Professional Documents
Culture Documents
Management
Statistical Process Control
Supplement 6
S6-1
Outline
Statistical Process Control (SPC).
Acceptance Sampling.
S6-2
S6-3
Take Samples
Create
Control Chart
Inspect Sample
Is process
in control?
Yes
No
Stop Process
Find Out Why
S6-4
80
Upper control limit
60
40
20
0
13
17
Time
S6-5
21
Control Charts
Process is not in control if:
S6-6
x
Standard deviation of
x
the sample means
n
3 x 2 x 1 x
x 2 x 3 x
(mean)
95.5% of all x fall within 2 x
99.7% of all x fall within 3 x
S6-7
distribution of mean
values becomes
approximately normal
for any population
distribution.
X
X
S6-8
Continuous
Numerical Data
Categorical or
Discrete Numerical
Data
Variables
Charts
R
Chart
Attributes
Charts
P
Chart
X
Chart
S6-9
C
Chart
Quality Characteristics
Variables
Attributes
Continuous values.
Categorical or discrete
values.
S6-10
Good or Bad.
# of defects.
X Chart
Shows sample means over time.
Sample size = n.
LCLx x z x
xi
x
n
i 1
n
sample mean
at time i
= known process
standard deviation
S6-12
X Chart - Example 1
Each sample is 4 measurements.
Process mean is 5 lbs.
Process standard deviation is 0.1 lbs.
Determine 3 control limits.
0.1
UCLx 5 3
5.15
4
0.1
LCLx 5 3
4.85
4
S6-13
n=9
Hour 1
Hour Mean
Hour Mean
Sample
Weight of
1
16.1
7
15.2
Number
Oat Flakes
2
16.8
8
16.4
1
17
3
15.5
9
16.3
2
13
4
16.5
10
14.8
3
16
5
16.5
11
14.2
4
18
6
16.4
12
17.3
5
17
6
16
For 99.73% control limits, z = 3
7
15
8
17
UCLx = x + zx = 16 + 3(1/3) = 17 ozs
9
16
Mean 16.1
=
1
LCLx = x - zx
2011
Pearson
= 16 - 3(1/3) = 15 ozs
Variation due to
assignable
causes
Out of
control
17 = UCL
Variation due to
natural causes
16 = Mean
15 = LCL
| | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12 Out of
Sample number
2011
Pearson
control
Variation due to
assignable
causes
LCL x x A2 R
n
Ri
i
1
R
n
xi
i 1
sample range
at time i
sample mean
at time i
S6-16
Mean
Upper
Lower
Factor, A 2 Range, D4 Range, D3
1.880
3.268
0
1.023
2.574
0.729
2.282
0.577
2.115
0.483
2.004
0.419
1.924
0.076
0.373
1.864
0.136
0.337
1.816
0.184
10
0.308
1.777
0.223
S6-17
X Chart - Example 2
Each sample is 4 measurements.
Determine 3 control limits.
sample
1
2
3
4
5
mean
5.02
4.99
4.97
5.03
4.99
x 5.0
range.
.12
.08.
.13.
.18.
.14.
R 0.13
X Chart - Example 2
Sample Mean
5.1
5.0
Lower control limit
4.9
Time
S6-19
values
5.05, 5.00, 4.80, 4.95
5.00, 5.10, 5.10, 5.00
4.80, 5.20, 5.10, 5.00
Sample Mean
5.1
mean
4.95
5.05
5.025
range
0.25
0.10
0.40
5.0
Lower control limit
4.9
Time
S6-20
2011
Pearson
= x + A2R
= 12 + (.577)(.25)
= 12 + .144
= 12.144 ounces
From Table
S6.1
2011
Pearson
LCLx
= x + A2R
= 12 + (.577)(.25)
= 12 + .144
= 12.144 ounces
UCL = 12.144
= x - A2R
= 12 - .144
= 11.857 ounces
LCL = 11.857
2011
Pearson
Mean = 12
R Chart
Shows sample ranges over time.
Sample size = n.
LCL R D3R
sample range at
time i
Ri
i 1
n
S6-25
R Chart - Example 2
Each sample is 4 measurements.
Determine 3 control limits.
sample
1
2
3
4
5
mean
5.02
4.99
4.97
5.03
4.99
x 5.0
range
.12
.08
.13
.18
.14
R 0.13
Sample Range
R Chart - Example 2
0.3
0.2
0.1
Lower control limit
0
Time
S6-27
Sample Range
sample
6
7
8
values
5.05, 5.00, 4.80, 4.95
5.00, 5.10, 5.10, 5.00
4.80, 5.20, 5.10, 5.00
0.3
mean
4.95
5.05
5.025
range
0.25
0.10
0.40
0.2
0.1
Lower control limit
0
Time
S6-28
S6-29
S6-30
Measurement is typically
counting defectives
^p =
LCLp = p - zp^
where
p
z
p^
n
=
=
=
=
p(1 - p)
n
1
2
3
4
5
6
7
8
9
10
p=
Number
of Errors
Fraction
Defective
Sample
Number
6
5
0
1
4
2
5
3
3
2
.06
.05
.00
.01
.04
.02
.05
.03
.03
.02
11
12
13
14
15
16
17
18
19
20
80
(100)(20) =
.04
^p =
2011
Pearson
Number
of Errors
6
1
8
7
5
4
11
3
0
4
Total = 80
(.04)(1 - .04)
100
Fraction
Defective
.06
.01
.08
.07
.05
.04
.11
.03
.00
.04
= .02
Fraction defective
UCLp = 0.10
p = 0.04
10
12
14
16
Sample number
2011
Pearson
| LCLp = 0.00
18 20
Fraction defective
.11
.10
.09
.08
.07
.06
.05
.04
.03
.02
.01
.00
Possible
LCLp = p - zp^ = .04 - 3(.02) = assignable
0
causes
present
UCLp = 0.10
p = 0.04
10
12
14
16
Sample number
2011
Pearson
| LCLp = 0.00
18 20
LCLc = c - 3 c
2011
Pearson
LCLc = c - 3 c
=6-3 6
=0
UCLc = 13.35
14
Number defective
UCLc = c + 3 c
=6+3 6
= 13.35
12
10
8
6
c= 6
4
2
0 |
1
|
2
|
3
|
4
|
5
Day
2011
Pearson
|
6
|
7
|
8
LCLc = 0
|
9
Table S6.3
2011
Pearson
S6-42
Acceptance Sampling
Quality testing for incoming materials or
finished goods.
Procedure:
S6-43
Acceptance Sampling
Inspecting all items is too expensive.
The larger the sample inspected:
Key questions: