STAT8010

Applied Statistical Techniques

Control Charts for Variable Data

 Today’s Learning Outcomes

Construct and use variables control charts for process

management.
Apply the principles of rational subgrouping.
 Variables Control Charts
• Variables control charts can be used when a quality characteristic is being
measured on a continuous variable
• Usually used in pairs
– Variation chart -monitors short term variation and answers the question “Is the variation
within subgroups constant?”
– Location chart (Data chart)–monitors changes in the average value of the process and is
a visualization of the longer term variation.
 X bar and R Charts
•Probably
  the most commonly used chart

• R Chart – Subgroup range (R) is plotted which monitors process

variability
• chart – Subgroup average ( is plotted which monitors the central
tendency of the process
• We typically need to select and evaluate at least 25 samples of
size n
 Range (R) Chart
•Centerline
  =
= individual sample or subgroup range for subgroup i
k = number of samples or subgroups

  UCL (R)
  LCL (R)
 X bar Chart
•Centerline
  = Process Average (𝜇) = Grand Mean of the
Sample Means =
= sample mean for subgroup i
k = number of samples or subgroups used

  UCL ()
  LCL ()
 X bar and S Charts
• For subgroup sizes n < 10 , the range provides a
reasonable estimate with greater simplicity and
efficiency than the standard deviation
• For samples of size n=10 or more, the X bar and s
charts can be used
• s chart examines the variability of the process
instead of the R chart
 s Charts
•  
= sample standard deviation for sample or subgroup i
k = number of subgroups

  UCL (s)
  LCL (s)
 X bar Chart (using s)
•Centerline
  = Process Average (𝜇) = Grand Mean of the
Sample Means =
= sample mean for subgroup i
k = number of samples or subgroups used

  UCL ()
  LCL ()
 Control Charts for Individuals (X charts)
• When it is not practical or possible to collect data on subgroups
– Low volume operations
– Lengthy intervals between output units
– When a single measurement represents work output for an entire time period
– Evaluation of the quality characteristic requires destruction of the item or unit and testing samples
greater than n = 1 might be prohibitively expensive

• Consider each individual observation as a “subgroup” of size n=1

• When there is only one observation in each subgroup, there will be no variation within
the subgroups and must estimate process variability another way
1. Evaluate with moving range
 Individual Value (X) Chart with the Moving Range
Estimates
•   process variability by considering the differences between consecutive
observations

Moving Range = = - |

estimates the process variability and is used as the centre line of the moving range chart

Note that the calculation of MR considers the absolute value of the difference between consecutive measurements
 Moving Range Chart
•UCL
  (MR)
LCL (MR)

If the chart shows the process to be out of control, we should

investigate and eliminate the special causes that can be identified

If the moving range charts shows the process to be in control, we can

be confident that will provide a good estimate of 𝜎 to proceed with
construction of the trial limits for the X chart
 Individual Value (X) Chart
Centerline
•   =
is the ith individual value
k is the number of individual values available for calculating trial limits
UCL(X) = + 2.66
LCL(X) = - 2.66

To estimate Sigma using Moving Range Average:

S = / 1.128
 Guideline on Control Chart Interpretation
• Process stability is reflected in the relatively constant variation exhibited in
Control Charts. If a process is stable, the likelihood of a point falling outside the
band between +/- 3σ is so small that such an occurrence is taken as a signal of
a special cause of variation. In other words, something abnormal is occurring
within your process. However, even though all the points fall inside the control
limits, special cause variation may be at work. The presence of unusual
patterns can be evidence that your process is not in statistical control. Such
patterns are more likely to occur when one or more special causes is present.
• Using control limits which are less than 3 sigma from the centerline may trigger
a hunt for special causes when the process is already stable.
 When to change Control limits?
1. When removing out-of-control data points. When a special cause has been
identified and removed while you are working to achieve process stability.
2. When replacing trial limits. When a process has just started up, or has
changed, you may want to calculate control limits using only the limited data
available. Once you have 20 or 30 groups of 4 or 5 measurements without a
signal, you can use the limits to monitor future performance.
3. When there are changes in the process. When there are indications that
your process has changed, it is necessary to re-compute the control limits
based on data collected since the change occurred.
 Guidelines for Sample Selection
• Small frequent samples will usually be more effective than large infrequent
samples
• Use small frequent samples whenever the process is a high-volume one and
units of output are produced rapidly
– Important to detect shifts as soon as possible after they occur
– The longer the interval between samples, the greater the risk that a large number of
output units will be unacceptable in terms of quality
• Use small frequent samples whenever many special causes are possible
• Increase the frequency of sampling whenever a special cause is suspected
 Guidelines for Sampling
• Small problems and minor variations at the beginning of a process
tend to become magnified as the process progresses
– Monitoring toward the beginning of a process will generally be of greater
benefit than waiting to monitor at the end
• Sample at points where the likelihood that a problem will occur is
greatest or where special causes are more likely to occur
• Sample where the potential for cost reduction is greatest should a
special cause occur
• Sample where is it feasible and safe to do so
 Rational Subgroups
• Subgroup data allow us to monitor two types of variability:
• Inherent random variability of the process
– Estimated by the variability within subgroups
– Monitored by the variability portion of the chart
• Variability in process average 
– Between-group variability reflects process change
– Monitored by the central-tendency portion of the chart
• If a process is in a state of statistical control, variability within subgroups will reflect only
inherent variability of the process and will be equal to the between-group variability
 Rational Subgroups
Two basic strategies to select subgroups:
1. Select units produced as closely together in time as possible
– Will minimize variation within subgroups
– Will increase chances of detecting between-group variability indicating process shifts
2. Randomly sample continuously throughout production or the sampling
interval
– Sample will then be representative of all units produced during the interval in which the
sample was selected
– Unfortunately, maximizes within-sample variation and is not as effective when it is
important to detect shifts in process average
 Frequency of Sampling
• The more frequently samples are drawn, the more sensitive the
chart will be to the presence of special causes and the more
quickly a shift in process average will be detected
• Need to balance sample size and frequency of sampling against
budgetary requirements, time and the costs of failing to detect a
shift in the process
 Homework

Compute the control limit for the x and s control charts

 Homework
• Ch 15: 15.3.3, 15.3.5, 15.4.1