ME C 443 Quality Control,

Assurance and Reliability

L-31 Extra Class
BITS Pilani Dr. Sachin Waigaonkar
K K Birla Goa Campus
Control Charts Sub Topics Covered

• Introduction to Control Charts

• Type I and Type II errors.
• Example of Type I and Type II errors.
• OC curve
• Thumb Rules for Identifying an Out-of-Control Process
• Control Charts for Variables

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OC curve

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Constructing OC curve

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Control Chart for Variables

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Control Limits for X bar and R chart

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BITS Pilani, K K Birla Goa Campus
Drawing Control charts

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Example

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Calculations

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Control Charts

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Revised X bar and R by eliminating
observations 3, 22, 23.
X R
21.6 3
19.8 4
21 2
21.6 5
19.4 4
19 2
20.4 5
22 4
20 2
21 3
21.6 3
19.4 4
21.2 2
22.8 4
21.2 4
19.2 2
22.4 4
20.2 4
22 3
21.8 3
20.8 2
20.6 3

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Control Limits for a Given Target or Standard

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Suppose that the target values for the average resistance
and standard deviation are 21.0 and 1.0 ohm respectively.
(Sample Size 5)

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Control Limits for a Given Target or
Standard
• Let's suppose that the target values for the average
resistance and standard deviation are 21.0 and 1.0 ohm
respectively. (Sample Size 5)
• X0 Target Process Mean
• σ0 Target Process Std. Deviation

CLR = d2 σ0
UCLR=D2 σ0
LCLR = D1 σ0
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Control Limits for a Given Target or
Standard

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Table of Multiplying factors for control
Charts

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Example
X R
• Suppose that the 21.6
19.8
3
4
specifications are 21 ± 3 Ω. 21 2
21.6 5
Determine the proportion of 19.4 4
the output that is 19 2
20.4 5
nonconforming, assuming 22 4
that coil resistance is 20
21
2
3
normally distributed. 21.6 3
19.4 4
• If the daily production rate is 21.2 2
10,000 coils and if coils with a 22.8
21.2
4
4
resistance less than the LSL 19.2 2
22.4 4
cannot be used for the 20.2 4
desired purpose, what is the 22 3
21.8 3
loss to the manufacturer if the 20.8 2
unit cost of crap INR 35? 20.6 3

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BITS Pilani, K K Birla Goa Campus
BITS Pilani, K K Birla Goa Campus
BITS Pilani, K K Birla Goa Campus
BITS Pilani, K K Birla Goa Campus
Typical Trends of Control Charts

• Cyclic Pattern
• Mixture Pattern
• Trend Pattern
• Shift Pattern
• Stratification Pattern

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Cyclic Pattern

Such pattern result from repetitive periodic behavior in the system such as
temperature, operator fatigue, regular rotation of operators and/or machines, or
fluctuation in voltage or pressure or some other variable in the production
equipment.
R charts will sometimes reveal cycles because of maintenance schedules, operator
fatigue, or tool wear resulting in excessive variability.

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Mixture Pattern

• A mixture is indicated when the plotted points tend to fall near or slightly outside
the control limits, with relatively few points near the center line.
• Sometimes mixtures result from “overcontrol,” where the operators make process
adjustments too often, responding to random variation in the output rather than
systematic causes.
• A mixture pattern can also occur when output product from several sources (such
as parallel machines) is fed into a common stream which is then sampled for
process monitoring purposes
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Trend Pattern

Trend, or continuous movement in one direction, is shown on the

control chart. Trends are usually due to a gradual wearing out or
deterioration of a tool or some other critical process component.
They can also result from human causes, such as gradual
improvement in operator skill resulting from on-the-job training, or a
decrease in operator skill due to fatigue operator.

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Shift Pattern

Reasons: introduction of new workers; changes in methods, raw materials, or

machines; a change in the inspection method or standards; or a change in either
the skill, attentiveness, or motivation of the operators.
Sometimes an improvement in process performance is noted following
introduction of a control chart program

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Stratification Pattern

Stratification, or a tendency for the points to cluster artificially around the center
line. We note that there is a marked lack of natural variability in the observed
pattern.
One potential cause of stratification is incorrect calculation of control limits. This
pattern may also result when the sampling process collects one or more units from
several different underlying distributions within each subgroup.

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Control Charts for individual units

• Situations:
• The rate of production is low, it is not feasible for a
sample size to be greater than 1.
• Additionally, if the testing process is destructive and the
cost of the item is expensive, the sample size might be
chosen to be 1.
• Solution:
• The variability of the process is estimated from the
moving range (MR), found from two successive
observations.

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Drawing MR chart

For n=2, D4=3.267, D3=0

For n=2, d2=1.128

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Example

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BITS Pilani, K K Birla Goa Campus
MR charts

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