Presentation XXII PDF

Quality Control-Lecture XXII
THIRD YEAR-SEMESTER –I 2-CREDITS

Ruwan Punchi-Manage (PhD)
Demerit system
Demerit system is a system that classifies defects into
categories according to its severity. There are four such
classes.
1
Ruwan Punchi-Manage (PhD), Department of Statistics & Computer Science, Faculty of Science, University of Peradeniya.
Class A defects
 Very serious.
 Units with this type of defects are very difficult to
correct.
 Such defects may cause product units to be completely
unfit for usage.
2
Class A defects & Cost
 Severe harm to users and damage to properties.
 Need a full replacement of the unit.
 High replacement cost.
 Lost of reputation.
3
Class B defects
 Serious defects.
 One or more failures of the parts or functions of the
product.
4
Class B defects & cost:
 Reduce the durability of the product.
 Frequent service to the product is necessary.
 Possible to correct.
 Several parts need to be replaced.
 Expensive to the manufacturer due to high replacement
cost.
5
Class C defects
 Moderately serious.
 Major problem in the appearance.
 Possible to correct.
 Units are functioning, cost for maintenance is high.
6
Class D defects
 Minor defects.
 Affects in the appearance or color.
 Performance and functioning of such products are

difficult distinguish from the non-defective items.
 Cause very little or no harm to the consumers or

properties.
 Easily corrected without replacing the parts of

the units.
7
Demerit System & Weights
Demerit System & Weights
A unit contains four types of defects; A, B, C, and D.
Demerit weights of four classes are,
Defect Class Demerit Weight No. of Defects

A wiA diA
B wiB diB
C wiC diC
D wiD diD
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Aggregated Damage of Demerit System
The aggregated damaged (demerit) to the ith unit, Di
Di=diAwiA + diBwiB + diCwiC + diDwiD
Suppose a sample of n units inspected
D
i 1
i  wiA d iA  wiB d iB  wiC d iC  wiD d iD
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Usually these weights are 100, 50, 10, and 1 for four classes;
A, B, C, and D respectively.
This means that one defect from Class-A is equivalent

100 defects from Class-D.
Di=100 diA+ 50 diB+ 10 diC+ 1diD
10
Suppose a sample of n units inspected

n
D
i 1
i  wiA d iA  wiB d iB  wiC d iC  wiD d iD
11
Average Demerits Per Unit of Demerit System
Average demerits per unit is,
D i
D i 1
n
12
u - Charts
Characteristic of interest for u - charts
u-chart is based on the average number of non-conformities

per inspection unit.
The characteristic of interest is u.
13
Example for u - charts
e.g. the average no. of defects in a circuit board (u).
14
Sampling for u - charts
Suppose we take a sample of size n and found there are x
number of nonconformities in the sample.
What is the average number of nonconformities per
inspection unit (u)?
15
Suppose we take a sample of size n and found there are x
number of nonconformities in the sample.
d1
1
Lot Sample 3
i 2 d2
n
N dn
n d3
x   di
i 1
16
What is the average number of nonconformities per
inspection unit (u)?
17
Distribution of u
The average number of nonconformities per
inspection unit (u) is,
x
u ; where x  0,1,..., 
n
18
Distribution of X
We know that X follows a Poisson distribution.
X ~ Poisson ( )
e   x
P( X  x)  ; x  0,1,....
x!
Therefore, expected value and variance are same.
Suppose, E(x)=V(x)= 
19
Distribution of u
What is the expected value of u
 x 
E (u )  u  E     u
n n
u  u
20
Distribution of u
What is the variance of u
 x 1
V (u )    V    2 
2
u
n n
1 1
    u
2
u
nu  n
1
 u  u
n
21
Construction of control limits for u - charts
UCL  u  L u
CL  u
LCL  u  L u
22
u
UCL  u  L u  u  L
n
CL  u  u
u
LCL  u  L u  u  L
n
23
u
UCL  u  L
n
CL  u
u
LCL  u  L
n
24
25
Construction of control limits for u – charts-Example
26
Construction of control limits for u - charts-Example
27

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Quality Control-Lecture XXII

THIRD YEAR-SEMESTER –I 2-CREDITS

Demerit system is a system that classifies defects into

categories according to its severity. There are four such

 Units with this type of defects are very difficult to

 Such defects may cause product units to be completely

unfit for usage.

 Severe harm to users and damage to properties.

 Need a full replacement of the unit.

 High replacement cost.

 One or more failures of the parts or functions of the

 Reduce the durability of the product.

 Frequent service to the product is necessary.

 Several parts need to be replaced.

 Expensive to the manufacturer due to high replacement

 Major problem in the appearance.

 Units are functioning, cost for maintenance is high.

 Affects in the appearance or color.

 Performance and functioning of such products are

 Cause very little or no harm to the consumers or

 Easily corrected without replacing the parts of

A unit contains four types of defects; A, B, C, and D.

Demerit weights of four classes are,

Defect Class Demerit Weight No. of Defects

The aggregated damaged (demerit) to the ith unit, Di

Di=diAwiA + diBwiB + diCwiC + diDwiD

Suppose a sample of n units inspected

This means that one defect from Class-A is equivalent

Di=100 diA+ 50 diB+ 10 diC+ 1diD

Suppose a sample of n units inspected

Average demerits per unit is,

u-chart is based on the average number of non-conformities

The characteristic of interest is u.

e.g. the average no. of defects in a circuit board (u).

Suppose we take a sample of size n and found there are x

number of nonconformities in the sample.

What is the average number of nonconformities per

inspection unit (u)?

Suppose we take a sample of size n and found there are x

number of nonconformities in the sample.

What is the average number of nonconformities per

inspection unit (u)?

The average number of nonconformities per

inspection unit (u) is,

We know that X follows a Poisson distribution.

Therefore, expected value and variance are same.

What is the expected value of u

What is the variance of u

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