ANALYTICS TRAINING MODULES

SERIES-A:
BASIC PROBLEM SOLVING TOOLS

Module A-05 : CONTROL CHARTS

Doc. No. A-05.04.20210713
Revision 04; 13th July 2021
Authors: Pankaj Lochan / Soumeek Das

For further clarifications, write to

pankaj.lochan@jindalsteel.com / soumeek.das@jindalsteel.com © Jindal Steel & Power Ltd. All rights reserved.
ANALYTICS TRAINING MODULES
Series A Series C Series D Series F
Basic Problem Solving Tools Management Systems Productivity & Efficiency Tools Advanced Statistical Tools
A-01 Flow Charts C-01 Quality Mgmt. Basics D-01 Theory of Constraints F-01 Sampling & Distribution
A-02 Cause & Effects Diagram C-02 Basic Statistics D-02 Capacity & Bottlenecks F-02 Hypothesis Testing
A-03 Stratification C-03 Statistical Process Control D-03 Value Stream Mapping (VSM) F-03 Regression
A-04 Scatter Diagram C-04 KPI Drill Down D-04 Time & Motion Study F-04 Basics of DoE
A-05 Control Charts C-05 KPI Benchmarking D-05 SMED F-05 Factorial DoE
A-06 Check Sheets C-06 KPI Target Setting D-06 Wrench Time Analysis F-06 Principal Component Analysis
A-07 Histogram C-07 Strategic Analysis Tools-1 D-07 Queuing Theory F-07 Cluster Analysis
A-08 Pareto Charts C-08 Strategic Analysis Tools-2 D-08 Inventory Management F-08 Conjoint Analysis
A-09 Graphs C-09 Strategy Management
D-09 Linear Programming Problem F-09 Discriminant Analysis
C-10 Daily Mgmt. in Operations
D-10 Game Theory F-10 Factor Analysis
C-11 Daily Mgmt. in Maint.-1
Series B D-11 OEE F-11 Response Surface Method
C-12 Daily Mgmt. in Maint.-2
Basic Management Tools D-12 PERT & CPM F-12 Taguchi DoE
C-13 Daily Mgmt. in Services
C-14 Cross Functional Mgmt. F-13 Weibull Analysis
B-01 Brainstorming Series E
B-02 Affinity Diagram C-15 Quality Assurance Basics
C-16 MSA Decision-making Tools
B-03 Arrow Diagram
C-17 PFD, FMEA, Control Plan E-01 Quality Function Deployment
B-04 Tree Diagram
C-18 Improvement Fundamentals E-02 Fault Tree Analysis
B-05 PDPC
C-19 5S E-03 AHP & Paired Analysis
B-06 Matrix Diagram
C-20 Quality Circles E-04 Pugh Matrix
B-07 Matrix Data Analysis
C-21 QC Story Approach
B-08 Relation Diagram E-05 Time Motion Series
C-22 Kaizen, OPL, Poka Yoke

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FLOW OF THE TRAINING DOCUMENT

1 Introduction to Control Chart

2 Steps of Control Chart Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

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Control Chart: Introduction

▪ Statistical Process Control (SPC) emphasizes on

controlling the process not the product. Control

Sample characteristic
charts is the basic tool of SPC.
▪ The basic purpose of Control charts is to monitor
process variation; is a graph used to study how a
process behaves over a period of time. Data is
plotted in timely order.

▪ A control chart always has a central line for the

average, an upper line for the upper control limit and
Sample number or time
a lower line for the lower control limit.
▪ Control lines are determined from historical data. By
comparing current data to these lines, you can draw Control charts can be
conclusions about whether the process variation is plotted for both Variable
consistent (in control) or is unpredictable (out of control, and Attribute type of data
affected by special causes of variation).

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 Control Chart: Introduction

●
Upper Control Limit
9:05 am
●
Sample characteristic

●
● ●
Centre Line
●
●
●
●
●

8:57 am
Lower Control Limit

Sample number or time

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Control Chart: History

Common Causes Special Cause

• The control chart was invented by Walter A.
Shewhart at Bell Labs in 1920s while working for the
reliability of telephony transmission systems.
• He analysed different processes and concluded that
all manufacturing processes display variation. He

Sample characteristic
identified two components of variation:
– A Steady component which appears to be Central Line

inherent to the process and called this as Chance

causes / Common Cause & it cannot be
economically removed until basic changes are
made in the process
– An Intermittent component, called this as
Assignable cause / Special Cause, which can be
predicted and economically removed Sample number or time

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‘Common Causes’ And ‘Special Causes’ Variations

▪ Even in best designed production processes, certain amount of variability exists. Also
known as “background noise”, variability is a cumulative effect of many small and
unavoidable causes.
▪ When variation is relatively small, it is considered acceptable. In Statistical Process
Control, this natural variability is often called a “stable system of Chance causes /
Common causes.” A process that is operating with only chance causes of variation
(inherent part of process) is said to be in control.
▪ Other kinds of variability may arise from three major sources - incorrect operation,
incorrect design, or defective inputs. Such variability is generally large when chance
causes, and it usually represents an unacceptable level of process performance. These
are called Assignable causes / Special Causes. A process that is operating in the
presence of assignable causes is said to be out of control.
▪ Purpose of SPC is to quickly detect occurrence of assignable / special causes or process
shifts so that investigation and corrective action may be undertaken before any
nonconformity occurs. The control chart is an online process-monitoring
technique widely used for this purpose.

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 Control Chart: Introduction

Special Causes/
● Assignable Causes

● Upper Control Limit

9:05 am
●
Sample characteristic

● Common Causes/
● Chance Causes ●
Centre Line
●
●
●
●
●

8:57 am
Lower Control Limit

Sample number or time

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‘Common Causes’ And ‘Special Causes’ Variations

Comparison criteria Common Causes / Chance Causes Special Causes / Assignable Causes

Poor design, Poor maintenance, Lack of Machine malfunction, Operator error,

Generic types of
clearly defined SOPs, Vibration in Defective raw material, Power surges,
variations
industrial processes, etc. Automation failures, etc.

Nature / source System deficiencies Process failure

Process behavior Stable and predictable Scattered, unstable & unpredictable

Type of Improvement Requires fundamental changes and ROI

In-process corrections and ROI is high
actions required is low

Responsibility of action Management Operator / supervisor

Approx. % in total 85%-95% are of this type 5% - 15% are of this type

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Control Chart: Control Limits

The fundamental relationships in developing Theatrical Normal Curve Actual Process Curve
control charts are as follows:
The center (or central) line is the mean of the
process. UCL

No. of Standard Deviations from the Mean

The upper control limit (UCL) is the mean plus 3 +3σ

standard deviations.
+2σ
The lower control limit (LCL) is the mean minus 3
standard deviations. +1σ

So, the limits are: Μean ±3σ Mean

The reason for using 3 standard deviations is based
on the assumption that the process output is - 1σ

normally distributed.
- 2σ
If the process is in control, there is a very small
probability of an observation falling outside of the - 3σ
LCL
control limits. This probability increases as the
process deviates from the in - Control State.

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DISCRETE AND CONTINUOUS DATA

Discrete Data
A set of data is said to be discrete if the values / observations belonging to it are distinct and
separate, i.e. they can be counted. It is also a set of data that cannot take decimal values.
Example: Number of good or bad parts in a lot, Number of students in a class etc.
Continuous Data
A set of data is said to be continuous if the values / observations belonging to it may take on
any value within a finite or infinite interval. You can count, order and measure continuous
data. So continuous data can take decimal values and still make a sense.
Example: height, weight, temperature, the amount of carbon percentage in hot metal, the
time required to complete one heat.

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Types of Control Charts

Control Charts

Variable Control Attribute Control

Charts Charts

Defects -
No. of measurements in each Defectives – Contain single/
subgroup Total Defects in individual / all multiple defects
Items

Subgroup Subgroup Subgroup Subgroup

One 2 to 8 More than 8 sample size sample size sample size sample size
Constant Different Constant Different

Average &
Individual & Average & Standard Defects per Defects per No. of Proportion of
Moving Range Chart Deviation Unit Subgroup Defectives Defectives
Range Chart (X-Bar, R Chart C - Chart U- Chart np - Chart P - Chart
(X-MR) Chart) (X-Bar, S)

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X bar & R Chart (If Subgroups are of size, n=2-8)

1 2 3 4 5 6 7 8 9 10 ………………………………………...n

X1+X2+X3+X4 +X5+………..+Xn
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 ………………………………………. Xn X =
n

R1+R2+R3+R4 +R5+………..+Rn
R =
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 ………………………………………. Rn n
Where R1= Sample-1’s (Max. Value – Min. Value)

X bar Chart R Chart

Centre LineX bar = X Centre LineR = R

UCLX bar = UCLR = D4 * R

X + A2*R
LCLX bar = LCLR = D3 * R
X - A2*R

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X bar & R Chart (If Subgroups are of size, n=2-8)

● ●●
● ●●
X bar ●●

● ● ●●
● ●●
● ● ●● ●
●● ● ● ●●
● ● ● ●
● ● ●
● ● ●

Note: The black dots are not a part of X bar Chart. This has been plotted to make the participants understand how x bar is plotted

R Chart ●

● ●
●
● ●

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X & MR Chart (If Subgroups are of size, n=1)

1 2 3 4 5 6 7 8 9 10 ………………………………………...n

X1+X2+X3+X4 +X5+………..+Xn
X =
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 ………………………………………. Xn n

………………………………………………… MRn-1
MR1+MR2+MR3+MR4+…..+MRn-1
MR1 MR2 MR3 MR4 MR5 MR6 MR7 MR8 MR9 MR =
n-1

X Chart X Chart ●
Centre LineX = X
●
UCLX ● ●
= X + E2 *MR
● ●
● ●
LCLX = X – E2 *MR

MR Chart
MR Chart
●

Centre LineMR = MR ●
● ●
UCLMR = D4 * MR ●
● ●
LCLMR = D3 * MR = 0

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X bar & S Chart (If Subgroups are of size, n>8)

1 2 3 4 5 6 7 8 9 10 ………………………………………...n

X1+X2+X3+X4 +X5+………..+Xn
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 ………………………………………. Xn X =
n

S1+S2+S3+S4 +S5+………..+Sn
S =
S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 ………………………………………. Sn n

X bar Chart S Chart

Centre LineX bar = X Centre LineS = S

UCLX bar = UCLS = B4 * S

X + A3*S
LCLX bar = LCLS = B3 * S
X - A3*S

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 P Chart for defectives when n is not constant

Sample
1 2 3 4 5 6 7 8 9 10 ………………………………………...k
Set
Items
Inspected (n) 15 20 25 20 28 20 20 15 20 22 20
Items
Defective (D) 5 3 2 4 2 0 1 7 5 15 3

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 ………………………………………. Dk Here D is the Number of Defectives in each sub group

n1 n2 n3 n4 n5 n6 n7 n8 n9 n10 ………………………………………. nk Here n is the Number of Samples in each subgroup

p1 p2 p3 p4 p5 p6 p7 p8 p9 p10 ………………………………………. pk
Where p1 = D1/n1 and so on
0.33 0.15 0.08 0.2 0.71 0 0.05 0.46 0.25 0.68 0.15

p1+p2+p3+p4 +p5+………..+pk
p = P Chart
k
Centre Linep = ഥ
𝒑
ഥ 𝟏−𝒑
𝒑 ഥ
UCLp ഥ
𝒑 + 𝟑×
= 𝒏

ഥ ഥ
LCLp = ഥ
𝒑 - 𝟑× 𝒑 𝟏−𝒑
𝒏

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NP Chart for defectives when n is constant

Sample
1 2 3 4 5 6 7 8 9 10 ………………………………………...k
Set
Items 20 20 20 20 20 20 20 20 20 20 20 Here n is the Number of Samples in each subgroup
Inspected (n) which is CONSTANT
Items
Defective (np) 5 3 2 4 2 0 1 7 5 15 3

np1 np2 np3 np4 np5 np6 np7 np8 np9 np10 ………………………………………. npk

𝒑 = np1+np2+np3+np4 +np5+………..+npk
𝒏ഥ
k

NP Chart

Centre Linenp = 𝒏ഥ
𝒑
𝒏ഥ
𝒑
UCLnp = 𝒏ഥ
𝒑 + 𝟑 × 𝒏ഥ
𝒑 𝟏−
𝒏

𝒏ഥ
𝒑
LCLnp = 𝒏ഥ
𝒑 - 𝟑 × 𝒏ഥ
𝒑 𝟏−
𝒏

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C Chart for defects when n is constant

Sample
1 2 3 4 5 6 7 8 9 10 ………………………………………...k
Set

Total No. of
Defects (C) 5 3 2 4 2 0 1 7 5 15 3

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 ………………………………………. Ck Here C is the Number of Defects in each sub group

n1 n2 n3 n4 n5 n6 n7 n8 n9 n10 ………………………………………. nk Here n is the Number of Samples in each subgroup

where n is constant n

C1+C2+C3+C4 +C5+………..+Ck
C = C Chart
k
Centre Linec = C
UCLc = C + 3*√c

LCLc = C - 3*√c

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 U Chart for defects when n is not constant

Sample
1 2 3 4 5 6 7 8 9 10 ………………………………………...k
Set
Items 10 20 15 20 19 20 17 20 20 20 15
Inspected (n)
Total No. of
Defects (C) 5 3 2 4 2 0 1 7 5 15 3

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 ………………………………………. Ck Here C is the Number of Defects in each sub group

n1 n2 n3 n4 n5 n6 n7 n8 n9 n10 ………………………………………. nk Here n is the Number of Samples in each subgroup

U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 ………………………………………. Uk Where U1 = C1/n1 and so on

U1+U2+U3+U4 +U5+………..+Uk
U = U Chart
k
Centre LineU = U
UCLU = U + 3 * √ U/n

LCLU = U - 3 * √ U/n

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FLOW OF THE TRAINING DOCUMENT

1 Introduction to Control Chart

2 Steps of Control Chart Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

21 of 65
Steps of making a control chart

Step 1 Identify the parameter to be studied for variation

▪ Decide the process characteristic / parameter which you want to
study,
▪ Example : ‘Si’ content in hot metal, hot metal temperature, Coil
thickness, Defects in each coil etc.

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Steps of making a control chart

Step 2 Data Collection

▪ As per AIAG(Automotive Industry Action Group), minimum number of data points required to
analyze the process for variation is 100
▪ The data related to process parameter is collected in the in the form of subgroups which contain
one / more samples.
▪ Subgroup size: Size of the subgroup depends on the process under study. If variation in the process
is relatively small, then large subgroup size (sample size more than 8 in each subgroup) needed to
detect the process shift. If process has a large variation then small subgroup sample size (sample
size less than 8 in each subgroup) is sufficient to detect the process shift.
▪ Subgroup frequency: The subgroups are taken sequentially in time, ie once in hour / shift / day
etc. frequency of subgroup has to be decided in such a way that, it can reflect the potential
opportunity for a process change.

23 of 65
Steps of making a control chart

Step 3 Determine the type of control chart to be used

▪ Determine the type of data,
▪Data can be of two types:
▪Variable data
▪Variable data are measured on a continuous scale and also can be measured in fractions or decimals
▪example: time, weight, distance or temperature.

▪Attributes Data
▪Attribute data are counted and cannot have fractions or decimals. Attribute data arise when you are
determining only the presence or absence of something: success or failure, accept or reject, correct
or not correct.
▪example, a report can have four defects , but it cannot have four and a half defects.
▪ Select the appropriate control chart based on whether parameter under study is variable or attribute,
subgroup sample size & considering whether subgroup sample size is constant or different.

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Steps of making a control chart

Step 4 Calculate the control statistics & sample control

limits
▪ The control statistics such as Mean, Range, Standard Deviation
are to be calculated for the collected data.
▪ Using these control characteristics, and control chart formulae,
calculate sample limits such as, Central Line (CL), Upper Control
Limit (UCL) & Lower Control Limit (LCL)

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Steps of making a control chart

Step 5 Plotting the sample limits & data on the chart

▪ Plot the calculated sample limits on the chart, plot the subgroup data, connect the
points and visualize the patterns & trends.
Subgroup data
Sample characteristic

Central Line

Sample number or time

26 of 65
Steps of making a control chart

Step 6 Find and address the special causes

▪ Look for out of control points , ie points outside the control limits
(UCL / LCL), those variations are due to special causes.
▪ Conduct a process analysis to determine the root causes of special
causes, with the help of process log.
▪ Improve the process by taking suitable corrections / corrective
actions on special causes.

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Steps of making a control chart

Step 7 Recalculate the control limits

▪ While conducting initial process study, the control limits should be
recalculated to exclude the effects of special causes.
▪ For this we can either eliminate the special cause from the process by
taking actions or exclude all subgroup data which are affected from special
cause. Confirm that all subgroup data points are fully within control limits,
if not repeat the above process.

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Steps of making a control chart

Step 8 Extend the control limits to ongoing process

▪ When all data points are falling within control limits (no special cause in the process), plot these calculated control limits on the blank
chart and use them to detect the occurrence of special cause.
▪ Provide these blank charts to the Operator / Supervisor, who will record the online data and plot them on these charts, and he can
respond to signs of out-of-control(special causes0 conditions.
Apply below rules of Special cause detection for Control chart Interpretation
1. One point outside the Control limits
2. 2 of 3 consecutive points more than 2 away from the mean on one side.
3. 4 of 5 consecutive points more than 1 away from the mean on one side
4. 7 consecutive points on one side of mean
5. 6 consecutive points trending up or down
6. 14 consecutive points alternating up or down
▪ If Rule No. 1 is violated, immediately analyze the cause of variation & if necessary stop the process .
▪ Violation of any of above Rule 2 to 6, indicates the presence of special cause in the process, With the help of process log, identify
the root cause/s ,due to which out of control variation occurred in the process.
▪ Take Corrective & Preventive actions to eliminate the those special causes.

29 of 65
FLOW OF THE TRAINING DOCUMENT

1 Introduction to Control Chart

2 Steps of Control Chart Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

30 of 65
Plant Example – 1: Control Chart For Variable Data

Hot Metal Hot Metal Temperature in °C

Temperature

Reading 3

Reading 4
Reading 1

Reading 2

Reading 5

Reading 6
Date

Step 1 Identify the parameter to be studied for variation 1-Jan-15 1500 1512 1500 1510 1503 1510
2-Jan-15 1506 1500 1505 1508 1503 1505
• Parameter under study for variation is Blast Furnace Hot 3-Jan-15 1504 1505 1506 1500 1510 1511
4-Jan-15 1517 1505 1505 1510 1508 1500
• Metal Temperature
5-Jan-15 1513 1514 1500 1500 1511 1508
6-Jan-15 1515 1520 1495 1502 1506 1511
7-Jan-15 1519 1515 1510 1503 1515 1510
Step 2 Data Collection 8-Jan-15 1510 1512 1517 1520 1522 1525
9-Jan-15 1510 1515 1511 1510 1512 1510
▪ Parameter : Hot Metal temperature 10-Jan-15 1506 1514 1515 1505 1505 1500
▪ Subgroup sample size : 6 11-Jan-15 1500 1520 1505 1509 1510 1508
12-Jan-15 1505 1515 1510 1522 1510 1500
▪ Sampling frequency : Two times a shift, i.e. 6 data points are 13-Jan-15 1500 1515 1510 1513 1508 1492
collected in day 14-Jan-15 1485 1490 1500 1510 1520 1505
15-Jan-15 1510 1508 1500 1505 1520 1510
16-Jan-15 1505 1510 1505 1500 1510 1515
Step 3 Determine the type of control chart to be used 17-Jan-15 1511 1510 1510 1502 1500 1500
18-Jan-15 1520 1505 1502 1510 1505 1500
▪ As temperature is continuous type of data , we can go for Variable 19-Jan-15 1511 1505 1515 1511 1504 1505
20-Jan-15 1512 1500 1500 1514 1500 1510
type control charts.
21-Jan-15 1525 1510 1500 1498 1510 1500
▪ As sample size is less than 8, we can go for X-bar, R charts. 22-Jan-15 1515 1505 1500 1505 1515 1510
23-Jan-15 1500 1500 1505 1500 1510 1515

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Calculate the control statistics & sample control limits

Step 4
(X)
1. Calculate Average of each sub groups
2. Calculate the Range R of each subgroup, Range= Max value in sub group – minimum
value in sub group + + + - - - -Xn
X X2 X3
3. Calculate Grand average X using formula X= 1
Where ‘K’ is the no of subgroups.
K

R R1 +R2 + R3+ - - - -Rn

4. Calculate Average of ranges ( R ) using formula
= K
UCL = X + A2 R
5. Calculate Upper Control Limit

6. Calculate Central Line = X

7. Calculate Lower Control Limit

LCL = X - A2 R

Where - A2 is a statistical constant, taken from standard

table, Ref. Table 1, and whose values depend on the
collected data sample size

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Calculate the control statistics & sample control limits

33 of 65
 Hot Metal Temperature in °C
Mean of

Reading 1

Reading 2

Reading 3

Reading 4

Reading 5

Reading 6
CL for X - UCL for X- LCL for X- UCL for R- LCL for
Readings Range CL R - Chart
Date Bar Chart bar Chart Chart Chart R-Chart
(X-bar)

1-Jan-15 1500 1512 1500 1510 1503 1510 1505.83 12.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
2-Jan-15 1506 1500 1505 1508 1503 1505 1504.50 8.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
3-Jan-15 1504 1505 1506 1500 1510 1511 1506.00 11.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
4-Jan-15 1517 1505 1505 1510 1508 1500 1507.50 17.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
5-Jan-15 1513 1514 1500 1500 1511 1508 1507.67 14.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
6-Jan-15 1515 1520 1495 1502 1506 1511 1508.17 25.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
7-Jan-15 1519 1515 1510 1503 1515 1510 1512.00 16.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
8-Jan-15 1510 1512 1517 1520 1522 1525 1517.67 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
9-Jan-15 1510 1515 1511 1510 1512 1510 1511.33 5.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
10-Jan-15 1506 1514 1515 1505 1505 1500 1507.50 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
11-Jan-15 1500 1520 1505 1509 1510 1508 1508.67 20.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
12-Jan-15 1505 1515 1510 1522 1510 1500 1510.33 22.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
13-Jan-15 1500 1515 1510 1513 1508 1492 1506.33 23.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
14-Jan-15 1485 1490 1500 1510 1520 1505 1501.67 35.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
15-Jan-15 1510 1508 1500 1505 1520 1510 1508.83 20.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
16-Jan-15 1505 1510 1505 1500 1510 1515 1507.50 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
17-Jan-15 1511 1510 1510 1502 1500 1500 1505.50 11.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
18-Jan-15 1520 1505 1502 1510 1505 1500 1507.00 20.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
19-Jan-15 1511 1505 1515 1511 1504 1505 1508.50 11.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
20-Jan-15 1512 1500 1500 1514 1500 1510 1506.00 14.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
21-Jan-15 1525 1510 1500 1498 1510 1500 1507.17 27.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
22-Jan-15 1515 1505 1500 1505 1515 1510 1508.33 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
23-Jan-15 1500 1500 1505 1500 1510 1515 1505.00 15.00 1507.78 1515.89 1499.68 16.78 33.63 0.00
Average 1507.78 16.78 34 of 65
 Plotting the sample limits and data on the chart & Find and address special causes

Step 5 & 6

R Chart Special Cause Variation X - Bar Chart

40.00 1520.00 Special Cause Variation

Hot Metal Temperature in °C

Hot Metal Temperature in °C

35.00 UCL 1515.00
30.00
1510.00
25.00
CL
20.00 1505.00

15.00 1500.00
10.00 LCL
1495.00
5.00
0.00 1490.00

4-Jan-15
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9-Jan-15

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16-Jan-15
17-Jan-15

19-Jan-15
20-Jan-15
21-Jan-15
22-Jan-15
23-Jan-15
1-Jan-15
2-Jan-15
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15
7-Jan-15
8-Jan-15
9-Jan-15
Date
Range CL R - Chart Date
UCL for R-Chart LCL for R-Chart
Mean of Readings (X-bar) CL for X - Bar Chart
Analysis of control chart: UCL for X- bar Chart LCL for X-Chart

• Examine the R chart first because the process variation must be in control to correctly interpret the X bar chart.
• In this example Rule No. 1 is Violated ie One point outside the Control limits.
• A special cause exists in the process .
▪ Conduct a process analysis to determine the root causes of special causes, with the help of process log.
▪ Improve the process by taking suitable corrections / corrective actions on special causes.
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 Step 7

Hot Metal Temperature in °C

10.00
15.00
20.00
25.00
30.00
35.00

0.00
5.00
1-Jan-15
2-Jan-15

Range
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15
7-Jan-15
8-Jan-15

CL R - Chart
9-Jan-15
10-Jan-15
11-Jan-15
12-Jan-15
R Chart

Date

13-Jan-15
14-Jan-15
Recalculate the control limits

UCL for R-Chart

15-Jan-15
16-Jan-15
17-Jan-15
18-Jan-15
19-Jan-15
20-Jan-15
LCL for R-Chart

21-Jan-15
22-Jan-15
23-Jan-15

Hot Metal Temperature in °C

1490.00
1495.00
1500.00
1505.00
1510.00
1515.00
1520.00

1-Jan-15
within control limits, if not repeat the above process.

2-Jan-15
3-Jan-15
4-Jan-15
5-Jan-15
6-Jan-15
7-Jan-15
8-Jan-15
UCL for X- bar Chart

9-Jan-15
Mean of Readings (X-bar)

10-Jan-15
11-Jan-15
12-Jan-15
Date

13-Jan-15
X - Bar Chart

14-Jan-15
15-Jan-15
LCL for X-Chart

16-Jan-15
CL for X - Bar Chart

17-Jan-15
18-Jan-15
19-Jan-15
20-Jan-15
▪ Recalculate CL, UCL & LCL and Confirm that all subgroup data points are fully

21-Jan-15
22-Jan-15
36 of 65

23-Jan-15
Extend the control limits to ongoing process

Step 8
▪ When all data points are falling within control limits (no special cause in the process), plot
these calculated control limits on the blank chart and use them to detect the occurrence
of special cause in ongoing process.
R Chart X - Bar Chart
35.00 1520.00
Hot Metal Temperature in °C

Hot Metal Temperature in °C

30.00
UCL
1515.00 UCL
25.00
1510.00
20.00 CL
15.00 CL 1505.00

1500.00
10.00 LCL
5.00 1495.00

0.00 LCL 1490.00

Date Date

CL R - Chart UCL for R-Chart LCL for R-Chart CL for X - Bar Chart UCL for X- bar Chart LCL for X-Chart

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 Plant example – 2: Control Chart for Attribute Data

No. of Defects spotted

on CRCA coils
Coil No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

No. of
2 3 4 2 5 2 1 2 3 2 1 3 2 3 5 2 3 2 3 1

Step 1
Identify the parameter to be studied Defects( C )

for variation Coil No 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

• Parameter under study for variation is No. of Defects
No. of
spotted in CRCA coils Defects( C )
2 3 3 1 2 4 1 0 2 3 1 2 3 4 1 5 4 2 2 3

Step 2 Data Collection Coil No 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

▪ Parameter : No. of Defects spotted in CRCA coils
▪ Subgroup sample size : Same , that is one sample (one No. of
0 2 3 2 2 5 1 2 3 2 1 5 4 8 5 4 3 2 0 2
Defects( C )
coil)
▪ No. of samples: 100 Coil No 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Step 3 Determine the type of control chart to be No. of

1 2 0 3 2 4 5 0 1 2 1 2 3 1 2 3 4 2 3 0
Defects( C )
used
▪ As No. of defects is attribute type of data , we can go for 10
Coil No 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99
0
Attribute type of control charts and in that we are
counting defects per Unit, so we can go for C- Chart No. of
2 4 5 1 2 3 1 2 1 2 3 3 2 3 5 1 0 2 2 3
Defects( C )

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Calculate the control statistics & sample control limits

Step 4

1. Calculate the average Number Defects per Unit ( C )

Using formula C1 + C2 + C3+ - - - - Cn

C=
K
Where ‘K’ No. of subgroups inspected for defects

4. Upper Control Limit is given by

UCL = C+3 C
5. Central Line is

CL = C
4. Lower Control Limit is given by

LCL = C- 3 C

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Calculate the control statistics & sample control limits

No. of C-chart
Coil No Defects
CL LCL UCL
(C)
1 2 2.43 0.00 7.11
2 3 2.43 0.00 7.11
3 4 2.43 0.00 7.11
4 2 2.43 0.00 7.11
5 5 2.43 0.00 7.11
6 2 2.43 0.00 7.11
7 1 2.43 0.00 7.11
8 2 2.43 0.00 7.11
9 3 2.43 0.00 7.11
10 2 2.43 0.00 7.11
11 1 2.43 0.00 7.11
12 3 2.43 0.00 7.11
13 2 2.43 0.00 7.11
99 2 2.43 0.00 7.11
100 3 2.43 0.00 7.11
Average 2.43

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Plotting the sample limits and data on the chart & Find and address special causes

Step 5 & 6
Special Cause Variation
9

7 UCL

6
No. of Defects

3 CL
2

1
LCL
0

Analysis of control chart: Coil No

• Examine the chart out of control signals No. of Defects ( C ) CL LCL UCL

• In this example Rule No. 1 is Violated ie One point is outside the Control limits.
• A special cause exists in the process .
▪ Conduct a process analysis to determine the root causes of special causes, with the help of process log.
▪ Improve the process by taking suitable corrections / corrective actions on special causes.

41 of 65
 Recalculate the control limits

Step 7
8

7 UCL
No. of Defects 6

3
CL
2

1
LCL
0

Coil No

No. of Defects ( C ) CL LCL UCL

▪ Improve the process by taking suitable corrections / corrective actions on special causes.
▪ Recalculate CL, UCL & LCL and Confirm that all subgroup data points are fully within control limits, if not
repeat the above process.

42 of 65
Extend the control limits to ongoing process

▪ When all data points are falling within control limits (no special cause in the process), plot
Step 8 these calculated control limits on the blank chart and use them to detect the occurrence
of special cause in ongoing process.
8.00

7.00 UCL

6.00
No. of Defects

5.00

4.00

3.00
CL
2.00

1.00
LCL
0.00
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99
Coil No

CL LCL UCL

43 of 65
FLOW OF THE TRAINING DOCUMENT

1 Introduction to Control Chart

2 Steps of Control Chart Construction

3 Examples from our Plant

4 Making Control Chart in MS-Excel

44 of 65
Construction of Control Chart in Excel

Shift SL. No Silicon(Si) % - (X)

A 1 0.70
▪ Parameter under study for variation is Silicon 2
3
0.80
0.75
(Si) % in hot metal 4
5
0.80
0.79
6 0.85
▪ Parameter : Silicon (Si) % in hot metal of SMS 7 0.86
8 0.89
converter 9
10
0.85
0.75
B 11 0.79
▪ Subgroup sample size : 1 12 0.80
13 0.81
▪ Sampling frequency : One sample is 14
15
0.86
0.90
16 0.92
collected once and total Ten samples are 17 0.94
18 0.98
collected in a shift. Total 30 samples are 19 0.92
20 0.89
collected in day. C 21 0.80
22 0.72
▪ As ‘Si’ % is continuous type of data , and no. 23
24
0.75
0.80
25 0.78
of samples taken each time is one we can go 26 0.86
27 0.70
for Individual & Moving Range Chart (X-MR) 28 0.75
29 0.72
30 0.70

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Construction of Control Chart in Excel

=ABS(0.80-0.70)

Range= Max value in sub group

– minimum value in sub group.

To calculate moving range we

can use xl sheet formula
=ABS(select 1st value – select
2nd )
Info: To eliminate negative
symbol we use ABS formula

46 of 65
Construction of Control Chart in Excel

Click on the first moving

range (MR) and drag till
the end to get all moving
ranges

47 of 65
Construction of Control Chart in Excel

Calculate averages of :

1. Silicon(Si) % -
(X)
1. Moving Range (MR) -
( MR)

To calculate averages we can use xl

formula
=AVERAGE (select values for which
you need average)

48 of 65
Construction of Control Chart in Excel

Calculate CL, UCL & LCL using above formulae for both X- Chart & MR - Chart

49 of 65
Construction of Control Chart in Excel

Copy the values of CL, UCL &

LCL of both X-Chart & MR-
Chart, in the table form, beside
values of X & MR

50 of 65
Construction of Control Chart in Excel

Select tables of CL, UCL &

LCL for X- Chart, for plotting
the X- Chart (Individual
Chart)

51 of 65
Construction of Control Chart in Excel

After selecting the tables;

Go to, Insert – Line – Select Line
with Markers, for plotting the X-
Chart (Individual Chart)

1.00

0.95

0.90

0.85

0.80

0.75

0.70

0.65

0.60
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Silicon(Si) % - (X) CL for X - Chart UCL for X-Chart LCL for X-Chart

52 of 65
Construction of Control Chart in Excel

Select these tables of CL,

UCL & LCL for MR-Chart for
plotting the MR- Chart
(Moving Range Chart)

53 of 65
Construction of Control Chart in Excel

After selecting the tables ;Go

to, Insert – Line – Select Line
with Markers, for plotting the
MR- Chart (Moving Range
Chart)

0.18

0.16

0.14

0.12

0.1

0.08

0.06

0.04

0.02

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Moving Range (MR) CL for MR - Chart

UCL for MR-Chart LCL for MR-Chart

54 of 65
Construction of Control Chart in Excel

To add heading and

data labels : Click
on the chart and
select chart layouts

55 of 65
Construction of Control Chart in Excel

Select: Layout 10, chart will be displayed in

below form

Delete vertical lines, and add chart title &

data labels

56 of 65
Construction of Control Chart in Excel

To format legends: right

click on the legends-
select format legend –
select legend options –
bottom to display the
legends in the bottom

57 of 65
Construction of Control Chart in Excel

To improve aesthetics of the

chart: right click on the line-
select- format data series

58 of 65
Construction of Control Chart in Excel

In the format data series window - select marker

options – select none, to get line without markers

59 of 65
Construction of Control Chart in Excel

To change color of control lines: right click on the line-

select- format data series – Line color – Solid line –
select desired line color

60 of 65
Construction of Control Chart in Excel

Final Control Chart

61 of 65
Benefits Of Control Chart

Properly used, control chart can:

▪ Be used by operator for on going control of the process
▪ Help the process perform consistently and predictably
▪ Allow the process to achieve
- Higher Quality
- Lower unit cost
- Higher effective capability
▪ Provide a common language for discussing the performance of the process
▪ Distinguish special from common cause variation.
▪ Acts as a guide for deciding, whether to take local action or action on the system

62 of 65
Additional Information

= 11.23

In this data Standard

Deviation is 11.23

To calculate the standard deviation in a data set – use XL formula = STDEV

(Select the data set) – and enter

63 of 65
Control Chart
Formulae

64 of 65
END OF MODULE

It is not enough to do your best; you must know what to do, and then do your best.

THANK YOU
Thank You

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