Statistical Process Control

1. Example 1

ABC Pharmaceuticals manufacture needles that are subjected to a bend test.

They use statistical process control (SPC) and the results (measured in grams)
are plotted on a chart.

• If the process average is 26,1 and the average range is 5, what will the control limits be if the sample
size n = 8? The factor for calculation of control limits is 0,373 for sample size n=8.

• Draw a chart and explain whether an investigation for an assignable

cause should be undertaken given that one sample average is 26,08?

Solution

UCL = Control limits are: X+A2R= 26.1 +.0373 x 5 = 27.965

LCL = Control limits are: X-A2R= 26.1 -.0373 x 5 = 24.235

X = 26.1

Sample average – process in control, No need for investigation

2. Example 2

A production process at FLOWLINE INC is being monitored for quality assurance purposes. Thirty (30) samples with a
sample size of 8 have been taken and have yielded an overall mean of 28.5 and an average range of 1.6. The constant
values for the sample size are as follows:

n A A2 A3 c4 d2 D1 D2 D3 D4

8 1.061 0.373 1.099 0.9650 2.847 0.388 5.306 0.136 1.864

Asked:

(a) Construct an R - and an x bar chart.

(b) At a later stage, 6 samples produce the following sample means: 28.001, 28.250, 29.130, 28.720, 28.900, and
28.300. Motivate – is the process in control?

(c) Does the following sequence of sample means indicate that the process is out of control: 28.300. 28.700.
28.100, 28.900, 28.010, 29.010? Justify your answer.

Solution

Evans & Collier (2007: 720 / 701)

(a) Insert control charts:

x bar chart UCL 28.5 + 0.373(1.6) = 29.097
LCL 28.5 – 0.373(1.6) = 27.903;

R chart UCL = D41.864(1.6) = 2.982

LCL = D3 0.136(1.6) = 0.218

(b) Sample means of 29.13 above UCL – process out-of-control.

(c) All points within control limits and no shifts or trends seem present.
 3. Example 3

Four samples of three observations each have been taken, with actual measurements (in centimetres) shown below.
Construct three sigma mean and range charts, and determine if corrective action is needed. Refer to Table 10.3 in your
textbook for the applicable factors.

Sample
1 2 3 4
12.3 11.9 12.0 12.1
12.2 12.2 12.2 11.8
12.1 12.2 11.8 11.8

To answer question 2.1, you will need to refer to this table.

Table 1:
_ FACTORS FOR R CHARTS FACTORS FOR R
Number of Observations Factor for X Chart Lower Control Limit CHARTS
in Subgroup Upper Control
Limit
n A2 D3 D4
2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
16 0.21 0.36 1.64
17 0.20 0.38 1.62
18 0.19 0.39 1.61
19 0.19 0.40 1.60
20 0.18 0.41 1.59
Solution

MEAN AND RANGE CHARTS (ROUNDED TO 1 DECIMAL) n=3

Sample Sample Sample Sample A2 = 1.02
1 2 3 4 Overall D3 = 0
Observation D4 = 2.57
1 12.3 11.9 12.0 12.1 R = 0.30
Observation
X = 12.1
2 12.2 12.2 12.2 11.8
Observation
3 12.1 12.2 11.8 11.8
Mean 12.2 12.1 12.0 11.9 12.1
Range 0.20 0.30 0.40 0.30 0.30
RANGE
MEAN CALCULATIONS CALCULATIONS

UCL = X + A2 R UCL = D4 R
= 12.1 + (1.02) (0.30) = 2.57 (0.30)
= 12.406 = 0.771

LCL = X - A2 R LCL = D3 R
= 12.1 – (1.02) (0.30) = 0 (0.30)
= 11.794 =0
In control because all measures are within these limits In control, because all points are
within these limits