions on
special causes.
Steps of making a control chart

Step 7 Recalculate the control limits

 While conducting initial process study, the control limits should be
recalculated to exclude the effects of special causes.
 For this we can either eliminate the special cause from the process by taking
actions or exclude all subgroup data which are affected from special cause.
Confirm that all subgroup data points are fully within control limits, if not
repeat the above process.
Steps of making a control chart

Step 8 Extend the control limits to ongoing process

 When all data points are falling within control limits (no special cause in the process), plot these
calculated control limits on the blank chart and use them to detect the occurrence of special
cause.

 Provide these blank charts to the Operator / Supervisor, who will record the online data and plot
them on these charts, and he can respond to signs of out-of-control(special causes0 conditions.

Apply below rules of Special cause detection for Control chart Interpretation
1. One point outside the Control limits
2. 2 of 3 consecutive points more than 2 away from the mean on one side.
3. 4 of 5 consecutive points more than 1 away from the mean on one side
4. 7 consecutive points on one side of mean
5. 6 consecutive points trending up or down
6. 14 consecutive points alternating up or down

 If Rule No. 1 is violated, immediately analyze the cause of variation & if necessary stop the process .
 Violation of any of above Rule 2 to 6, indicates the presence of special cause in the process, With the help of process log,
identify the root cause/s ,due to which out of control variation occurred in the process.
 Take Corrective & Preventive actions to eliminate the those special causes.
Flow of the training Document

1 Introduction to Control Chart

Steps of Control Chart

2 Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

 Plant example – 1: Control Chart for Variable Data

Hot Metal Hot Metal Temperature in °C

Temperature

Reading 5
Reading 1

Reading 2

Reading 3

Reading 4

Reading 6
Date

1-Jan-15 1500 1512 1500 1510 1503 1510

Step 1 Identify the parameter to be studied for variation 2-Jan-15 1506 1500 1505 1508 1503 1505
3-Jan-15 1504 1505 1506 1500 1510 1511
• Parameter under study for variation is Blast Furnace Hot 4-Jan-15 1517 1505 1505 1510 1508 1500
Metal Temperature 5-Jan-15 1513 1514 1500 1500 1511 1508
6-Jan-15 1515 1520 1495 1502 1506 1511

Step 2 Data Collection 7-Jan-15

8-Jan-15
1519
1510
1515
1512
1510
1517
1503
1520
1515
1522
1510
1525
 Parameter : Hot Metal temperature 9-Jan-15 1510 1515 1511 1510 1512 1510
10-Jan-15 1506 1514 1515 1505 1505 1500
 Subgroup sample size : 6 11-Jan-15 1500 1520 1505 1509 1510 1508
 Sampling frequency : Two times a shift, i.e. 6 data points are 12-Jan-15 1505 1515 1510 1522 1510 1500
collected in day 13-Jan-15 1500 1515 1510 1513 1508 1492
14-Jan-15 1485 1490 1500 1510 1520 1505
Step 3 Determine the type of control chart to be used 15-Jan-15 1510 1508 1500 1505 1520 1510
16-Jan-15 1505 1510 1505 1500 1510 1515
 As temperature is continuous type of data , we can go for 17-Jan-15 1511 1510 1510 1502 1500 1500
Variable type control charts. 18-Jan-15 1520 1505 1502 1510 1505 1500
 As sample size is less than 8, we can go for X-bar, R charts. 19-Jan-15 1511 1505 1515 1511 1504 1505
20-Jan-15 1512 1500 1500 1514 1500 1510
21-Jan-15 1525 1510 1500 1498 1510 1500
22-Jan-15 1515 1505 1500 1505 1515 1510
23-Jan-15 1500 1500 1505 1500 1510 1515
Calculate the control statistics & sample
control limits
Step 4
1. Calculate Average of each sub groups ( X )
2. Calculate the Range R of each subgroup, Range= Max value in sub group – minimum
value in sub group
+ + + - - - -Xn
3. Calculate Grand average X using formula X1 X 2 X 3
X=
Where ‘K’ is the no of subgroups. K
- - - -Rn
4. Calculate Average of ranges ( R ) using formula R R1 +R2 + R3+
= K
5. Calculate Upper Control Limit UCL = X + A2 R

6. Calculate Central Line = X

7. Calculate Lower Control Limit

LCL = X - A2 R
Where - A2 is a statistical constant, taken from standard table, Ref. Table 1, and whose values
depend on the collected data sample size
Calculate the control statistics & sample
control limits

Step 4
 Hot Metal Temperature in °C

Reading 3
Reading 1

Reading 2

Reading 4

Reading 5

Reading 6
Mean of
CL for X - UCL for X- LCL for X- UCL for R- LCL for
Readings Range CL R - Chart
Date Bar Chart bar Chart Chart Chart R-Chart
(X-bar)

1-Jan-15 1500 1512 1500 1510 1503 1510 1505.83 12.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
2-Jan-15 1506 1500 1505 1508 1503 1505 1504.50 8.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
3-Jan-15 1504 1505 1506 1500 1510 1511 1506.00 11.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
4-Jan-15 1517 1505 1505 1510 1508 1500 1507.50 17.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
5-Jan-15 1513 1514 1500 1500 1511 1508 1507.67 14.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
6-Jan-15 1515 1520 1495 1502 1506 1511 1508.17 25.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
7-Jan-15 1519 1515 1510 1503 1515 1510 1512.00 16.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
8-Jan-15 1510 1512 1517 1520 1522 1525 1517.67 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
9-Jan-15 1510 1515 1511 1510 1512 1510 1511.33 5.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
10-Jan-15 1506 1514 1515 1505 1505 1500 1507.50 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
11-Jan-15 1500 1520 1505 1509 1510 1508 1508.67 20.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
12-Jan-15 1505 1515 1510 1522 1510 1500 1510.33 22.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
13-Jan-15 1500 1515 1510 1513 1508 1492 1506.33 23.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
14-Jan-15 1485 1490 1500 1510 1520 1505 1501.67 35.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
15-Jan-15 1510 1508 1500 1505 1520 1510 1508.83 20.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
16-Jan-15 1505 1510 1505 1500 1510 1515 1507.50 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
17-Jan-15 1511 1510 1510 1502 1500 1500 1505.50 11.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
18-Jan-15 1520 1505 1502 1510 1505 1500 1507.00 20.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
19-Jan-15 1511 1505 1515 1511 1504 1505 1508.50 11.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
20-Jan-15 1512 1500 1500 1514 1500 1510 1506.00 14.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
21-Jan-15 1525 1510 1500 1498 1510 1500 1507.17 27.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
22-Jan-15 1515 1505 1500 1505 1515 1510 1508.33 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
23-Jan-15 1500 1500 1505 1500 1510 1515 1505.00 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
Average 1507.78 16.78
 Plotting the sample limits and data on the chart &
Find and address special causes

Special Cause
R Chart X - Bar Chart
Variation Special Cause
40.00 1520.00
Variation
Step 5 & 6

Hot Metal Temperature in °C

Hot Metal Temperature in °C
35.00 UCL 1515.00
30.00
25.00 1510.00
20.00 CL 1505.00
15.00
10.00 1500.00
5.00 1495.00
LCL
0.00

7-Jan-15
1-Jan-15
2-Jan-15
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15

8-Jan-15
9-Jan-15

15-Jan-15

23-Jan-15
10-Jan-15
11-Jan-15
12-Jan-15
13-Jan-15
14-Jan-15

16-Jan-15
17-Jan-15
18-Jan-15
19-Jan-15
20-Jan-15
21-Jan-15
22-Jan-15
1490.00

1-Jan-15
2-Jan-15
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15
7-Jan-15
8-Jan-15
9-Jan-15
10-Jan-15
11-Jan-15
12-Jan-15
13-Jan-15
14-Jan-15
15-Jan-15
16-Jan-15
17-Jan-15
18-Jan-15
19-Jan-15
20-Jan-15
21-Jan-15
22-Jan-15
23-Jan-15
Date Date
Range CL R - Chart
UCL for R-Chart LCL for R-Chart Mean of Readings (X-bar) CL for X - Bar Chart
UCL for X- bar Chart LCL for X-Chart

Analysis of control chart:

• Examine the R chart first because the process variation must be in control to correctly interpret the X bar chart.
• In this example Rule No. 1 is Violated ie One point outside the Control limits.
• A special cause exists in the process .
 Conduct a process analysis to determine the root causes of special causes, with the help of process log.
 Improve the process by taking suitable corrections / corrective actions on special causes.
 Step 7

Hot Metal Temperature in °C

20.00
25.00
30.00
35.00

10.00
15.00

0.00
5.00
1-Jan-15

Range
2-Jan-15
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15
7-Jan-15

CL R - Chart
8-Jan-15
9-Jan-15
10-Jan-15
11-Jan-15
12-Jan-15
R Chart

Date

13-Jan-15
14-Jan-15
UCL for R-Chart

15-Jan-15
16-Jan-15
17-Jan-15
18-Jan-15
19-Jan-15
20-Jan-15
Recalculate the control limits

21-Jan-15
22-Jan-15
LCL for R-Chart

23-Jan-15

Hot Metal Temperature in °C

control limits, if not repeat the above process.
1520.00

1490.00
1495.00
1500.00
1505.00
1510.00
1515.00

1-Jan-15
2-Jan-15
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15
7-Jan-15
UCL for X- bar Chart

8-Jan-15
9-Jan-15
Mean of Readings (X-bar)

10-Jan-15
11-Jan-15
12-Jan-15
Date

13-Jan-15
14-Jan-15
X - Bar Chart

15-Jan-15
16-Jan-15
LCL for X-Chart

17-Jan-15
CL for X - Bar Chart

18-Jan-15
19-Jan-15
 Recalculate CL, UCL & LCL and Confirm that all subgroup data points are fully within

20-Jan-15
21-Jan-15
22-Jan-15
23-Jan-15
 Extend the control limits to ongoing process

Step 8
 When all data points are falling within control limits (no special cause in the
process), plot these calculated control limits on the blank chart and use
them to detect the occurrence of special cause in ongoing process.

R Chart X - Bar Chart

35.00 1520.00
UCL
Hot Metal Temperature in °C

Hot Metal Temperature in °C

30.00 1515.00 UCL
25.00
1510.00
20.00 CL
1505.00
15.00 CL
1500.00
10.00 LCL
5.00 1495.00

0.00
Date LCL 1490.00
Date

CL R - Chart UCL for R-Chart LCL for R-Chart CL for X - Bar Chart UCL for X- bar Chart LCL for X-Chart
 Plant example – 2: Control Chart for Attribute Data
No. of Defects
spotted on CRCA
coils

Step 1 Identify the parameter to be studied for variation

• Parameter under study for variation is No. of Defects Coil No 1 2 3 4 5 6 7 8 9
1 1 1 1 1 1 1 1 1 1
20
spotted in CRCA coils 0 1 2 3 4 5 6 7 8 9
No. of
2 3 4 2 5 2 1 2 3 2 1 3 2 3 5 2 3 2 3 1
Defects( C )
2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3
Step 2 Data Collection Coil No 21
2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
40
No. of
 Parameter : No. of Defects spotted in CRCA coils Defects( C )
2 3 3 1 2 4 1 0 2 3 1 2 3 4 1 5 4 2 2 3

 Subgroup sample size : Same , that is one sample (one Coil No 41

4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5
60
2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
coil) No. of
0 2 3 2 2 5 1 2 3 2 1 5 4 8 5 4 3 2 0 2
 No. of samples: 100 Defects( C )

Determine the type of control chart to Coil No 61

6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 7
80
Step 3 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

be used No. of
Defects( C )
1 2 0 3 2 4 5 0 1 2 1 2 3 1 2 3 4 2 3 0
 As No. of defects is attribute type of data , we can go for Coil No 81
8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 10
2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
Attribute type of control charts and in that we are counting No. of
defects per Unit, so we can go for C- Chart 2 4 5 1 2 3 1 2 1 2 3 3 2 3 5 1 0 2 2 3
Defects( C )
Calculate the control statistics & sample control limits

Step 4

(C
1. Calculate the average Number Defects per Unit
)

C C1 +C2 + C3 + - - - -Cn
Using formula
= K
Where ‘K’ No. of subgroups inspected for defects

4. Upper Control Limit is given by

UCL = C + 3C

5. Central Line is CL = C

4. Lower Control Limit is given by

LCL = C - 3C
Calculate the control statistics & sample
control limits
No. of C-chart
Step 4 Coil No Defects
CL LCL UCL
(C)
1 2 2.43 0.00 7.11
2 3 2.43 0.00 7.11
3 4 2.43 0.00 7.11
4 2 2.43 0.00 7.11
5 5 2.43 0.00 7.11
6 2 2.43 0.00 7.11
7 1 2.43 0.00 7.11
8 2 2.43 0.00 7.11
9 3 2.43 0.00 7.11
10 2 2.43 0.00 7.11
11 1 2.43 0.00 7.11
12 3 2.43 0.00 7.11
13 2 2.43 0.00 7.11
99 2 2.43 0.00 7.11
100 3 2.43 0.00 7.11
Average 2.43
 Plotting the sample limits and data on the chart &
Find and address special causes
Special Cause
Step 5 & 6 9 Variation
8

No. of Defects 7 UCL

3
CL
2

1
LCL
0
1
3
5
7
9

15

31

47

63

79

95
11
13

17
19
21
23
25
27
29

33
35
37
39
41
43
45

49
51
53
55
57
59
61

65
67
69
71
73
75
77

81
83
85
87
89
91
93

97
99
Coil No
No. of Defects ( C ) CL LCL UCL

Analysis of control chart:

• Examine the chart out of control signals
• In this example Rule No. 1 is Violated ie One point is outside the Control limits.
• A special cause exists in the process .
 Conduct a process analysis to determine the root causes of special causes, with the help of process log.
 Improve the process by taking suitable corrections / corrective actions on special causes.
Recalculate the control limits

Step 7
8

7 UCL

No. of Defects 6

3
CL
2

0 LCL
9
1
3
5
7

23

39

55

71

87
11
13
15
17
19
21

25
27
29
31
33
35
37

41
43
45
47
49
51
53

57
59
61
63
65
67
69

73
75
77
79
81
83
85

89
91
93
95
97
99
Coil No

No. of Defects ( C ) CL LCL UCL

 Improve the process by taking suitable corrections / corrective actions on special

causes.
 Recalculate CL, UCL & LCL and Confirm that all subgroup data points are fully within
control limits, if not repeat the above process.
Extend the control limits to ongoing process

Step 8

 When all data points are falling within control limits (no special cause in the
process), plot these calculated control limits on the blank chart and use
them to detect the occurrence of special cause in ongoing process.
8.00

7.00 UCL
6.00
No. of Defects

5.00

4.00

3.00
CL
2.00

1.00
LCL
0.00
1
3
5
7
9

13

17

39

65

87

91
11

15

19
21
23
25
27
29
31
33
35
37

41
43
45
47
49
51
53
55
57
59
61
63

67
69
71
73
75
77
79
81
83
85

89

93
95
97
99
Coil No

CL LCL UCL
Flow of the training Document

1 Introduction to Control Chart

Steps of Control Chart

2 Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

Construction of Control Chart in Excel
Shift SL. No Silicon(Si) % - (X)
A 1 0.70
2 0.80
 Parameter under study for variation is Silicon 3
4
0.75
0.80
(Si) % in hot metal 5 0.79
6 0.85
 Parameter : Silicon (Si) % in hot metal of SMS 7 0.86
8 0.89
converter 9 0.85
10 0.75
 Subgroup sample size : 1 B 11 0.79
12 0.80
 Sampling frequency : One sample is collected 13 0.81
once and total Ten samples are collected in a 14 0.86
15 0.90
shift. Total 30 samples are collected in day. 16 0.92
17 0.94
 As ‘Si’ % is continuous type of data , and no. of 18 0.98
samples taken each time is one we can go for 19
20
0.92
0.89
Individual & Moving Range Chart (X-MR) C 21 0.80
22 0.72
23 0.75
24 0.80
25 0.78
26 0.86
27 0.70
28 0.75
29 0.72
30 0.70
Construction of Control Chart in Excel

=ABS(0.80-
0.70)

Range= Max value in sub group –

minimum value in sub group.

To calculate moving range we can use xl

sheet formula =ABS(select 1st value –
select 2nd )
Info: To eliminate negative symbol we
use ABS formula
Construction of Control Chart in Excel

Click on the first moving

range (MR) and drag till
the end to get all moving
ranges
Construction of Control Chart in Excel

Calculate averages of :

1. Silicon(Si) % -(X)

1. Moving Range (MR) -( MR)

To calculate averages we can

use xl formula
=AVERAGE (select values for
which you need average)
Construction of Control Chart in Excel

Calculate CL, UCL & LCL using above formulae for both
X- Chart & MR - Chart
Construction of Control Chart in Excel

Copy the values of CL, UCL &

LCL of both X-Chart & MR-
Chart, in the table form,
beside values of X & MR
Construction of Control Chart in Excel

Select tables of CL, UCL

& LCL for X- Chart, for
plotting the X- Chart
(Individual Chart)
Construction of Control Chart in Excel

After selecting the tables;

Go to, Insert – Line – Select
Line with Markers, for plotting
the X- Chart (Individual Chart)

1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

Silicon(Si) % - (X) CL for X - Chart

UCL for X-Chart LCL for X-Chart
Construction of Control Chart in Excel

Select these tables of

CL, UCL & LCL for MR-
Chart for plotting the
MR- Chart (Moving
Range Chart)
Construction of Control Chart in Excel

After selecting the tables

;Go to, Insert – Line –
Select Line with Markers,
for plotting the MR- Chart
(Moving Range Chart)

0.18
0.16
0.14
0.12
0.1
0.08
0.06
0.04
0.02
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Moving Range (MR) CL for MR - Chart
UCL for MR-Chart LCL for MR-Chart
Construction of Control Chart in Excel

To add heading and

data labels : Click
on the chart and
select chart layouts
Construction of Control Chart in Excel

Select: Layout 10, chart will be displayed in

below form

Delete vertical lines, and add chart title &

data labels
Construction of Control Chart in Excel

To format legends: right

click on the legends-
select format legend –
select legend options –
bottom to display the
legends in the bottom
Construction of Control Chart in Excel

To improve aesthetics of the chart:

right click on the line- select- format
data series
Construction of Control Chart in Excel

In the format data series window - select

marker options – select none, to get line
without markers
Construction of Control Chart in Excel

To change color of control lines: right click on

the line- select- format data series – Line color
– Solid line – select desired line color
Construction of Control Chart in Excel

Final Control
Chart
Benefits of control Chart

Properly used, control chart can:

 Be used by operator for on going control of the process
 Help the process perform consistently and predictably
 Allow the process to achieve
- Higher Quality
- Lower unit cost
- Higher effective capability
 Provide a common language for discussing the performance of the process
 Distinguish special from common cause variation.
 Acts as a guide for deciding, whether to take local action or action on the
system
Additional Information

= 11.23

In this data
Standard
Deviation is 11.23

To calculate the standard deviation in a data set – use XL

formula = STDEV (Select the data set) – and enter
Control Chart
Formulae
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to read the training modules
THANK YOU