Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 1

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery.
1
Copyright (c) 2013 John Wiley & Sons, Inc.
Learning Objectives
Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 2

15.1 The Acceptance Sampling Problem
Typical application of acceptance sampling is for lot disposition, sometimes
referred to as lot sentencing, for receiving inspection activities
Accepted lots are put into production
Rejected lots may be returned to supplier or subjected to other lot-
disposition action
Sampling methods may also be used during various stages of production

Situations where acceptance sampling is likely to be useful:

Types of sampling plans
• One major classification is by data type, variables and attributes
• Another is based on the number of samples required for a decision. These include:
– Single-sampling plans
– Double-sampling plans
– Multiple-sampling plans
– Sequential-sampling plans
• Single-, double-, multiple-, and sequential sampling plans can be designed to
produce equivalent results. Factors to consider include:
– Administrative efficiency
– Type of information produced by the plan
– Average amount of inspection required by plan
– Impact of the procedure on manufacturing flow

Lot Formation
There are a number of important considerations informing lots for inspection,
including:
• Lots should be homogeneous.
• Larger lots are preferred over smaller ones.
• Lots should be conformable to materials-handling systems used in both
supplier and consumer facilities.

Random Sampling
• Another possibility would be to use a three-digit random number to
represent the length, width, and depth in a container.
• Sometimes the inspector may stratify the lot. This consists of dividing the
lot into strata or layers and then subdividing each strata into cubes, as
shown in Fig. 15.1. Units are then selected from within each cube.
• Although this stratification of the lot is usually an imaginary activity
performed by the inspector and does not necessarily ensure random
samples, at least it ensures that units are selected from all locations in the
lot.

Random Sampling
• The units selected for inspection from the lot should be chosen at random,
and they should be representative of all the items in the lot.
• The random-sampling concept is extremely important in acceptance
sampling. Unless random samples are used, bias will be introduced.
• For example, the supplier may ensure that the units packaged on the top of
the lot are of extremely good quality, knowing that the inspector will select
the sample from the top layer.
– “Salting” a lot in this manner is not a common practice, but if it occurs and nonrandom-
sampling methods are used, the effectiveness of the inspection process is destroyed.
• The technique often suggested for drawing a random sample is to first
assign a number to each item in the lot. Then n random numbers are drawn,
where the range of these numbers is from 1 to the maximum number of
units in the lot.
– If products have serial or other code numbers, these numbers can be used to avoid the
process of actually assigning numbers to each unit.

15.1.5 Guidelines for Using Acceptance Sampling
• An acceptance-sampling plan consists of sample size (n) and acceptance/rejection
criteria (c) for lot sentencing
• An acceptance-sampling scheme is a set of procedures consisting of acceptance-
sampling plans in which lot sizes, sample sizes, and acceptance/rejection criteria
along with amount of 100% inspection and sampling are related
• A sampling system is a unified collection of one or more schemes
• The selection of an acceptance-sampling procedure depends on both the
objective of the sampling organization and the history of the organization
whose product is sampled.
• Furthermore, the application of sampling methodology is not static; that is,
there is a natural evolution from one level of sampling effort to another.
Percentage of application of various quality-assurance techniques as

a function of the maturity of the business organization
Chapter 15 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 12
Effect of n and c on OC curves:

• The poorest quality level for the supplier’s process that a consumer
would consider to be acceptable as a process average is called the
acceptable quality level (AQL)
• AQL is a property of the supplier’s manufacturing process, not
a property of the sampling plan
• The protection obtained for individual lots of poor quality is

established by the lot tolerance percent defective (LTPD)
• Also called rejectable quality level (RQL) and the limiting
quality level (LQL)
• LTPD is a level of lot quality specified by the consumer, not a
characteristic of the sampling plan
• Sampling plans can be designed to have specified performance at

the AQL and the LTPD points

Other Aspects of OC Curve Behavior
The probability of acceptance begins to drop very rapidly, even for small values of the lot
fraction defective. For example, consider the sampling plans in Fig. 15.5. Suppose the
acceptable quality level is 1%.
This implies that we would like to accept lots that are 1% defective or better.
• If sampling plan n = 89, c = 1 is used, the probability of lot acceptance at the AQL is
about 0.78.
• On the other hand, if the plan n = 89, c = 0 is used, the probability of acceptance at the
AQL is approximately 0.41. That is, nearly 60% of the lots of AQL quality will be
rejected if we use an acceptance number of zero.
AOQL is the maximum
point on the curve

15.3 Double, Multiple and Sequential Sampling

Advantage of a double-sampling plan over single sampling is that it may reduce total
amount of required inspection
Suppose first sample in a double-sampling plan is smaller than for a single-sampling plan
If lot is accepted or reject on first sample, cost of inspection is lower
Also possible to reject a lot without completing inspection of second sample

The OC Curve:
See textbook for

calculations

The ASN with curtailment:
In practice, inspection of the second sample is usually terminated and the lot
rejected as soon as the number of observed defective items in the combined sample
exceeds the second acceptance number c2.
This is referred to as curtailment of the second sample.
• The use of curtailed inspection lowers the average sample number required in
double-sampling.
• It is not recommended that curtailment be used in single-sampling, or in the first
sample of double-sampling, because it is usually desirable to have complete
inspection of a fixed sample size in order to secure an unbiased estimate of the
quality of the material supplied by the supplier.

Refer to Table 15.3 in the textbook (p. 654) for an example

Sampling procedure for inspection by attributes developed during World War II and is
the most widely used acceptance-sampling system for attributes in the world today
A collection of sampling schemes; therefore an acceptance-sampling system
Provides for three types of sampling: single, double, and multiple
Primary focal point is the acceptable quality level (AQL)
Different AQLs may be designated for different types of defects: critical, major,
and minor
Generally specified in contract or by authority responsible for sampling
Sample size is determined by lot size and by choice of inspection level

• The AQL is generally specified in the contract or by the
authority responsible for sampling.
• Different AQLs may be designated for different types of
defects.
• For example, the standard differentiates critical defects, major
defects, and minor defects.
• It is relatively common practice to choose an AQL of 1% for
major defects and an AQL of 2.5% for minor defects.
• No critical defects would be acceptable.

• The sample size used in MIL STD 105E is determined by the
lot size and by the choice of inspection level.
• Three general levels of inspection are provided.
– Level II is designated as normal.
– Level I requires about one-half the amount of inspection as Level II and
may be used when less discrimination is needed.
– Level III requires about twice as much inspection as Level II and
should be used when more discrimination is needed.
– There are also four special inspection levels, S-1, S-2, S-3, and S-4.
The special inspection levels use very small samples and should be
employed only when the small sample sizes are necessary and when
greater sampling risks can or must be tolerated.

Refer to Tables 15.5, -6 and -7 in the textbook on pp. 658 – 660.

15.4.3 Discussion
• Several points about MIL STD 105E should be
emphasized:
– MIL STD 105E is AQL-oriented
– Not all possible sample sizes are possible
(2,3,5,8,13,20,32,50, etc.)
– Sample sizes are related to lot sizes
– Switching rules are subject to criticism for both
misswitching between inspection plans and
discontinuation even though there has been no actual
quality deterioration
– But a flagrant and common abuse of MIL STD 105E is
failure to use the switching rules at all
AOQL Plans:
•Dodge-Romig (1959) tables give AOQL sampling plans for specified

AOQL values
•Six classes of values for process average are specified for various lot
sizes
•Tables are available for both single and double sampling
•Designed so that average total inspection at a given AOQL and
process average is approximately a minimum
•Refer to Table 15.8 for an example
LTPD Plans:
•Dodge-Romig LTPD tables are designed so that the probability of lot
acceptance at the LTPD is 0.1
•Tables are provided for various LTPD values
•Six classes of values for process average are specified for various lot
sizes
•Refer to Table 14-9 for an example


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Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery.

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 2

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 3

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 4

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 7

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 8

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 9

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 10

Percentage of application of various quality-assurance techniques as

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 16

• The protection obtained for individual lots of poor quality is

• Sampling plans can be designed to have specified performance at

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 17

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 24

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 28

If lot is accepted or reject on first sample, cost of inspection is lower

Also possible to reject a lot without completing inspection of second sample

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 29

See textbook for

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 30

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 34

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 41

A collection of sampling schemes; therefore an acceptance-sampling system

Provides for three types of sampling: single, double, and multiple

Primary focal point is the acceptable quality level (AQL)

Generally specified in contract or by authority responsible for sampling

Sample size is determined by lot size and by choice of inspection level

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 43

Chapter 15 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 44

Chapter 15 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 45

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 50

•Dodge-Romig (1959) tables give AOQL sampling plans for specified

Chapter 15 Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 54

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