CONTROL CHART

BASIS
BPT2423 – STATISTICAL PROCESS CONTROL
CHAPTER OUTLINE
 Control Chart Functions
 Variation
 Basic Principles
 Choice of Control Limits
 Upper Control Limit (UCL)
 Lower Control Limit (LCL)
 Sample Size and Sampling Frequency
 Rational Subgroups
 Analysis of Patterns
LESSON OUTCOMES
 Understand the concept of variation
 Explain the statistical basis of the control chart,
including control limits and rational subgroup
concept
 Identify some practical issues in the
implementation of statistical process control
CONTROL CHART
FUNCTIONS
 A control chart enhances the analysis of the process by
showing how the process is performing over time
 Serve 2 basic functions:
1. Control charts are decision making tools
Provide an economic basis for making a decision as to
whether to investigate for potential problems; to
adjust the process or to leave the process alone
2. Control charts are problem-solving tools
Point out where improvement is needed and help to
provide a statistical basis on which to formulate
improvement actions
CONTROL CHART FUNCTIONS
 Control charts have had a long history of use in U.S.
industries; Five reasons for it popularity:
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
VARIATION
 Definition : Where no two items / services are exactly the
same
 The goal of most processes is to produce products or provide
services that exhibit little or no variation
 Several types of variation are tracked with statistical methods:
1. Within-piece : variation within a single item or surface
2. Piece-to-piece : variation that occurs among pieces
produced at approximately the same item
3. Time-to-time : variation in the product produced at
different times of the day
 Variation in a process is studied by sampling the process;
understanding variation and its causes results in better
decisions
VARIATION

Stable and Unstable Variation

BASIC PRINCIPLES
The Chart contains:
 Center line that represents the average value of the quality
characteristics corresponding to the in-control state
 Two other horizontal lines, called the upper control limit
(UCL) and the lower control limit (LCL)
 All the sample points on the control chart are connected
with straight-line segments, so that it’s easier to visualize
how the sequence of points has evolved over time
BASIC PRINCIPLES
 If the process is in control, nearly all of the sample
points will fall between chosen control limits and no
action is necessary
 However, a point that plots outside of the control limits
is interpreted as evidence that the process is out of
control, investigation and corrective action are required
to find and eliminate the causes
 Even if all the points plot inside the control limits, if they
behave in a systematic or non random manner, then this
could be an indication that the process is out of control
 If the process is in control, all the plotted points should
have an essentially random pattern
CHOICE OF CONTROL LIMITS
 99.73% of the data under a normal curve falls within ± 3σ;
because of this, control limits are established at ± 3σ from
the centerline of the process
 Let w be a sample statistic that measures some quality
characteristic of interest, and suppose that the mean of w
is µw and the standard deviation of w is σw

 Formula:
Upper Control Limit (UCL) = µw + 3σw
Center Line = µw
Lower Control Limit (LCL) = µw – 3σw
SAMPLE SIZE AND
SAMPLING FREQUENCY
 In designing a control chart, sample size and the frequency of
sampling must be specify
 In general, larger samples will make easier to detect small
shifts in the process
 When choosing the sample size, user must keep in mind the
size of the ‘shift’ that are trying to detect
 The most desirable situation form the point of view of
detecting shifts would be to take large samples very
frequently (not economic feasible)
 General problem is one of allocating sampling effort – either
take small samples at short intervals or larger samples at
longer intervals
SAMPLE SIZE AND
SAMPLING FREQUENCY
 Average run length (ARL) can be use to evaluate the
decisions regarding sample size & sampling frequency of
the control chart
 ARL is the average number of points that must be plotted
before a point indicates an out-of-control condition by
using formula:
ARL = 1/p
 where p is the probability that any point exceeds the
control limits
SAMPLE SIZE AND
SAMPLING FREQUENCY
 Example:
Chart with 3σ limits, p=0.0027 : the probability that a
single point falls outside the limits when the process is in
control

ARL = 1/p = 1/0.0027 = 370

which means an out-of-control signal will be generated

every 370 samples, on the average
RATIONAL SUBGROUPS
 Subgroups and the samples composing them must be
homogeneous
 A homogeneous subgroup will have been produced
under the same conditions, by the same machine, the
same operator, the same mold and so on
 Subgroups used in investigating piece-to-piece variation
will not necessarily be constructed in the same manner
as subgroups formed to study time-to-time variation
 Subgroup formation should reflect the type of variation
 When constructing variables chart, keep the subgroup
sample size constant for each subgroup taken
RATIONAL SUBGROUPS
Some guidelines to be followed
 The larger the subgroup size, the more sensitive the chart
becomes to small variations in the process average. This
provide a better picture of the process since it allows the
investigator to detect changes in the process quickly
 While a larger subgroup size makes for a more sensitive
chart, it also increases inspection costs
 Destructive testing may make large subgroup sizes
unfeasible
 Subgroup sizes smaller than four do not create a
representative distribution of subgroup averages
ANALYSIS OF PATTERNS
A control chart exhibits a state of control when:
1. 2/3 of the points are near the center value
2. A few of the points are on or near the center value
3. The points appear to float back and forth across the centerline
4. The points are balanced (in roughly equal numbers) on both
sides of the centerline
5. There are no points beyond the control limits
6. There are no patterns or trends on the chart

A process that is not under control or is unstable, displays

patterns of variation - the process need to be investigate
and determine if an assignable cause can be found for the
variation
ANALYSIS OF PATTERNS

Patterns in Control Chart:

 Oscillating

 Change / Jump / Shift

 Runs

 Recurring Cycles

 Freaks / Drift
ANALYSIS OF PATTERNS
Example : Change / Jump / Shift

Description :
The process begins at one level and jump quickly to another level as the
process continues to operate. Causes for sudden shifts in level tend to reflect
some new and significant difference in the process.

Possible causes :
New operator, new batches of raw material or changes to the process settings
ANALYSIS OF PATTERNS
Example : Runs