QUALITY CONTROL

ENGINEERING
(TI 184517)

WEEK #5
MANUFACTURING SYSTEMS LABORATORY
DEPARTMENT OF INDUSTRIAL ENGINEERING
©2021
OBJECTIVES

Our objectives for this section are to learn how to use control charts to monitor continuous data,
and the assumptions behind the charts, their application, and their interpretation.
INTRODUCTION (3)
INTRODUCTION
• An attribute is a quality characteristic for which a numerical value is not specified.
• It is measured in a nominal scale.
• For instance, the taste of a certain dish is labeled as: acceptable or unacceptable, or is
categorized as exceptional, good, fair, or poor.
• A quality characteristic that does not meet certain prescribed standards (or specifications) is said
to be a nonconformity (or defect).
• A product with one or more nonconformities is a nonconforming item (or defective).
ADVANTAGES

• Certain quality characteristics are best measured as attributes. For instance: the taste of food.
• There are circumstances in which a quality characteristic can be measured as variable but is
instead measured as an attribute because of limited time, money, worker availability, or other
resources. For example: the inside of a hole diameter (using go/no-go gage instead of micrometer).
• Attributes are encountered at all levels of an organization, while variables are typically used at the
lowest level, i.e. machine level.
DISADVANTAGES

• Attribute information does not state the degree to which specifications are met or not met.
• Example: for item with specification limit of 20 ± 0.1 mm; both 20.2 and 22.3 are classified
as nonconforming.
• Variable plots generally provide more information as to the potential causes and hence make
identification of remedial actions easier.
• A variable chart can indicate an upcoming out-of-control condition even though items are not yet
nonconforming.
• Attribute chart requires larger sample size to ensure adequate protection against a certain level
of process changes, while larger sample sometimes can be problematic.
THE VARIABLE CHART FOREWARN US WHEN THE PROCESS IS ABOUT
TO GO OUT OF CONTROL . . .
μ1 : Target value
μ2 : Variable chart reacts to change in process mean
μ3 : Attribute chart reacts

Proportion of
nonconforming
item

Lower Upper
specification specification
limit limit
PRELIMINARY DECISIONS

• If no historical information is available, use attribute charts. As problem areas are identified, the
attributes may be replaced by variables to collect more specific information.
• The choice of sample size is important.
• For situations in which summary measures are required (i.e. higher level of management), attribute
charts are preferred.
• On the other hand, variable charts are more meaningful at the operator or supervisor level
because they provide specific clues for remedial actions.
• What is going to constitute a nonconformity should be properly defined. This definition will depend
on the product, its functional use, and customer needs.
CHART FOR PROPORTION NONCONFORMING (P-CHART)

• Based on binomial distribution:

• The probability of obtaining a nonconforming item must remain constant from item to item.
• The sample must be identical and are assumed to be independent.
• The proportion and the distribution of the number of nonconforming items in a sample:

x
p= Note: X is number of nonconforming item, n is number of sampel
n
n!
P(X = x) = p x (1- p)n-x , x = 0, 1, 2, . . . , n
(n - x)!x!
CHART FOR PROPORTION NONCONFORMING (P-CHART)

• Mean and variance of the sample proportion are as follow:

E( p) = p
p(1- p)
Var( p) =
n

• These measures are used to determine the center line and control limits for p-Chart.
• A p-chart is one of the most versatile control charts as it can be used in many levels.
CHART FOR PROPORTION NONCONFORMING (P-CHART)

• P Chart digunakan untuk mengukur proporsi ketidaksesuaian dari item-item dalam

kelompok yang sedang diinspeksi.

• P chart digunakan untuk mengendalikan proporsi produk cacat yang dihasilkan dalam
suatu proses.
CONSTRUCTING A P-CHART

Step 1: Select the objective

Select on the level it will be used, and
Step 2: Determine the sample size and decide to control either a single
the sampling interval characteristic, multiple, a single product,
or a number of products.

Step 3: Obtain the data and record on an

A bound for the sample size can be
appropriate form
obtained using this guidelines:

Step 4: Calculate the center line and the n p ³ 5 or n > 5

trial control limits p

Step 5: Calculate the revised control Plot the values. Examine whether the
limits
process is in control.

Step 6: Implement the chart

STEP 4: CALCULATING THE CENTER LINE AND THE TRIAL
CONTROL LIMITS

No standard specified Standard specified

If target value is known or specified, the

p(1 − p) center line is selected as the target value.
UCL p = p + 3
n
p0 (1- p0 )
UCL p = p0 + 3
g g

 p x i i n
CL p = p = i =1
= i =1
CL p = p0
m n.m
p(1 − p) p0 (1- p0 )
LCL p = p − 3 LCL p = p0 - 3
n n

• If the lower control limit for p turns out to be negative, it is simply counted as zero.
• When sample sizes vary, control limits can be constructed for individual sample
using ni or using average sample size n-bar
EXAMPLE

Twenty five observations with samples of size 50 are chosen from a plastic injection molding
machine producing small containers. The number of nonconforming containers for each sample is
shown in the Table (next page). Determine the center line and limits.

If the chart limits need revision, find the revised center line and control limits.
 Number of Number of
Oberservation Date Time inspected nonconforming
items (n) items (x)
1 6-Oct 8:30 50 4
2 6-Oct 9:30 50 2
3 6-Oct 10:00 50 5
4 6-Oct 10:20 50 3
5 7-Oct 8:40 50 2
6 7-Oct 9:50 50 1
7 7-Oct 10:10 50 3
8 7-Oct 10:50 50 2
9 8-Oct 9:10 50 5
10 8-Oct 9:40 50 4
11 8-Oct 10:40 50 3
12 8-Oct 11:20 50 5
13 9-Oct 8:20 50 5
14 9-Oct 9:10 50 2
15 9-Oct 9:50 50 3
16 9-Oct 10:20 50 2
17 10-Oct 8:40 50 4
18 10-Oct 9:30 50 10
19 10-Oct 10:10 50 4
20 10-Oct 11:30 50 3
21 11-Oct 8:20 50 2
22 11-Oct 9:10 50 5
23 11-Oct 9:50 50 4
24 11-Oct 10:20 50 3
25 11-Oct 11:30 50 4
1250 90
SOLUTION

90
CL p = p = = 0.072
1250
p(1- p) 0.072(1- 0.072)
UCL p = p + 3 = 0.072 + 3 = 0.182
n 50
p(1- p) 0.072(1- 0.072)
LCL p = p - 3 = 0.072 - 3 = -0.38 ® 0
n 50

Based on the limits, sample 18 is deleted.

P CHART
SOLUTION

The revised center line and control limits are then:

90 -10
CL p = p = = 0.067
1250 - 50
p(1- p) 0.067(1- 0.067)
UCL p = p + 3 = 0.067 + 3 = 0.173
n 50
p(1- p) 0.067(1- 0.067)
LCL p = p - 3 = 0.067 - 3 = -0.39 ® 0
n 50
P CHART
EXAMPLE 2
Management has decided to set a standard of 3% for the proportion of nonconforming test tubes
produced in a plant. Data collected from 20 observations with 100 sample size, are shown below.
Draw a control chart for the situation.
Observations n x p Observations n x p
1 100 4 0.04 11 100 9 0.09
2 100 2 0.02 12 100 3 0.03
3 100 5 0.05 13 100 3 0.03
4 100 3 0.03 14 100 4 0.04
5 100 6 0.06 15 100 2 0.02
6 100 4 0.04 16 100 5 0.05
7 100 3 0.03 17 100 3 0.03
8 100 9 0.09* 18 100 1 0.01
9 100 5 0.05 19 100 4 0.04
10 100 6 0.06 20 100 3 0.03

*die not aligned

CHART FOR NUMBER OF NONCONFORMING ITEMS (NP-
CHART)

• As an alternative to the proportion nonconforming, we can count the number of

nonconforming items in samples and use it as the basis for the control chart.
• The assumptions made for the construction of p-charts apply to np-charts.
• There is one drawback to the np-chart: if sample size changes, the center line and control
limit change as well. Making inferences in such circumstances is difficult.
• Thus, it should not be used when sample varies.

Diagram kontrol NP menggunakan ukuran banyaknya item yang tidak memenuhi spesifikasi atau banyaknya
item yang tidak sesuai dalam suatu pemeriksaan
CONSTRUCTING NP-CHART
No standard specified Standard specified
If target value is known or specified,
UCL p = p + 3s np the center line is selected as the
target value.
CL p = n p
UCL p = p0 + 3np0
LCL p = p - 3s np
CL p = np0
where s np = n p(1- p)
LCL p = p0 - 3np0
where np0 = np0 (1- p0 )

If the lower control limit calculation yields negative, it is converted to zero.

 Number of Number of
Oberservation Date Time inspected nonconforming
items (n) items (x)
1 6-Oct 8:30 50 4
2 6-Oct 9:30 50 2
3 6-Oct 10:00 50 5
4 6-Oct 10:20 50 3
5 7-Oct 8:40 50 2
6 7-Oct 9:50 50 1
7 7-Oct 10:10 50 3
8 7-Oct 10:50 50 2
9 8-Oct 9:10 50 5
10 8-Oct 9:40 50 4
11 8-Oct 10:40 50 3
12 8-Oct 11:20 50 5
13 9-Oct 8:20 50 5
14 9-Oct 9:10 50 2
15 9-Oct 9:50 50 3
16 9-Oct 10:20 50 2
17 10-Oct 8:40 50 4
18 10-Oct 9:30 50 10
19 10-Oct 10:10 50 4
20 10-Oct 11:30 50 3
21 11-Oct 8:20 50 2
22 11-Oct 9:10 50 5
23 11-Oct 9:50 50 4
24 11-Oct 10:20 50 3
25 11-Oct 11:30 50 4
1250 90
CONSTRUCT THE NP CHART
REVISION OF NP CHART
CHART FOR THE NUMBER OF NONCONFORMITIES (C-
CHART)
• A nonconformity is defined as a quality characteristic that does not meet some specification.
• A nonconforming item has one or more nonconformities that make it nonfunctional.
• p-charts and np-charts deal with nonconforming items, while c-chart is used to track the total number of
nonconformities in samples of constant size.
• When the sample varies, a u-chart is used to track the number of nonconformities per unit.
• The occurrence of nonconformities is assumed to follow a Poisson Distribution.
• If x represents the number of nonconformities in the sample unit c is the mean, then the Poisson
distribution yields:
-c x
e c
p(x) =
x!
Diagram kontrol C atau C chart yang didasarkan pada banyaknya titik spesifik yang tidak memenuhi syarat dalam
suatu item..
CONSTRUCTING C-CHART

No standard specified Standard specified

UCL c = c + 3 c UCL c = c0 + 3 c0
CL c = c CL c = c0

LCL c = c - 3 c LCL c = c0 - 3 c0
EXAMPLE
Samples of fabric from a textile mill, each 100 m2 are selected, and the number of
occurrences of foreign matter are recorded. Data for 25 samples are shown below.
Construct a c-chart for the number of nonconformities.
Observ Nonconformities Observ Nonconformities
1 5 14 11
2 4 15 9
3 7 16 5
4 6 17 7
5 8 18 6
6 5 19 10
7 6 20 8
8 5 21 9
9 16 22 9
10 10 23 7
11 9 24 5
12 7 25 7
13 8
SOLUTION
• The center line is given:

189
CL c = c = = 7.560
25
• The control limits are:

UCL c = c + 3 c = 7.560 + 3 7.560 =15.809

LCL c = c - 3 c == 7.560 - 3 7.560 = -0.689 ® 0
SOLUTION

Sample 9 is deleted;
UCL c = c + 3 c = 7.208 + 3 7.208 =15.262
189 -16
CL c = c = = 7.208 LCL p = c - 3 c == 7.208 - 3 7.208 = -0.846 ® 0
24
CHART FOR NUMBER OF NONCONFORMITIES PER UNIT
(U-CHART)
• A c-chart is used when the sample size is constant. For situations in which the sample size varies,
a u-chart is used.
• For variable sample size and no specified standard:

åc i u
CL u = i=1 UCL u = u + 3
g ni
ån i
u
i=1
LCL u = u - 3
ni
CHART FOR DEMERITS PER UNIT (U-CHART)

• The c and u-charts treat all types of nonconformities equally, regardless of their degree of severity.
• An alternative approach assign weights to nonconformities according to their relative degree of
severity. These are often helpful in service applications.
• Classification of nonconformities (by the ANSI/ASQC standard A3, 1978):
1. Class 1 defects – very serious. Defects that lead directly to severe injury or to catastrophic
economic loss.
2. Class 2 defects – serious. Defects that lead to significant injury or to significant economic loss.
3. Class 3 defects – major. Defects that can cause major problems with normal use of a product
or service rendered.
4. Class 4 defects – minor. Defects that can cause minor problems with normal use of a product
or service rendered.
CONSTRUCTING CHART FOR DEMERITS PER UNIT (U-CHART)

• An organization may establish their own classification.

• The number of categories and the definitions of each should relate specifically to the
problem environment.
• The demerits per unit for the sample are given by:

D w1c1 + w2 c2 + w3c3 + w4c4

U= =
n n

• While center line and limits are:

CLU = U = w1 m1 + w2 m 2 + w3 m 3 + w4 m 4
w12m1 + w 22 m 2 + w32 m 3 + w 24 m 4
LCLU = U + 3s U where s U =
n
UCLU = U - 3s U
EXAMPLE

A department store obtains feedback on customer satisfaction regarding a certain product. Twenty
observations, each involving 10 customers, are taken in which customers are asked about the
number of serious, major, and minor nonconformities that they have experienced. Clear definitions
of each category are provided. The weights assigned to serious, major, and minor nonconformity are
50, 10, and 1 respectively. Construct a control chart for the number of demerits per unit.
 Serious Major Minor Total Demerits
Observati
Nonconformities Nonconformities Nonconformities Demerits per unit
on
c1 c2 c3 D U
1 1 4 2 92 9.2
2 0 3 8 38 3.8
3 0 5 10 60 6
4 1 2 5 75 7.5
5 0 6 2 62 6.2
6 0 0 8 8 0.8
7 0 7 5 75 7.5
8 1 1 1 61 6.1
9 1 3 2 82 8.2
10 0 4 12 52 5.2
11 1 5 3 103 10.3
12 2 0 2 102 10.2
13 0 0 9 9 0.9
14 0 6 8 68 6.8
15 1 12 10 180 18
16 0 5 7 57 5.7
17 0 1 1 11 1.1
18 1 2 5 75 7.5
19 0 5 6 56 5.6
20 0 3 8 38 3.8
Total 9 74 114
SOLUTION

9 74 114
u1 = = 0.045 u2 = = 0.37 u3 = = 0.57
200 200 200
The center line is given:

U = 50(0.045) + 10(0.37) + 1(0.57) = 6.52

With estimated standard deviation:

50 2 (0.045) + 10 2 (0.37) + 12 (0.57)

U = = 3.874
10

The control limits are:

UCLU = 6.52 + 3(3.874) = 18.142
LCLU = 6.52 − 3(3.874) = −5.102 → 0
SOLUTION
EXERCISE
The number of nonconforming cables is found for 20 samples of size 100 as shown below.
Construct a control chart for the problem. Revise the control limits, assuming special causes
for points outside the control limits.

Number of Number of
Sample nonconforming Sample nonconforming
cables cables
1 2 11 5
2 5 12 4
3 4 13 2
4 3 14 5
5 4 15 3
6 2 16 12
7 3 17 3
8 2 18 2
9 4 19 5
10 11 20 2
EXERCISE (CONT’D)

If the desired standard for the nonconformance rate is set by the management at 3%,
establish the control limits for this standard. Comment on the ability of the process to meet
this standard.

If management were to set the standard at 2% for improvement, can the process meet this
goal? What action would you recommend?
THANK YOU