Classification of Control Charts

Submitted to: Saami Khan

Prof. R. Shringi Roll no. 16/858
M.Tech
IEM 3rd sem

Submitted by: 1
 CONTROL CHARTS

Control charts are the tools that are used in SPC to indicate when
special-cause variation is present in a process.

Control charts may also be used to estimate the parameters of a

production process and through this information, to determine
process capability.

The control chart may also provide information useful in

improving the process.

2
Fig. A typical control chart.

3
 Control charts

Variable Attribute Shewhar

control control t control
charts charts charts
Moving
p-charts range
charts
Cumulative
np-charts sum(cusum)
R-charts
c-charts EWMA
control
s-charts charts
u-charts Moving
s charts
2
average
control charts

Fig. Classification of control charts

4
 Control charts for variables
• 
The types of variables control charts include the following:

 chart:-Control of the process average or mean quality level is

usually done with the control chart for means, or the control
chart.

R(or s) chart:-Process variability can be monitored with either a

control chart for the standard deviation, called the s control chart,
or a control chart for the range, called an R control chart.

5
 Statistical Basis of the Charts
•Let
  x̅ x̅ ,…., x̅ be the average of each sample.
1, 2 m

Then the best estimator of μ

=
Range of the sample: R = xmax - xmin
Let R1, R2, . . . , Rm be the ranges of the m samples. The
average range is
=

6
 Statistical Basis of the Charts
•Control
  limits for the chart:
=/ is an unbiased estimator of σ.
is an estimator of .
UCL =
Central line =
LCL= =
We have,

UCL=
Central line =
LCL=
is a constant for various sample sizes

7
  Control limits for chart
•When
  standard values are given for and
Then,
UCL
Central line
LCL
We have,
A=3/, is a constant for varous sample size n.
UCL
Central line
LCL

8
Control limits for R chart
•The
  standard deviation of is
=
Three-sigma control limits are
UCL= +3+
Central line =
LCL = 3
We have,
and are constants for n.
UCL=
Central line =
LCL

9
 R chart with standard values
•The
  standard deviation of R

Also,
UCL
Central line
LCL
We define,
and are constant for sample size n.
UCL
Central line
LCL
10
 Control limits for the s chart:

• 

Consequently, we may write the parameters of the s chart as

UCL=B4s̅
Center line =s̅
LCL=B3s̅

11
 s chart with standard values
•Standard
  value is given for
E(s)
Three-sigma control limits for s chart
UCL
Central line
LCL
We have,
and are constant for sample size n.
UCL
Central line
LCL

12
When s̅ /c4 is used to estimate σ, we may define the control limits
on the corresponding x̅ chart as

•  UCL= x̿ +
Center line =x̿
LCL= x̿ -

Let the constant A3 = 3/(c4). Then the x̅ chart parameters become

UCL= x̿ + A3 s̅
Center line = x̿
LCL= x̿ - A3 s̅

13
 Control limits for the s2 control chart
• 
UCL=
Center line =
LCL =
Where and denote the upper and lower percentage
points of the chi-square distribution with n-1 degree of
freedom.

14
Factors for Constructing Variables Control Charts

15
 The Shewhart Control Chart for Individual
Measurements

There are many situations in which the sample size used for process
monitoring is n=1; that is, the sample consists of an individual unit.
Some examples are as follows:

1. Automated inspection and measurement technology is used, and

every unit manufactured is analyzed so there is no basis for rational
subgrouping.

2. Repeat measurements on the process differ only because of

laboratory or analysis error, as in many chemical processes.

3. Multiple measurements are taken on the same unit of product, such

as measuring oxide thickness at several different locations on a wafer
in semiconductor manufacturing.

16
• 
In such situations, the control chart for individual units is useful.
The moving range is defined as:
MRi =xi − xi-1|
Where, MR =Moving Range

For the control chart for individual measurements, the

control limits are:

UCL= + 3
Center line =
LCL= - 3

17
Cumulative sum (cusum) control chart
•Control
  limits for the cusum H=Decision interval.(H=5)
chart:

= max[0,]

Where,
are called one-sided upper and
lower cusums.
K= Reference value.
K=
= Target value of mean.
=Out of control value of mean.
18
 The exponentially weighted moving average
control chart
•The
  EWMA is defined as:

Where 0 is a constant.
The variance of is

Control limits for the EWMA chart:

UCL =
Center line =
LCL =
L= width of the control limits.

19
Moving average control chart
• 
The moving average of span w at time i is defined as

The variance of is
V() =
Control limits for moving average charts are
UCL=
Central line =
LCL=
= target value of the mean

20
 Control charts for attributes

Data that can be classified into one of several categories or

classifications is known as attribute data.

Classifications such as conforming and nonconforming are

commonly used in quality control.

Two important terms to differentiate:

1. Defect- items that contribute to nonconformity of a quality

characteristics

2. Defective- part/product inspected not conforming or meeting

specification (can have > 1 defects)

21
 Control Charts for Fraction Nonconforming

The binomial distribution with parameters n  0 and 0 < p < 1, is

given by

n x
p( x )    p (1  p) n  x
x
The mean and variance of the binomial distribution are

μ= np
σ2= np(1-p)

22
Development of the Fraction Nonconforming Control
Chart
•Assume:
 
n = number of units of product selected at random.
D = number of nonconforming units from the sample
p = probability of selecting a nonconforming unit from the sample.
Then:
n x
P( D  x )    p (1  p) n  x
x
The sample fraction nonconforming is given as
p̂ =
Where p̂ is a random variable with mean and variance

p(1  p)
p  2

n
23
 Control limits for the p chart:
• 
Standard Given:

If a standard value of p is given, then the control limits

for the fraction nonconforming are

UCL= p + 3

Center line = p

LCL= p - 3

24
No Standard Given
If no standard value of p is given, then the control limits for the
fraction nonconforming are

p (1  p )
UCL  p  3
n
CL  p
p (1  p )
LCL  p  3
n
Where,
m m

m= No. of sample  Di  p̂ i
n= Sample size p  i 1
 i 1
mn m

25
 Control Charts for Fraction
Nonconforming
The np control chart
The actual number of nonconforming can also be charted.
Let n = sample size, p = proportion of nonconforming.
The control limits are:

UCL  np  3 np(1  p)
CL  np
LCL  np  3 np(1  p)

(if a standard p is not given, then use p )

26
 Control Charts for
Nonconformities (Defects)

There are many instances where an item will

contain nonconformities but the item itself is
not classified as nonconforming.

It is often important to construct control charts

for the total number of nonconformities or the
average number of nonconformities for a given
“area of opportunity”. The inspection unit must
be the same for each unit.
27
 Control Charts for
Nonconformities (Defects)
Poisson Distribution
The number of nonconformities in a given area can be modeled
by the Poisson distribution. Let c be the parameter for a Poisson
distribution, then the mean and variance of the Poisson
distribution are equal to the value c.
The probability of obtaining x nonconformities on a single
inspection unit, when the average number of nonconformities is
some constant, c is found using:

e cc x
Where, x= 0,1,2,3,… p( x ) 
x!
28
 Procedures with Constant
Sample Size
•c-chart
 
UCL  c  3 c
Standard Given:
CL  c
LCL  c  3 c

Note: Should these calculations yield a negative value for the LCL,
set LCL = 0.
No Standard Given: UCL  c  3 c
CL  c
LCL  c  3 c

Where, c̅ =

29
 Procedures with Constant
Sample Size
The u Chart
If we find c total nonconformities in a sample of n inspection
units, then the average number of nonconformities per
inspection unit is u = c/n.
The control limits for the average number of nonconformities is

u
UCL  u  3
n
CL  u
u
LCL  u  3
n
30
 Trial Control Limits

Control limits that are based on a preliminary set of

data can often be referred to as trial control limits.

The quality characteristic is plotted against the trial

limits, if any points plot out of control, assignable
causes should be investigated and points removed.

With removal of the points, the limits are then

recalculated.

31
 Choice Between Attributes
and Variables Control Charts
Each has its own advantages and disadvantages
Attributes data is easy to collect and several characteristics
may be collected per unit.
Variables data can be more informative since specific
information about the process mean and variance is obtained
directly.
Variables control charts provide an indication of impending
trouble (corrective action may be taken before any defectives
are produced).
Attributes control charts will not react unless the process has
already changed (more nonconforming items may be
produced).
32
 Guidelines for Implementing
Control Charts
Determine which process characteristics to control.

Determine where the charts should be implemented in the

process.

Choose the proper type of control chart.

Take action to improve processes as the result of

SPC/control chart analysis.

Select data-collection systems and computer software. .

33
Thank You…!!

34