by Mohammed Aashiq 12PGDT06, M. Sundaresan 12PGDT10.

Introduction
It has become a trend to purchase products with high quality. This is because of the increase in the literacy level of the customers. Hence it becomes necessary for the manufacture to produce products with high accuracy.

Introduction

cont.,

It is possible to produce high quality products by

Introducing quality in the process being adopted for manufacturing. Adopting a process of manufacturing which is repeatable.

The process adopted for manufacturing should have capability to operate with limited variability which is set around the specified tolerances of the product.

Introduction

cont.,

For this reason only , the subject of SQC and SPC are introduced into the field of E&T. In the subject of SQC a number of SQC charts have been developed. These charts are though simple they serve as a powerful means in solving problems related to process stability and improvement of capability by reducing the variability in the process adopted .

Introduction

cont.,

The control charts are widely being used in all types of industries throughout the world to improve the quality of the product and also to reduce certain unwanted cost. It should be noted that these control charts can be used for controlling the characteristics of any kind of process.

Objectives of Control Charts

The macro level objectives of control charts used for process control are as follows.
To detect at the earliest the cause for process shifts , so that corrective measure are initiated at the earliest. Rejections are minimized .
Control or not Reduce the cost involved in inspection Improve existing production procedures. To find process is capable (spec). To establish new spec.

Variable data and Attribute data

Variable data :
Whenever the quality characteristic is measured actually by the use of inspection instruments and recorded , the quality is said to be expressed by variables.
Eg: Dia of shaft is 25.310 mm. Operating temp in degree C. Hardness in Rockwell units.

Variable data and Attribute data cont.,

Attribute data :
When a record shows only the number of articles conforming and the number of articles failing to confirm to any specified requirement , it is said to be a record by attribute.
Eg: Go , NOGO gauges Avg height of INDIANS is 6 feet

Types of control charts

Control charts may be classified into two general categories depending upon the quality characteristic used for process control. Some quality characteristics can be measured as variable data and some other quality characteristics can be only differentiated as either conforming or non-conforming to given specifications.

Types of control charts cont.,

So,
Control charts for variables .
Control charts for attributes.

Generally , control chart is the simplest statistical technique and are used in online statistical process control.

Control charts for Variables

There are two types of control charts used for variable data namely, X-Bar and R Chart X-Bar and S Chart
Where ,
X-Bar R S - Sample mean - Range - Sample standard deviation.

Steps for calculating and plotting an X-Bar and R Control Chart

The X-Bar (arithmetic mean) and R (range) Control Chart is used with variables data when subgroup or sample size is between 2 and 10. The steps for constructing this type of Control Chart are: Step 1 : Inspect the component . When the process achieves the process-in-control stage , start collecting data (measurement)

Steps Continued
Step 2 - Collect and enter the data by subgroup. A subgroup is made up of variables data that represent a characteristic of a product produced by a process. The sample size relates to how large the subgroups are. Enter the individual subgroup measurements in time sequence in the portion of the data collection section of the Control Chart labeled MEASUREMENTS

Steps Continued
Step 3 : Calculate and enter the average for each subgroup. Use the formula below to calculate the average (mean) for each subgroup and enter it on the line labeled Average in the data collection section

Steps Continued

Steps Continued
Step 4 - Calculate and enter the range for each subgroup. Use the following formula to calculate the range (R) for each subgroup. Enter the range for each subgroup on the line labeled Range in the data collection section. RANGE =(Largest Value in each Subgroup) (Smallest Value in each Subgroup)

Example

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Step 5 - Calculate the grand mean of the subgroups average. The grand mean of the subgroups average (XBar) becomes the centerline.

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Step 6 - Calculate the average of the subgroup ranges.

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Step 7 - Calculate the upper control limit (UCL) and lower control limit (LCL) for the averages of the subgroups.

Control limits define the parameters for determining whether a process is in statistical control.

Steps continued
To find the X-Bar control limits, use the following formula:

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Step 8 - Calculate the upper control limit for the ranges. When the subgroup or sample size (n) is less than 7, there is no lower control limit. To find the upper control limit for the ranges, use the formula:

Steps continued

Steps continued
Step 9 - Select the scales and plot the control limits, centerline, and data points, in each plotting area. The scales must be determined before the data points and centerline can be plotted. Once the upper and lower control limits have been computed, the easiest way to select the scales is to have the current data take up approximately 60 percent of the vertical (Y) axis. The scales for both the upper and lower plotting areas should allow for future high or low out-of control data points.

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Step 10 - Provide the appropriate documentation. Each Control Chart should be labeled with who, what, when, where, why, and how information to describe where the data originated, when it was collected, who collected it, any identifiable equipment or work groups, sample size, and all the other things necessary for understanding and interpreting it. It is important that the legend include all of the information that clarifies what the data describe.