Professional Documents
Culture Documents
and Operations
Management: Eighth Edition
Manufacturing and
Services
Acceptance Sampling
– Operating Characteristic Curve
Process Control Procedures
– Variable data
– Attribute data
Process Capability
2
Basic Forms of Statistical Sampling for
Quality Control
3
Acceptance Sampling
Purposes
– Determine quality level
– Ensure quality is within predetermined level
Advantages
– Economy
– Less handling damage
– Fewer inspectors
– Upgrading of the inspection job
– Applicability to destructive testing
– Entire lot rejection (motivation for improvement)
4
Acceptance Sampling
Disadvantages
– Risks of accepting “bad” lots and rejecting “good”
lots
– Added planning and documentation
– Sample provides less information than 100-percent
inspection
5
Statistical Sampling--Data
Variable (Continuous)
– Usually measured by the mean and the standard
deviation.
6
Acceptance Sampling--Single Sampling
Plan
A simple goal
7
Risk
Acceptable Quality Level (AQL)
– Max. acceptable percentage of defectives defined by
producer.
(Producer’s risk)
– The probability of rejecting a good lot.
Lot Tolerance Percent Defective (LTPD)
– Percentage of defectives that defines consumer’s
rejection point.
(Consumer’s risk)
– The probability of accepting a bad lot.
8
Operating Characteristic Curve
1
0.9 = .05 (producer’s risk)
Probability of acceptance
0.8
0.7 n = 99
0.6 c=4
0.5
0.4
0.3 =.10
0.2 (consumer’s risk)
0.1
0
1 2 3 4 5 6 7 8 9 10 11 12
AQL LTPD
Percent defective
9
Example: Acceptance Sampling
Zypercom, a manufacturer of video interfaces, purchases
printed wiring boards from an outside vender, Procard.
Procard has set an acceptable quality level of 1% and
accepts a 5% risk of rejecting lots at or below this level.
Zypercom considers lots with 3% defectives to be
unacceptable and will assume a 10% risk of accepting a
defective lot.
10
Sorting It Out
AQL?
?
LTPD?
?
11
Example: Continued
LTPD .03
= = 3 n (AQL) = 3.286
AQL .01
c = 6, from Table
n (AQL) = 3.286, from Table
AQL = .01, given in problem
Sampling Procedure:
Take a random sample of 329 units from a lot.
Reject the lot if more than 6 units are defective.
13
The Normal Curve (Revisited)
x
Z
-3 -2 -1 0 1 2 3
Averaging
reduces
variability
x 14
Control Limits
x
LCL UCL
15
UCL
LCL
Statistical UCL
Process
Control
LCL
UCL
LCL
T o ta l N u m b e r o f D efe c tiv e s
p =
T o ta l N u m b e r o f O b se rv a tio n s
p (1 - p )
Sp =
n
UCL = p + Z sp
LCL = p - Z sp
18
1. Calculate the sample proportion, p, for each
sample.
Sample n Defectives p
1 100 4 0.04
2 50 2 0.04
3 100 5 0.05
4 100 3 0.03
5 75 6 0.08
6 100 4 0.04
7 100 3 0.03
8 50 7 0.14
9 100 1 0.01
10 100 2 0.02
11 100 3 0.03
12 100 2 0.02
13 100 2 0.02
14 100 8 0.08
15 100 3 0.03
19
2. Calculate the average of the sample proportions.
55
p= = 0.04
1375
3. Calculate the standard deviation of the
sample proportion
p (1 - p) .04(1 - .04)
sp = = = .020467
n 91.6667
20
4. Calculate the control limits.
UCL = p + Z sp
LCL = p - Z sp
.04 3(.020467)
UCL = 0.1014
21
p-Chart (Continued)
5. Plot the individual sample proportions, the average
of the proportions, and the control limits
0.16
0.14
0.12
0.1 UCL
p 0.08
0.06
0.04
0.02
0 LCL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Observation 22
Example: x-Bar and R Charts
Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5
1 10.68 10.689 10.776 10.798 10.714
2 10.79 10.86 10.601 10.746 10.779
3 10.78 10.667 10.838 10.785 10.723
4 10.59 10.727 10.812 10.775 10.73
5 10.69 10.708 10.79 10.758 10.671
6 10.75 10.714 10.738 10.719 10.606
7 10.79 10.713 10.689 10.877 10.603
8 10.74 10.779 10.11 10.737 10.75
9 10.77 10.773 10.641 10.644 10.725
10 10.72 10.671 10.708 10.85 10.712
11 10.79 10.821 10.764 10.658 10.708
12 10.62 10.802 10.818 10.872 10.727
13 10.66 10.822 10.893 10.544 10.75
14 10.81 10.749 10.859 10.801 10.701
15 10.66 10.681 10.644 10.747 10.728
23
Calculate sample means, sample ranges, mean
of means, and mean of ranges.
Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5 Avg Range
1 10.68 10.689 10.776 10.798 10.714 10.732 0.116
2 10.79 10.86 10.601 10.746 10.779 10.755 0.259
3 10.78 10.667 10.838 10.785 10.723 10.759 0.171
4 10.59 10.727 10.812 10.775 10.73 10.727 0.221
5 10.69 10.708 10.79 10.758 10.671 10.724 0.119
6 10.75 10.714 10.738 10.719 10.606 10.705 0.143
7 10.79 10.713 10.689 10.877 10.603 10.735 0.274
8 10.74 10.779 10.11 10.737 10.75 10.624 0.669
9 10.77 10.773 10.641 10.644 10.725 10.710 0.132
10 10.72 10.671 10.708 10.85 10.712 10.732 0.179
11 10.79 10.821 10.764 10.658 10.708 10.748 0.163
12 10.62 10.802 10.818 10.872 10.727 10.768 0.250
13 10.66 10.822 10.893 10.544 10.75 10.733 0.349
14 10.81 10.749 10.859 10.801 10.701 10.783 0.158
15 10.66 10.681 10.644 10.747 10.728 10.692 0.103
Exhibit
ExhibitS6.4
S6.4
x Chart Control Limits
n A2 D3 D4
rol Limits
UCL = x + A 2 R 2 1.88 0 3.27
3 1.02 0 2.57
LCL = x - A 2 R 4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
25
x-Bar Chart
10.850 UCL
10.800
10.750
M eans
10.700
10.650
10.600
LCL
10.550
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sam ple 26
R-Chart
0 .7 0 0
0 .6 0 0
0 .5 0 0
UCL
R 0 .4 0 0
0 .3 0 0
0 .2 0 0
0 .1 0 0
0 .0 0 0 LCL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S a m p le 27
Process Capability
Process limits
Tolerance limits
28
Process Capability Index, Cpk
X LTL UTL - X
C pk = min or
3 3
High High
Incremental Incremental
Cost of Cost of
Variability Variability
Zero Zero