196 STATISTICAL QUALITY CONTY

Some Control Chart Patterns

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Introduction. The avemge for different subgroups plotted on Reh
the ranges on R chart, describe a pattem of variation on the control e chart and
knowledge of the production process and the patern of variation on th
chart will lead to a proper interpretation of the working of the process. F
production process itis possible to find out the causes which might giveFor
a particular pattern of variation. One thing must be remembered that Xcha riseo to
not be interpreted properly unless the corresponding R chart is in statistical C can
The control chart patterns can be broadlly classified into two catear ntrol.
(a) Chance (natural) pattem of variation
ies:
(6) Assignable cause (un natural) patterm of variation.
The process will be in a state of statistical control if a chance Datem
variation is exhibited by the Xand R charts. The un natural patterm of variat of
iation
indicates that the process is out of control and corective action is necessr
The interpretation about the ability of the process to meet specified toleras
sary.
will depend upon the ability to distinguish between the chance pattern of variati
ation
and the assignable patterm of variation.
(a) Chance Pattern of Variation
We know hat central tendency is the characteristic of the distribution, i
most of the observations tend to concentrate near the centre of the distribution,
Since the distribution is symmetrical it is natural to expect an equal number of
points on either side of the central line. Also, since the distribution extends p
to 3s limits on either side of the central line, about 99.73 percent observations
will lie between these limits.
Thus, even if the process is interpreted by chance causes 3 in 1,000 producis
may fall outside the control limits.

- UCL

N -A X

LCLx

Subgroups
Flg. 6.1. Chance pattern of variation. have i
thus
A control chart having a chance patterm of variation will
following three characteristics.
Most of the points will lie near the central line.
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ROR
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197
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will be near the control limits.

few points
Very
of the points ept 3 in a thousand) fall outside the control limits.
None
an Cause (Unnatura) Pattern o Variation
(Assignable
( )A s s i g n a b l e
Pattems of variations
most inmportant
types of assignable cause are
The 2. Indication of Trend
1. Extreme Variationn
4. Erratic Fluctuations.
3. Shifts
variation is recognised by the points falling
1. Ertreme Variation. Exremelimits. control limits on
thè Upper and Lower control The width of the
tside the variation due to the inherent characteristics of the
control chart represents in machines, materials and men.
variation
that is, the nomal permissible
rocess,
proce
falls outside these limits on Xchart, P chart or both
ThS wben the sample pointcauses of eror are present and corrective action is
t means some assignable
the products within the specified limits.
Decessary to produce
- - UCLx

- X

- - --- LCLx

Fig. 6.2. Extreme Variation.

Causes of extreme variation
Eror in measurement and calculations.
) Samples chosen at a peak position of temperature, pressure and such
other factors
(üi) Wrong setting of machine, tools etc.
Samples chosen at the commencement or end of an operation.
Indication of Trend. If the consecutive points on Xor R chart tend to
mo
indicating either towards LCL or UCL, it can be assumed that process is
ane lying aa Trend i.e. change is taking place slowly and though all the points
within control limits, after some time it is likely that the process may
Control if proper care or comective action is not taken.
Causes of Trend
( Tool wear,
(i) Wear of threads on clamping device.
Effects of temperature and humidity.
Accumulation of dirt and clogging of fixtures
and
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Upward
trend

A: D o w n w a r d

trend

Fig. 6.3. Trend. of

indicates gradual wearing
the R chart indicates
trend (upwards)
on
on the R chart
An increasing trend (downwards) back process.
A decreasing control on
machine parts. improved
operating better mainteance, below the centre
in operations, fall above or
improvement consecutive points has taken
When a series of shift in the process
3. Shift. assumed that assumed that
chart it can be generally
Xor R cause. It
is
line on either s o m e assignable
ocurred.
presence
of
the centre line, the shift has
place indicating aboveor below -UCLx
points lie
7 consecuti ve
when

-X

W
- LClx
--UCLx
- .

- X

ww -LCLx

Fig. 6.4. Shift.

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199
Causes ofshift:
( Change-in material
(i) Change in operator, inspector, inspection equipment
machine setting.
ü) Change in
carelessness of the operator.
cy) New operator,
Loose fixture etc.

4. Erratic Fluctuations. Erractic fluctuation is characterised by ups and

downs as shown in Fig. 6.5. his may be due to single causes or a group of causes
sfecing the process level and spread. The cause of erratc fluctuations are rather
Aitficult to identify. It may be due to different causes acting at different times
on the prOcess.

--UCLx

A. Fig. 6.5. Erratic Fluctuations.

.- - LCLx

Causes of Eratic fluctuations

Frequent adjustment of machine.
(ü) Different types of material being processed.
ii) Change in operator, machine, test equipment etc.
Importance of R chart. The R chart is used as a measure of sub-group
dispersion. The importance of R chart depends on the type of production process.
Tbere are many production processes in which it is difticult to maintain uniform
process dispersion: in such processes R chart is extremely useful for process
control. It is useful particularly for those processes where the skill of the operator
is important. The first step in improving such processes should be to try to bring
statistical control.
the process dispersion into
but generally R chart is
og chart is the same,
The purpose of R chart and
used instead of o chart because RHs casier to compute. Secondly, R is easier to
understand. R as a measure of sub-group dispersion is always necessary to provide
a basis for calculating limits on a control chart for X and also for estimating

R
d