Statistical Process Control (SPC) II

Common Control Charts

Data Distribution Control charts

Continuous Normal Mean-Range

variable Mean-Standard deviation
Median-Range
Individual-Moving range I-MR

Attributes Binomial Proportion of defective p

-Defectives Number of defectives np

Attributes Poission Defects per unit u

- Defects Number of defects c

Normal Distribution

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 Statistical Process Control (SPC) II

Normal Distribution

Mean - 3s Mean Mean + 3s

SPC Control Chart and Normal Distribution

UCL
3s
Mean
3s
LCL

6s

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 Statistical Process Control (SPC) II

Control Limits

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 Statistical Process Control (SPC) II

Mean Chart ( Chart )

Range Chart ( R Chart)

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 Statistical Process Control (SPC) II

Constants for Variable Control Charts

Sample Size (n)

Chart S Chart R Chart Chart

A A2 A3 c4 B3 B4 B5 B6 d2 d3 D1 D2 D3 D4 m3 m3A2

2 2.121 1.880 2.659 0.7979 0 3.267 0 2.606 1.128 0.853 0 3.686 0 3.267 1.000 1.880

3 1.732 1.023 1.954 0.8862 0 2.568 0 2.275 1.693 0.888 0 4.358 0 2.574 1.160 1.187

4 1.500 0.729 1.628 0.9213 0 2.266 0 2.088 2.059 0.880 0 4.698 0 2.282 1.092 0.796

5 1.342 0.577 1.427 0.9400 0 2.089 0 1.964 2.326 0.864 0 4.918 0 2.114 1.198 0.691

Typical Out-of-Control Patterns

• Points outside or on the control limits (0.3%)

• Non-random distribution within the control limits:
− RUN-UP or RUN-DOWN
7 consecutive points moving upwards or downwards (1.53%)
9 consecutive points moving upwards or downwards (0.38%)
− RUN-ABOVE or RUN-BELOW
7 consecutive points above or below the mean (0.04%)
6 consecutive points above or below the mean (0.27%)
− Middle third rule
19 out of 20 points in the middle third region (0. 45%)
15 consecutive points in the middle third region (0.33%)

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 Statistical Process Control (SPC) II

Special Causes
Points outside or on the control limits

Point above the

Upper Limit

Point below the

Upper Limit

Special Causes
7 consecutive points above or below the mean

7 points above the line

7 points below the line

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 Statistical Process Control (SPC) II

Special Causes
7 consecutive points moving upwards or downwards
7 points in an upward
direction

7 points in an downward
direction

Special Causes
Middle third rule

Considerably less than 2/3 of Considerably more than 2/3

the points fall in this zone of the points fall in this zone

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 Statistical Process Control (SPC) II

In Control and Out of Control

• If Out-of-Control patterns occur, we assume
that the process is probably out of control and
that an investigation is warranted to find and
eliminate the cause(s).
• “In control" implies that all points are between
the control limits AND they form a random
pattern.

Developing Control Charts

1. Prepare
− Choose measurement
− Determine how to collect data, sample size, and
frequency of sampling
− Set up an initial control chart
2. Collect Data
− Record data
− Calculate appropriate statistics (e.g. mean, range)
− Plot statistics on chart

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 Statistical Process Control (SPC) II

Next Steps
3. Determine trial control limits
− Center line (process average)
− Compute UCL, LCL
4. Analyze and interpret results
− Determine if in control
− Eliminate out-of-control points
− Recompute control limits as necessary

Final Steps

5. Use as a problem-solving tool

− Continue to collect and plot data
− Take corrective action when necessary
6. Compute process capability

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 Statistical Process Control (SPC) II

Deducing the Capability Index from

the Process Control Chart

n 2 3 4 5 6
d2 1.13 1.69 2.06 2.33 2.53

Process Improvement Stages

Common cause
variation reduced

Special causes
eliminated

Process improved

Special causes
present
Process under control -
predictable

Process out of control

- unpredictable

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 Statistical Process Control (SPC) II

Control Charts for Attributes

Attribute Control Charts

• Some important characteristics cannot be measured on a continuous scale, e.g.
− missing components
− damaged surfaces
− burred holes
− fabric flaw
− missing labels
or
incorrect invoices
−
failure to return a telephone call
−
out of stock components
−
absentees
−
complaints
−
• We can only count the number of times these events occur. In the past AQL's
were used in such situations.
• Can we create a variable scale – Better! If not, we need a charting procedure for
go/no-go situations, if there is no alternative.

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 Statistical Process Control (SPC) II

Attribute Chart Statistics and Formulae

Chart Plot Process mean Control lines*

p p

np f

c c

u u

* The LCL is drawn at zero when the calculation gives a negative number.

Key to Symbols
• c Defects (faulty features) in sample
• f Defectives (faulty units) in sample
• n Sample size
• m Number of samples

• average sample size

• u Defects per sample unit

• p Proportion of defectives in sample

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 Statistical Process Control (SPC) II

p Chart for Proportion of Defectives

Defectives are sometimes called non-conforming or

faulty units.
• The p chart is used
− when there is variation in successive sample size and
− the data is expressed as the fraction or proportion of
defectives in the sample.
• Sample sizes should not vary by more than ±25% of
the average sample size.

Binomial Distribution

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 Statistical Process Control (SPC) II

Normal Approximation

p Chart

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 Statistical Process Control (SPC) II

p Chart

np Chart for Number of Defectives

• The np chart is similar to the p chart, the differences
are that
− the sample size must be constant and
− the plotted data can be the actual number of defectives
recorded.

• The p and np charts look exactly the same if plotted

for the same data when there is constant sample size
except that the respective vertical scales will be
labelled differently.

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 Statistical Process Control (SPC) II

np Chart

c Chart for Number of Defects

Defects are sometimes called faults.

• The c chart is similar to the np chart except that it describes

defects rather than defectives.
• Samples can be
− a single unit such as an assembly,
− a measured production output such as an area of material or
− a constant sized group of units such as an audit batch.
• Also used to illustrate discrete data that is not of attributes,
such as occurrences of accidents, births or aircraft movements
and it is sometimes called a simple run chart.

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 Statistical Process Control (SPC) II

Poisson Distribution and Approximation

c Chart

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 Statistical Process Control (SPC) II

u Chart for Proportion of Defects

• The u chart is similar to the c chart, the
differences are that
− the sample size can vary;
− the plotted data is the average number of defects
per unit in the sample.
• Like the p chart, sample sizes must not vary by
more than ±25% of the average sample size.

u Chart

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 Statistical Process Control (SPC) II

Binomial Distribution
- B(500,0.0323)

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 Statistical Process Control (SPC) II

Control Charts for Special Situations

• Individual and moving range charts
• Charts for short production runs
− Nominal or Target charts for similar components
− Standardized short run charts for varying
performance
• Standardized Z charts
• Cusum charts

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