Quality Control by Using Statistic

1
Statistical Quality
Control
CHAPTER OUTLINE
Learning Objectives for

Chapter 15
After careful study of this chapter, you should be able to
do the following:
1. Understand the role of statistical tools in quality improvement.
2. Understand the different types of variability, rational subgroups,
and how a control chart is used to detect assignable causes.
3. Understand the general form of a Shewhart control chart and
how to apply zone rules (such as the Western Electric rules) and
pattern analysis to detect assignable causes.
4. Construct and interpret control charts for variables such as X-bar,
R, S, and individuals charts.
5. Construct and interpret control charts for attributes such as P
and U charts.
6. Calculate and interpret process capability ratios.
7. Calculate the ARL performance for a Shewhart control chart.
8. Construct and interpret a cumulative sum and exponentiallyweighted moving average control chart.
9. Use other statistical process control problem-solving tools.
2
John Wiley & Sons, Inc. Applied Statistics and Probability for Engineers, by
15-1: Quality Improvement and

Statistics
Definitions of Quality
Quality means fitness for use
- quality of design
- quality of conformance
Quality is inversely proportional to
variability.
3
15-1: Quality Improvement and

Statistics
Quality Improvement
Quality improvement is the reduction of
variability in processes and products.
Alternatively, quality improvement is also
seen as waste reduction.
4
15-1.2: Statistical Process Control
Statistical process control is a

collection of tools that when used
together can result in process stability
and variance reduction
5
15-1.2: Statistical Process Control
The seven major tools are

1) Histogram
2) Pareto Chart
4) Cause and Effect Diagram
5) Defect Concentration Diagram
6) Control Chart
7) Scatter Diagram
8) Check Sheet
6
15-2: Introduction to Control

Charts
15-2.1 Basic Principles
A process that is operating with only

chance causes of variation present is said
to be in statistical control.
A process that is operating in the presence
of assignable causes is said to be out of
control.
The eventual goal of SPC is the elimination
of variability in the process.
7

Charts
A typical control chart has control limits set at values
such that if the process is in control, nearly all points
will lie within the upper control limit (UCL) and the
lower control limit (LCL).
Figure 15-1 A typical control
chart.
8

Charts
Figure 15-2 Process

improvement using
the control chart.
9

Charts
where
k = distance of the control limit from the center line
w = mean of some sample statistic, W.
w = standard deviation of some statistic, W.
10

Charts
Important uses of the control chart
1. Most processes do not operate in a state of statistical
control
2. Consequently, the routine and attentive use of control
charts will identify assignable causes. If these causes
can be eliminated from the process, variability will be
reduced and the process will be improved
3. The control chart only detects assignable causes.
Management, operator, and engineering action will be
necessary to eliminate the assignable causes.
11

Charts
Types of control charts
Variables Control Charts

These charts are applied to data that follow a
continuous distribution.
Attributes Control Charts

These charts are applied to data that follow a
discrete distribution.
12

Charts
Popularity of control charts
1) Control charts are a proven technique for improving
productivity.
2) Control charts are effective in defect prevention.
3) Control charts prevent unnecessary process adjustment.
4) Control charts provide diagnostic information.
5) Control charts provide information about process
capability.
13

Charts
15-2.2 Design of a Control Chart
Suppose we have a process that we assume the true
process mean is = 74 and the process standard
deviation is = 0.01. Samples of size 5 are taken
giving a standard deviation of the sample average,
is
0.01
x
0.0045
n
5
14

Charts
Control limits can be set at 3 standard

deviations from the mean in both directions.
3-Sigma Control Limits
UCL = 74 + 3(0.0045) = 74.0135
CL= 74
LCL = 74 - 3(0.0045) = 73.9865
15

Charts
Figure 15-3
X-bar control chart for piston ring diameter.

16

Charts
Choosing the control limits is equivalent to
setting up the critical region for hypothesis
testing
H0: = 74
H1: 74
17

Charts
15-2.3 Rational Subgrouping
Subgroups or samples should be selected

so that if assignable causes are present, the
chance for differences between subgroups
will be maximized, while the chance for
differences due to these assignable causes
within a subgroup will be minimized.
18

Charts
15-2.3 Rational Subgrouping
Constructing Rational Subgroups
Select consecutive units of production.
Provides a snapshot of the process.
Good at detecting process shifts.
Select a random sample over the entire sampling
interval.
Good at detecting if a mean has shifted
out-of-control and then back in-control.
19

Charts
15-2.4 Analysis of Patterns on Control Charts
Look for runs - this is a sequence of

observations of the same type (all above the
center line, or all below the center line)
Runs of say 8 observations or more could
indicate an out-of-control situation.
Run up: a series of observations are increasing

Run down: a series of observations are decreasing
20

Charts
Figure 15-4
X-bar control chart.
21

Charts
Figure 15-5 An X-bar chart with a cyclic pattern.

22

Charts
Figure 15-6 (a) Variability with the cyclic pattern. (b) Variability with the
23
cyclic pattern eliminated.

Charts
Western Electric Handbook Rules
A process is considered out of control if any of the
following occur:
1) One point plots outside the 3-sigma control limits.
2) Two out of three consecutive points plot beyond the 2sigma warning limits.
3) Four out of five consecutive points plot at a distance of
1-sigma or beyond from the center line.
4) Eight consecutive points plot on one side of the center
line.
24

Charts
Figure 15-7 The Western Electric zone rules.

25
15-3: X-bar and R or S Control

Charts
3-sigma control limits:
The grand mean:
26

Charts
The average range:
An unbiased estimator of :
27

Charts
x Control Chart (from R):
R Chart:
28

Charts
3-sigma control limits for S:
An unbiased estimator of :
29

Charts
S Chart:
Control Chart (from S ):
30

Charts
Example 15-1
31
32

Charts
Example 15-1
33

Charts
Example 15-1
Figure 15-8 Xand R
control charts for vane
opening.
34

Charts
Example 15-1
35

Charts
Example 15-1
36

Charts
Example 15-1
Figure 15-9 The S control chart for vane opening.

37

Charts
Example 15-1
38

Charts
Example 15-1
Figure 15-10
The X-bar
and R
control charts for
vane opening.
39
15-4: Control Charts for Individual

Measurements
What if you could not get a sample size greater than 1
(n =1)? Examples include
Automated inspection and measurement technology
is used, and every unit manufactured is analyzed.
The production rate is very slow, and it is
inconvenient to allow samples sizes of N > 1 to
accumulate before analysis
Repeat measurements on the process differ only
because of laboratory or analysis error, as in many
chemical processes.
The individual control charts are useful for samples of
40
sizes n = 1.

Measurements
The moving range (MR) is defined as the

absolute difference between two successive
observations:
MRi = |xi - xi-1|
which will indicate possible shifts or
changes in the process from one observation
to the next.
41

Measurements
Individuals Control Chart
42

Measurements
Interpretation of the Charts
X Charts can be interpreted similar to X-bar charts. MR charts cannot be

interpreted the same as X-bar or R charts.
Since the MR chart plots data that are correlated with one another, then
looking for patterns on the chart does not make sense.
MR chart cannot really supply useful information about process variability.
More emphasis should be placed on interpretation of the X chart.
43
15-5: Process Capability

Process capability refers to the performance of
the process when it is operating in control.
Two graphical tools are helpful in assessing
process capability:
Tolerance chart (or tier chart)
Histogram
44

Tolerance Chart
Figure 16-12 Tolerance

diagram of vane openings.
45

Histogram
Figure
15-13 Histogram for vane openings.
46

Process Capability Ratio
PCRk
47
Figure 15-14 Process

Fallout and the process
capability ratio (PCR).
48

Example 15-3
49
Figure 15-15 Mean of a six-sigma process shifts by 1.5 standard

deviations.
50
15-6: Attribute Control Charts

15-6.1 P Chart (Control Chart for Proportions)
51

Example 15-4
52

Example 15-4
Figure 15-16 P chart for a ceramic substrate.

53

Example 15-4
54

15-6.2 U Chart (Control Chart for Defects per Unit)
55

Example 15-5
56

Example 15-5
57

Example 15-5
Figure 15-17 U chart of defects per unit on printed circuit boards.

58
15-7: Control Chart Performance

Average Run Length
The average run length (ARL) is a very
important way of determining the
appropriate sample size and sampling
frequency.
Let p = probability that any point exceeds
the control limits. Then,
59
60
Figure 15-18 Process mean shift of 2.

61
15-8: Time-Weighted Charts

15-8.1 Cumulative Sum Control Chart
The cusum chart incorporates all information
in the sequence of sample values by plotting
the cumulative sums of the deviations of the
sample values from a target value.
xj
If 0 is the target for the process mean,
is
the average of the jth sample, then the
cumulative sum control chart is formed by
plotting the quantity
i
Si ( X j 0 )
j 1
62
63
Figure 15-19 Plot of

the cumulative sum
for the concentration
data, Table 15-7.
64
Figure 15-20 The cumulative sum control chart. (a) The V-mask and
scaling. (b) The cumulative sum control chart in operation.
65

15-8.1 Cumulative Sum Control Chart
CUSUM Control Chart
66

Example 15-6
67
68

Example 15-6
69

Example 15-6
Figure 15-21 The

CUSUM status chart
for Example 15-6.
70
71

15-8.2 Exponential Weighted Moving Average
Control Chart
72

Control Chart
73

Control Chart
Figure 15-22 EWMAs with =0.8 and =0.2 show a compromise

between a smooth curve and a response to a shift
74

Control Chart
EWMA Control Chart
75

Example 15-7
76

Control Chart
Figure 15-23 EWMA control chart for the Chemical Process

Concentration Data from Minitab.
77
15-9: Other SPC Problem-Solving

Tools
Pareto Diagram
Figure 15-24 Pareto

diagram for printed
circuit board defects.
78

Tools
Cause-and-effect Diagram
Figure 15-25 Cause-and-effect diagram for the printed circuit

board flow solder process.
79

Tools
Defect Concentration Diagram
Figure 15-26 Defect concentration diagram for a printed circuit

board.
80
15-10: Implementing SPC
Strategic Management of Quality

Demings 14 points
81
Important Terms & Concepts of

Chapter 15
82

Quality Control by Using Statistic

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Quality Control by Using Statistic

Uploaded by

Copyright:

Available Formats

1

Learning Objectives for

15-1: Quality Improvement and

15-1: Quality Improvement and

15-1.2: Statistical Process Control

Statistical process control is a

15-1.2: Statistical Process Control

The seven major tools are

15-2: Introduction to Control

A process that is operating with only

15-2: Introduction to Control

15-2: Introduction to Control

Figure 15-2 Process

15-2: Introduction to Control

15-2: Introduction to Control

15-2: Introduction to Control

Variables Control Charts

Attributes Control Charts

15-2: Introduction to Control

15-2: Introduction to Control

15-2: Introduction to Control

Control limits can be set at 3 standard

15-2: Introduction to Control

X-bar control chart for piston ring diameter.

15-2: Introduction to Control

15-2: Introduction to Control

Subgroups or samples should be selected

15-2: Introduction to Control

15-2: Introduction to Control

Look for runs - this is a sequence of

Run up: a series of observations are increasing

15-2: Introduction to Control

X-bar control chart.

15-2: Introduction to Control

Figure 15-5 An X-bar chart with a cyclic pattern.

15-2: Introduction to Control

15-2: Introduction to Control

15-2: Introduction to Control

Figure 15-7 The Western Electric zone rules.

15-3: X-bar and R or S Control

The grand mean:

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

x Control Chart (from R):

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

Control Chart (from S ):

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

Figure 15-9 The S control chart for vane opening.

15-3: X-bar and R or S Control

15-3: X-bar and R or S Control

15-4: Control Charts for Individual

15-4: Control Charts for Individual

The moving range (MR) is defined as the

15-4: Control Charts for Individual

15-4: Control Charts for Individual

X Charts can be interpreted similar to X-bar charts. MR charts cannot be

15-5: Process Capability

15-5: Process Capability