Professional Documents
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Quality Control
10-2
Quality Control
Quality Control
Quality control is a process that measures
output relative to standard, and acts when
output doesn't meet standards.
The purpose of quality control is to assure that
processes are performing in an acceptable
manner.
Companies accomplish quality control by
monitoring process output using statistical
techniques.
10-3
Quality Control
Inspection
before/after
production
Acceptance
sampling
The least
progressive
Inspection and
corrective
action during
production
Process
control
Quality built
into the
process
Continuous
improvement
The most
progressive
10-4
Quality Control
Inspection
Inspection is an appraisal activity that compares
goods or services to a standard.
Inspection can occur at three points:
- before production: is to make sure that inputs
are acceptable.
- during production: to make sure that the
conversion of inputs into outputs is proceeding
in an acceptable manner.
- after production: to make a final verification
of conformance before passing goods to
customers
10-5
Quality Control
Inspection
Inspection before and after production
involves acceptance sampling procedure.
Monitoring during the production process is
referred as process control
Inputs
Acceptance
sampling
Figure 10.2
Transformation
Process
control
Outputs
Acceptance
sampling
10-6
Quality Control
Inspection
The purpose of inspection is to provide
information on the degree to which items
conform to a standard.
The basic issues of inspection are:
1 - how much to inspect and how often
2- At what points in the process inspection
should occur.
3 - whether to inspect in a centralized or on-site
location.
4- whether to inspect attributes (counts) or
variables (measures)
10-7
Quality Control
10-8
Quality Control
Inspection Costs
Cost
Figure 10.3
Total Cost
Cost of
inspection
Cost of
passing
defectives
Optimal
Amount of Inspection
10-9
Quality Control
Finished products
10-10
Quality Control
Inspection
points
Cashier
Counter area
Eating area
Building
Kitchen
Hotel/motel Parking lot
Accounting
Building
Main desk
Supermarket Cashiers
Deliveries
Characteristics
Accuracy
Appearance, productivity
Cleanliness
Appearance
Health regulations
Safe, well lighted
Accuracy, timeliness
Appearance, safety
Waiting times
Accuracy, courtesy
Quality, quantity
10-11
Quality Control
10-12
Quality Control
10-13
Quality Control
Control Chart
10-14
Quality Control
Control Chart
Figure 10.4
Abnormal variation
due to assignable sources
Out of
control
UCL
Mean
Normal variation
due to chance
LCL
Abnormal variation
due to assignable sources
9 10 11 12 13 14 15
Sample number
10-15
Quality Control
10-16
Quality Control
10-17
Quality Control
10-18
Quality Control
Sampling Distribution
The variability of a sample statistic can be
described by its sampling distribution.
The sampling distribution is a theoretical
distribution that describe the random variability of
a sample statistic.
The goal of the sampling distribution is to
determine whether nonrandom-and thus,
correctable-source of variation are present in the
output of a process. How?
10-19
Quality Control
Sampling distribution
Suppose there is a process for filling bottles with
soft drink. If the amount of soft drink in a large
number of bottles (e.g., 100) is measured
accurately, we would discover slight differences
among the bottles.
If these amounts were arranged in a graph, the
frequency distribution would reflect the process
variability.
The values would be clustered close to the process
average, but some values would vary somewhat
from the mean.
10-20
Quality Control
10-21
Quality Control
Sampling Distribution
Figure 10.5
Sampling
distribution
Process
distribution
Mean
10-22
Quality Control
Sampling distribution
Properties
The sampling distribution exhibits much less
variability than the process distribution.
The sampling distribution has the same mean as
the process distribution.
The sampling distribution is a normal distribution
regardless of the shape of the process distribution.
(central limit theorem).
10-23
Quality Control
Where:
n = sample size
Sampling distribution
Mean =
Variance =
Standard deviation =
10-24
Quality Control
Normal Distribution
Figure 10.6
Standard deviation
Mean
95.44%
99.74%
10-25
Quality Control
Control limits
10-26
Quality Control
Control Limits
Figure 10.7
Sampling
distribution
Process
distribution
Mean
Lower
control
limit
Upper
control
limit
10-27
Quality Control
SPC hypotheses
Null hypothesis
H0: the process is in control
Alternative hypothesis
H1: the process is out of control
Actual situation
Decision
Reject H0
Dont reject H0
H0 is true
H0 is false
Type I error
Correct
Correct
Type II error
10-28
Quality Control
SPC Errors
Type I error
Type II error
10-29
Quality Control
Type I Error
Figure 10.8
/2
/2
Mean
Probability
of Type I error
LCL
UCL
10-30
Quality Control
LCL
1
2
Sample number
10-31
Quality Control
10-32
Quality Control
X-bar charts
R charts
10-33
Quality Control
The control limits of the mean chart is calculated as follows: (first approach)
x z x
x z
10-34
Quality Control
10-35
Quality Control
Mean chart
Sample
1
Observation
10-36
Quality Control
Solution
n=4
z=3
= 0.02
0.02
LCL : 12.11 3
12.08
4
10-37
Quality Control
Control chart
UCL
12.14
12.11
LCL
12.08
3
Sample
10-38
Quality Control
Mean chart
UCL x A2 R
LCL x A2 R
Where:
A2 = A factor from table 10.2 Page 441
This approach is
recommended when
the process standard
deviation is not
known
10-39
Quality Control
Example
x = 3 min. R,
10.2)
10-40
Quality Control
UCL D4 R
LCL D3 R
Where values of D3 and D4 are obtained from table
10.2 page 441
10-41
Quality Control
R-chart
Example
Twenty-five samples of n = 10 observations have been
taken from a milling process. The average sample range
was 0.01 centimeter. Determine upper and lower control
limits for sample ranges.
Solution
R = 0.01 cm, n = 10
From table 10.2, for n = 10, D4 = 1.78 and D3 = 0.22
10-42
Quality Control
R-Chart
Example
Small boxes of cereal are labeled net weight 10
ounces. Each hour, a random sample of size n = 4
boxes are weighted to check process control. Five hours
of observation yielded the following:
Time
9 A.M.
10 A.M
11 A.M
Noon
1 P.M
Box 1
9.8
10.1
9.9
9.7
9.7
Box 2
10.4
10.2
10.5
9.8
10.1
Box 3
9.9
9.9
10.3
10.3
9.9
Box 4
10.3
9.8
10.1
10.2
9.9
Range
0.6
0.4
0.6
0.6
0.4
10-43
Quality Control
R-Chart
Solution
n=4
For n = 4 , D3 = 0 and D4 = 2.28
0 .6 0 .4 0 .6 0 .6 0 .4
0.52
5
UCL D4 R 2.28(0.52) 1.1865
R
LCL D3 R 0(0.52) 0
10-44
Quality Control
10-45
Quality Control
UCL
Detects shift
x-Chart
LCL
UCL
R-chart
LCL
Does not
detect shift
10-46
Quality Control
Figure 10.10B
Sampling
Distribution
UCL
x-Chart
LCL
Does not
reveal increase
UCL
R-chart
Reveals increase
LCL
10-47
Quality Control
5.
10-48
Quality Control
10-49
Quality Control
Use of p-Charts
Table 10.3
Good or bad
Pass or fail
10-50
Quality Control
P-Charts
p (1 p )
n
10-51
Quality Control
P-Chart
p replaces p.
p
10-52
Quality Control
P-Chart
Example
An inspector counted the number of defective
monthly billing statements of a company
telephone in each of 20 samples. Using the
following information, construct a control chart
that will describe 99.74 percent of the chance
variation in the process when the process is in
control. Each sample counted 100 statements.
10-53
Quality Control
P-Chart
Example (cont.)
Sample
# of defective
Sample
# of defective
11
10
12
12
12
13
14
10
15
21
11
16
10
10
17
22
18
12
13
19
10
10
10
20
16
Total
220
10-54
Quality Control
P-Chart
Solution
Z for 99.74 percent is 3
p
^
220
0.11
20(100)
p (1 p )
0.11(1 0.11)
0.03
100
UCL p z
LCL p z
10-55
Quality Control
P-Chart
Solution (cont.)
Fraction
defective
0.20
UCL
0.11
0.02
LCL
1
10
Sample number
20
10-56
Quality Control
Use of c-Charts
Table 10.3
10-57
Quality Control
C-Chart
10-58
Quality Control
C-Chart
Control Limits
UCL c z c
LCL c z c
10-59
Quality Control
C-Chart
Example
Rolls of coiled wire are
monitored using c-chart.
Eighteen rolls have been
examined, and the number
of defects per roll has
been recorded in the
following table. Is the
process in control? Plot
the values on a control
chart using three standard
deviation control limit.
sample # of
Sample # of
defects
defects
1
2
3
4
5
6
7
8
9
3
2
4
5
1
2
4
1
2
10
11
12
13
14
15
16
17
18
1
3
4
2
4
2
1
3
1
45
10-60
Quality Control
C-Chart
Solution
Average number of defects per coil = c = 45/18 =2.5
10-61
Quality Control
10-62
Quality Control
Run Tests
10-63
Quality Control
10-64
Quality Control
Run Test
A run is defined as a sequence of observations with a
certain characteristic, followed by one or more
observations with a different characteristic.
The characteristic can be anything that is observable.
For example, in a series AAAB, there are two runs; a
run of three As followed by a run of one B.
The series AABBBA , indicates three runs; a run of
two As followed by a run of three Bs, followed by a
run of one A.
10-65
Quality Control
Run test
There are two types of run test:
1.
2.
There are three U/D and four A/B runs for the data:
25
29
42
40 35 38
U
U
D
D U
B
B
A
A
B
A
10-66
Quality Control
Counting Runs
Figure 10.12
B A
Figure 10.13
(7 runs)
B A
(8 runs)
10-67
Quality Control
1.
2.
E ( r ) med
E (r ) u / d
10-68
Quality Control
N 1
4
u/d
16 N 29
90
Z test
Z test
Z test
N 1
4
2N 1
r (
)
3
16 N 29
90
r (
Up and down
If the Ztest is
within 2 or 3;
then the process
is random;
otherwise, it is
not random
10-69
Quality Control
Run test
10-70
Quality Control
Run test
Solution
sample
mean
A/B
U/D
Sample
Mean
A/B
U/D
10
11
10.7
10.4
12
11.3
10.2
13
10.8
11.5
14
11.8
10.8
15
11.2
11.6
16
11.6
11.1
17
11.2
11.2
18
10.6
10.6
19
10.7
10
10.9
20
11.9
10-71
Quality Control
Run test
Solution (cont.)
1. A/B: 10 runs
and
U/D: 17 runs
2. Expected number of runs for each test is:
N
20
1
1 11
2
2
2 N 1 2(20) 1
13
3
3
E (r ) med
E (r ) u / d
N 1
20 1
2.18
4
u/d
16 N 29
90
16( 20) 29
1.8
90
2.22
1.8
Z med
Zu / d
10-72
Quality Control
Process Capability
Tolerances or specifications
Process variability
Process capability
10-73
Quality Control
Capability analysis
10-74
Quality Control
Process Capability
Figure 10.15
Lower
Specification
Upper
Specification
A. Process variability
matches specifications
Lower
Specification
Upper
Specification
B. Process variability
Lower
Upper
well within specifications Specification Specification
C. Process variability
exceeds specifications
10-75
Quality Control
Capability analysis
If the product doesnt meet specifications (not capable) a
manager might consider a range of possible solutions such
as:
1. Redesign the process.
2. Use an alternative process.
3. Retain the current process but attempt to eliminate
unacceptable output using 100% inspection.
4. Examine the specifications to see whether they are
necessary or could be relaxed without adversely affecting
customer satisfaction.
10-76
Quality Control
specification width
process width
10-77
Quality Control
Capability analysis
Example
A manager has the option of using any one of three
machines for a job. The machines and their standard
deviations are listed below. Determine which machines
are capable if the specifications are 10 mm and 10.8 mm.
Machine
Standard deviation
(mm)
0.13
0.08
0.16
10-78
Quality Control
Capability analysis
Solution
Capability = 6
Machine
Standard
deviation (mm)
Machine
capability
Capable
A
B
C
0.13
0.08
0.16
0.78
0.48
0.96
Yes
Yes
No
10-79
Quality Control
Capability ratio
Example
Compute the process capability ratio for each machine
in the previous example
Solution
Machine Standard Machine
deviation capability
(mm)
6
Cp
Capable
0.13
0.78
0.8/0.78= 1.03
No
B
C
0.08
0.16
0.48
0.96
0.8/0.48 = 1.67
0.8/0.96 = 0.83
Yes
No
10-80
Quality Control
Lower
specification
1.350 ppm
1.350 ppm
1.7 ppm
1.7 ppm
Process
mean
+/- 3 Sigma
+/- 6 Sigma
10-81
Quality Control
Cpk ratio
10-82
Quality Control
Cpk Ratio
Example
A process has a mean of 9.2 grams and a standard
deviation 0f 0.3 grams. The lower specification limit
is 7.5 grams and upper specification limit is 10.5
grams. Compute Cpk
Solution
1. Compute the ratio for the lower specification:
9.2 7.5 1.7
1.89
3(.3)
0. 9
1.44
3(0.3)
.9
10-83
Quality Control
10-84
Quality Control
Examples
Simplify
Standardize
Make
Design parts that can only be assembled
mistake-proof the correct way; have simple checks to
verify a procedure has been performed
correctly
Upgrade
equipment
Automate
10-85
Quality Control
Traditional
cost function
Cost
Taguchi
cost function
Lower
spec
Target
Upper
spec
10-86
Quality Control
2.
3.