1

6-1. Introduction
 Data that can be classified into one of
several categories or classifications is
known as attribute data.
 Classifications such as conforming and
nonconforming are commonly used in
quality control.
 Another example of attributes data is the
count of defects.

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6-2. Control Charts for Fraction
Nonconforming
 Fraction nonconforming is the ratio of the number
of nonconforming items in a population to the
total number of items in that population.
 Control charts for fraction nonconforming are
based on the binomial distribution.
 Each outcome is either a “success” or “failure”.
 The probability of success is constant at p. The
probability of a failure is (1-p).
 The binomial distribution with parameters n  0 and 0 <
p < 1, is given by p( x )   p x (1  p) n  x
n
x
 
 The mean and variance of the binomial distribution are
  np  2  np(1  p)
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Contoh :
Frozen Orange juice is packed in 6 oz cans that formed on
machine. When filled it could possibly leak either on the
side seam or around the bottom joint. To improve fraction
non conforming we find 30 sampels of n=50 cans that are
selected every half-hour over three shift period.
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Chapter 6
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Chapter 6
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Chapter 6
Design of Fraction
Nonconforming Chart
 Three parameters must be specified
1. The sample size
2. The frequency of sampling
3. The width of the control limits

 Common to base chart on 100% inspection of

all process output over time
 Rational subgroups may also play role in
determining sampling frequency

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Chapter 6
Sample size
 If p is very small, we should choose n
sufficiently large to find at least one
nonconforming unit
 Otherwise the presence of only one non-
conforming in the sample would indicate
out-of-control condition (example)
 To avoid this, choose n such that the
probability of finding at least one
nonconforming per sample is at least γ
(example)
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Chapter 6
Example
 p = 0.01 and n = 8

p(1  p) 0.01(1  0.01)

UCL  p  3  0.01  3  0.1155
n 8
 If there is one nonconforming in the sample, then
p =1/8=0.125
and we conclude that the process is out of control

Chapter 6
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 Sample size
 The sample size can be determined so that the
probability of finding at least one nonconforming
unit per sample is at least γ
 Example p = 0.01 and γ = 0.95
 Find n such that P(D ≥ 1) ≥ 0.95
 Using Poisson approximation of the binomial with
λ=np
 From cumulative Poisson table λ must exceed
3.00
 np ≥ 3  n ≥ 300

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 λ

x 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1

0 0.1003 0.0907 0.0821 0.0743 0.0672 0.0608 0.0550 0.0498 0.0450
1 0.3309 0.3084 0.2873 0.2674 0.2487 0.2311 0.2146 0.1991 0.1847
2 0.5960 0.5697 0.5438 0.5184 0.4936 0.4695 0.4460 0.4232 0.4012
3 0.7993 0.7787 0.7576 0.7360 0.7141 0.6919 0.6696 0.6472 0.6248
4 0.9162 0.9041 0.8912 0.8774 0.8629 0.8477 0.8318 0.8153 0.7982
5 0.9700 0.9643 0.9580 0.9510 0.9433 0.9349 0.9258 0.9161 0.9057
6 0.9906 0.9884 0.9858 0.9828 0.9794 0.9756 0.9713 0.9665 0.9612
7 0.9974 0.9967 0.9958 0.9947 0.9934 0.9919 0.9901 0.9881 0.9858
8 0.9994 0.9991 0.9989 0.9985 0.9981 0.9976 0.9969 0.9962 0.9953
9 0.9999 0.9998 0.9997 0.9996 0.9995 0.9993 0.9991 0.9989 0.9986
10 1.0000 1.0000 0.9999 0.9999 0.9999 0.9998 0.9998 0.9997 0.9996
11 1.0000 1.0000 1.0000 1.0000 0.9999 0.9999 0.9999
12 1.0000 1.0000 1.0000
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Sample size
 The sample size can be determined so that a shift
of some specified amount,  can be detected with
a stated level of probability (50% chance of
detection).
 UCL = pout
If  is the magnitude of a process shift, then n
must satisfy:
p(1  p)
L
n
2
Therefore, L
n    p(1  p)

Positive Lower Control Limit

 The sample size n, can be chosen so that

the lower control limit would be nonzero:

p(1  p)
LCL  p  L 0
n

and

(1  p) 2
n L
p

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 There are many instances where an item will
contain nonconformities but the item itself is not
classified as nonconforming.
 It is often important to construct control charts
for the total number of nonconformities or the
average number of nonconformities for a given
“area of opportunity”. The inspection unit must
be the same for each unit.

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• Refer to Table 6-9 for occurrence of defect type by type of printed
circuit board (part number)`
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 When defect levels or in general, count rates, in a process
become very low—say, under 1000 occurrences per
million—there will be very long periods of time between
the occurrence of a nonconforming unit. Conventional c
and u charts become ineffective as count rates are driven
into the low parts per million (ppm) range.

 The time-between-events control chart has been very

effective as a process-control procedure for processes with
low defect levels. If the “events” of interest occur
according to a Poisson distribution, the probability
distribution of the time between events is the exponential
distribution.

 Constructing a time-between-events control chart is

essentially equivalent to control charting an exponentially
distributed variable.
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