Control Charts

Control charts allow a company ’s performance over time to

be analyzed by combining performance data, average, range
and standard deviation.
Control charts usually used to analyze a process the
company performs.
Control Charts
As long as the points remain between the lower and upper control
limits, we assume that the observed variation is controlled variation
and that the process is in control
Why Use Control Charts?
• Monitor process variation over time
• Differentiate between special cause and common cause variation
• Assess effectiveness of changes
• Communicate process performance
Four sources of variables
There are four factors that contribute to these variables. They are
Processes, materials, operators and miscellaneous factors. The source
of miscellaneous variations includes environmental factors
such as
light,
Heat,
radiation and
 humidity .
TYPES OF VARIATIONS
Special Cause Outside the process (extraordinary)
Assignable causes - “special cause”
• variation due to outside influences
• if present, the process is “out of control”
Common Cause In the process (normal noise)
Chance causes - “common cause”
• inherent to the process or random and not controllable
• if only common cause present, the process is considered stable or “in
control”
Assignable causes of variations
Assignable causes are larger in magnitude and can be easily traced and
detected.
Reasons for assignable causes
i) Differences in machines
Ii) Differences among materials
Iii) Differences among processes
Iv) Differences in each of these factors over time, and
v) Differences in their relationship to one another.
The prime objective of a control chart is detecting assignable causes of
variation by analyzing data ( say, in length, diameter, weight, or a part).
Once the assignable causes of variations are identified and eliminated through
remedial actions, the process becomes statistically control.
 Chance causes of variations
Chance causes of variations are inevitable in any process. These are
difficult to trace and control even under best conditions of production.
All occur at random.
Random variables cannot be avoided. They are caused by factors such
as variability from one operation cycle to the next, minor variations in
raw material, fluctuations in working conditions, and lack of
supervision skills.
 Distinction between Chance and Assignable causes of variables
Chance Causes Assignable Causes
(i) Consist of many individual causes. Consists of one or just a few individual causes.
(ii) Any one chance causes results in only a minute
amount of variation. (However, many of the chance Any one assignable cause can result in a large
causes act simultaneously so that the total amount amount of variation.
of chance variation is substantial).

(lit) Some typical chance causes of variation are :

(a) Slight variations in raw material Some typical assignable causes of variation are :
(b) Slight vibration of machine Batch of defective raw material
(c) Lack of human perfection in reading instruments Faulty set up Untrained operator
and setting controls.

The presence of assignable variation can be

(jy) As a practical matter, chance variation cannot
detected and action to eliminate the causes is
economically be eliminated from a process.
usually justified.
Examples of common-cause and special-cause variation
Common cause of
Process
variation
Baking a loaf of bread The oven's thermostat
allows the temperature to
drift up and down slightly.
Recording customer An experienced operator
contact information makes an occasional
error.
Injection molding of Slight variations in the
plastic toys plastic from a supplier
result in minor variations
in product strength from
batch to batch.
Special cause of variation
Changing the oven's
temperature or opening the
oven door during baking can
cause the temperature to
fluctuate needlessly
An untrained operator new to
the job makes numerous
data-entry errors.
Changing to a less reliable
plastic supplier leads to an
immediate shift in the strength
and consistency of your final
product.
 Types of control charts
I) Control charts for variables  require a measurement of the quality
characteristics of interest.
The quality characteristics which can be measured and expressed in specific units
of measurements are called variables.
The three most common types of variables control charts are the x-charts, R-charts
and s- charts.

S – Chart
Quality characteristic measurement within one subgroup
Many factors contribute to variation
Source of variation - combination of equipments, materials,
environment, operator, etc.
Equipment  tool wear, electrical fluctuations for welding
Material  tensile strength, moisture content (e.g. raw material)
Environment temperature, light, humidity etc.
Operator  method, SOP followed, motivation level, training
Inspection  inspector, inspection equipment, environment
Example of Control charts
X – Charts – is used to monitor the centering of te process to control its accuracy.
Measurements such as the concentration of hazardous materials in the air,
the number of days it takes to return from an accident or the number of accidents
per period.
R – Chart – monitors the dispersion or precision of the process.
II) Control charts for attributes  require a determination of whether a part is
defective or how many defects are there in the sample.
If the data in each subgroup was collected under “homogeneous conditions”, then the Ranges
should reflect only Common Cause. The chart should not indicate the presence of Special Cause.
 Variable Control Chart – x (average)- R chart
Variable control chart – monitor measured data quality characteristic
Steps
◦ Select quality characteristic
◦ Choose rational subgroup
◦ Collect data
◦ Determine trial limits and central line
◦ Establish revised central line and control limits
◦ Achieve the objective