IENG 486 - Lecture 16

P, NP, C, & U Control Charts

(Attributes Charts)

4/7/2015 IENG 486: Statistical Quality & Process Control 1

 Assignment:
 Reading:
 Chapter 3.5
 Chapter 7
 Sections 7.1 – 7.2.2: pp. 288 – 304
 Sections 7.3 – 7.3.2: pp. 308 - 321
 Chapter 6.4: pp. 259 - 265
 Chapter 9
 Sections 9.1 – 9.1.5: pp. 399 - 410
 Sections 9.2 – 9.2.4: pp. 419 - 425
 Sections 9.3: pp. 428 - 430

 Assignment:
 CH7 # 6; 11; 27a,b; 31; 47
 Access Excel Template for P, NP, C, & U Control Charts
4/7/2015 IENG 486: Statistical Quality & Process Control 2
 Process for Statistical Control
Of Quality
 Removing Statistical Quality Control and Improvement
special causes Improving Process Capability and Performance
of variation
 Hypothesis Continually Improve the System
Tests
 Ishikawa’s
Characterize Stable Process Capability
Tools
 Managing the
process with
control charts Head Off Shifts in Location, Spread
 Process Time

Improvement Identify Special Causes - Bad (Remove)

 Process
Stabilization Identify Special Causes - Good (Incorporate)

 Confidence in Reduce Variability

“When to Act” Center the Process
LSL 0 USL

4/7/2015 IENG 486: Statistical Quality & Process Control 3

 Review

 Shewhart Control charts

 Are like a sideways hypothesis test (2-sided!) from a
Normal distribution
 UCL is like the right / upper critical region
 CL is like the central location
 LCL is like the left / lower critical region
 When working with continuous variables, we use two
charts:
 X-bar for testing for change in location
 R or s-chart for testing for change in spread
 We check the charts using 4 Western Electric rules

4/7/2015 IENG 486: Statistical Quality & Process Control 4

 Continuous & Discrete
Distributions
Continuous Discrete
 Probability of a range of  Probability of a range of
outcomes is area under outcomes is area under
PDF (integration) PDF (sum of discrete
outcomes)
35.0  35.0 
2.5 2.5

30.4 34.8 39.2 43.6 30 34 38 42

32.6 37 41.4 32 36 40
(-3) (-) (+) (+3)
(-2) () (+2) ()

4/7/2015 IENG 486: Statistical Quality & Process Control 5

 Continuous & Attribute
Variables
Continuous Variables:
 Take on a continuum of values.
 Ex.: length, diameter, thickness
 Modeled by the Normal Distribution

Attribute Variables:
 Take on discrete values
 Ex.: present/absent, conforming/non-conforming
 Modeled by Binomial Distribution if classifying
inspection units into defectives
 (defective inspection unit can have multiple defects)
 Modeled by Poisson Distribution if counting defects
occurring within an inspection unit
4/7/2015 IENG 486: Statistical Quality & Process Control 6
 Discrete Variables Classes

 Defectives
 The presence of a non-conformity ruins the entire unit – the
unit is defective
 Example – fuses with disconnects

 Defects
 The presence of one or more non-conformities may lower the
value of the unit, but does not render the entire unit defective
 Example – paneling with scratches

4/7/2015 IENG 486: Statistical Quality & Process Control 7

 Binomial Distribution

 Sequence of n trials
 Outcome of each trial is “success” or “failure”
 Probability of success = p
 r.v. X - number of successes in n trials
X ~ Bin  n , p 

 So: n x n x where  n  n!

P  X  x     p 1  p   
 x  x  x ! n  x  !

 Mean:   E  X   np Variance:   V  X   np  1  p 
2

4/7/2015 IENG 486: Statistical Quality & Process Control 8

 Binomial Distribution
Example
 A lot of size 30 contains three defective fuses.
 What is the probability that a sample of five fuses selected at
random contains exactly one defective fuse?
1 5 1
 5  3   3 
P [ X  1]      1    ( 5 )(. 1)(. 9 )
4
 . 328
 
1 30   30 

 What is the probability that it contains one or more

defectives?
0 50
 5  3   3 
P [ X  1]  1  P [ X  0 ]  1      1  
 
0  30   30 

 1  (1)(1)(. 9 )
5

 1  . 5905  . 4095
IENG 486: Statistical Quality &
4/7/2015 Process Control 9
 Poisson Distribution

 Let X be the number of times that a certain event

occurs per unit of length, area, volume, or time

X ~ Pois   


 So: e 
x

P  X  x 
x!
where x = 0, 1, 2, …

 Mean:   E  X    Variance:  2  V  X   

4/7/2015 IENG 486: Statistical Quality & Process Control 10

 Poisson Distribution
Example
 A sheet of 4’x8’ paneling (= 4608 in2) has 22
scratches.
 What is the expected number of scratches if checking only
one square inch (randomly selected)?
22
λ1   . 00477
4608
 What is the probability of finding at least two scratches in 25
in2? 25

λ 25  λi 1
1
 25 ( λ1 )  25 (. 00477 )  . 119

P [ X  2 ]  1   P [ X  0 ]  P [ X  1] 
 e  .119 (. 119 ) 0 e  .119 (. 119 ) 1   . 888 (1) . 888 (. 119 ) 
 1    

 1     1  (. 888  . 106 )  . 007
 0! 1!   1 1 
4/7/2015 IENG 486: Statistical Quality & Process Control 11
 Moving from Hypothesis
Testing to Control Charts
 Attribute control charts are also like a sideways
hypothesis test
 Detects a shift in the process
 Heads-off costly errors by detecting trends –

if constant control
2
limits are used
UCL

0 CL
 
2 2

LCL

0 2
Sample Number
2-Sided Hypothesis Test Sideways Hypothesis Shewhart Control Chart
Test

4/7/2015 IENG 486: Statistical Quality & Process Control 12

 P-Charts
Tracks proportion defective in a sample of insp. units
Can have a constant number of inspection units in the sample

 Sample Control Limits:  Standard Control Limits:

 Approximate 3σ limits are  Approximate 3σ limits
found from trial samples: continue from standard:

p (1  p ) p (1  p )
UCL  p  3 UCL  p  3
n n
CL  p CL  p

p (1  p ) p (1  p )
LCL  p  3 LCL  p  3
n n
4/7/2015 IENG 486: Statistical Quality & Process Control 13
 P-Charts (continued)

 More commonly has variable number of inspection units

 Can’t use run rules with variable control limits
 Mean Sample Size Limits:  Variable Width Limits:
 Approximate 3σ limits are  Approximate 3σ limits vary
found from sample mean: with individual sample size:

p (1  p ) p (1  p )
UCL  p  3 UCL  p  3
n ni

CL  p CL  p

p (1  p ) p (1  p )
LCL  p  3 LCL  p  3
n ni

4/7/2015 IENG 486: Statistical Quality & Process Control 14

 NP-Charts
Tracks number of defectives in a sample of insp. units
Must
have a constant number of inspection units in each sample
Use of run rules is allowed if LCL > 0 - adds power !
 Sample Control Limits:  Standard Control Limits:
 Approximate 3σ limits are  Approximate 3σ limits
found from trial samples: continue from standard:

UCL  n p  3 n p (1  p ) UCL  np  3 np (1  p )
CL  n p CL  np

LCL  n p  3 n p (1  p ) LCL  np  3 np (1  p )

4/7/2015 IENG 486: Statistical Quality & Process Control 15

 C-Charts
Tracks number of defects in a logical inspection unit
Must
have a constant size inspection unit containing the defects
Use of run rules is allowed if LCL > 0 - adds power !
 Sample Control Limits:
UCL  c  3 c
 Approximate 3σ limits are
found from trial samples: CL  c

LCL  c  3 c or 0 if LCL is negative

 Standard Control Limits:UCL  c3 c

 Approximate 3σ limits CL  c
continue from standard:
LCL  c  3 c or 0 if LCL is negative

4/7/2015 IENG 486: Statistical Quality & Process Control 16

 U-Charts
 Number of defects occurring in variably sized inspection unit
 (Ex. Solder defects per 100 joints - 350 joints in board = 3.5 insp. units)
 Can’t use run rules with variable control limits, watch clustering!

 Mean Sample Size Limits:  Variable Width Limits:

 Approximate 3σ limits are  Approximate 3σ limits vary
found from sample mean: with individual sample size:
u u
UCL  u  3 UCL  u  3
n ni

CL  u CL  u

u u
LCL  u  3 LCL  u  3
n ni

4/7/2015 IENG 486: Statistical Quality & Process Control 17

 Summary of Control Charts

Continuous Variable Charts Attribute Charts

 Smaller changes detected faster  Can cover several
 Require smaller sample sizes defects with one chart
 Can be applied to attributes data as  Less costly inspection

well (by CLT)*

 Use of the control chart decision tree…

4/7/2015 IENG 486: Statistical Quality & Process Control 18

 Control Chart Decision Tree
Defective Units Is the size of No, varies Use p-Chart
the inspection
(possibly with multiple defects) sample fixed?
Binomial Distribution
Yes, Use np-Chart
constant

Discrete What is the Individual Defects Is the size of Yes, Use c-Chart
inspection the inspection constant
Attribute basis? Poisson Distribution unit fixed?

Kind of
inspection No, varies Use u-Chart
variable?

Continuous Which spread Range Use X-bar and

method R-Chart
Variable preferred?
Standard Deviation
Use X-bar and
S-Chart

4/7/2015 IENG 486: Statistical Quality & Process Control 19

 Attribute Chart Applications

 Attribute control charts apply to “service”

applications, too!
 Number of incorrect invoices per customer
 Proportion of incorrect orders taken in a day
 Number of return service calls to resolve problem

4/7/2015 IENG 486: Statistical Quality & Process Control 20

 Questions & Issues

4/7/2015 IENG 486: Statistical Quality & Process Control 21