Control Chart For Attributes

Quality
Improvement
Chapter 9- Control
Charts for Attributes
PowerPoint presentation to accompany

Besterfield, Quality Improvement, 9e
Outline
 Attribute
 Control Charts for Nonconforming Units
 Control Charts for Count of Nonconformities
 A Quality Rating System
2
Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc
Dale H. Besterfield Upper Saddle River, New Jersey 07458 • All Rights Reserved
Learning Objectives
When you have completed this chapter you should:
 Know limitations of variable control charts and the different
types of attibute charts.
 Know the objectives of the p chart group and the applicable
distribution.
 Be able to construct a:
 Fraction defective chart- fixed subgroup size
 Fraction defective chart-variable subgroup size
 Percent defective chart
 Number defective chart
3
Learning Objectives cont’d.
When you have completed this chapter you should:

 Know how to minimize the effect of variable
subgroup size.
 Know the applications of the c chart group, the
applicable distribution and two conditions.
 Be able to construct a c chart and a u chart and
know the difference between them.
 Know the three classes of defect severity
4
Attribute
 The term Attribute refers to those quality
characteristics that conform to specifications
or do not conform to specifications.
 Attribute are used:
1. Where measurements are not possible.

2. Where measurements can be made but are
not made because of time, cost, or need.
5
Attribute
 A nonconformity is a departure of a quality
characteristic from its intended level or state
that occurs with a severity sufficient to cause
an associated product or service not to meet
a specification requirement.
 Defect is concerned with satisfying intended
normal, or reasonably foreseeable, usage
requirement.
6
Attribute
 Defect is appropriate for use when evaluation
is in terms of usage.
 Nonconformity is appropriate for conformance
to specifications.
 The term Nonconforming Unit is used to
describe a unit of product or service
containing at least one nonconformity.
7
Attribute
 Defective is analogous to defect and is
appropriate for use when unit of product
or service is evaluated in terms of usage
rather than conformance to specifications.
 Limitations of variable control charts:
These charts cannot be used for quality
characteristics which are attributes.
8
Attribute
Types of Attribute Charts:
1. Nonconforming Units (based on the
Binomial distribution): p chart, np chart.
2. Nonconformities (based on the Poisson
distribution): c chart, u chart.
9
The P Chart
 The P Chart is used for data that consist of the
proportion of the number of occurrences of an
event to the total number of occurrences.
 It is used in quality to report the fraction or
percent nonconforming in a product, quality
characteristic, or group of quality characteristics.
10
The P Chart
Formula:
np
p 
n
 The fraction nonconforming, p, is usually small,
say, 0.10 or less.
 Because the fraction nonconforming is very
small, the subgroup sizes must be quite large
to produce a meaningful chart.
11
The P Chart
 It can be used to control one quality
characteristic, as is done with X bar and R chart,
 Or to control a group of quality characteristics of
the same type or of the same part,
 Or to control the entire product.
 It can be established to measure the quality
produced by a work center, by a department, by a
shift, or by an entire plant.
12
The P Chart
 It is frequently used to report the
performance of an operator, group of
operators, or management as a means of
evaluating their quality performance.
 The subgroup size of the P chart can be
either variable or constant.
13
The P Chart
Objectives of the P Chart:
1. Determine the average quality level: This
information provides the process
capability in terms of attributes.
2. Bring to the attention of management
any changes in the average.
3. Improve the product quality: Ideas for
quality improvement.
14
The P Chart
Objectives of the P Chart cont’d:
4. Evaluate the quality performance of
operating and management personnel.
5. Suggest places to use Xbar and R chart:
They are more sensitive to variation.
6. Determine acceptance criteria of a
product before shipment to the customer.
15
The P Chart
P-Chart Construction for Constant
Subgroup Size
1. Select the quality characteristic(s):
a) Single quality characteristic.
b) Group of quality characteristics.
c) A part.
d) An entire product.
e) A number of products.
f) It can be established for performance control of an
operator, work center, department, shift, plant, or
corporation
16
The P Chart
P Chart Construction for Constant Subgroup Size
cont’d.
2. Determine the subgroup size and method:
 The size of the subgroup is a function of the
proportion nonconforming.
 A minimum size of 50 is suggested as a
starting point.
17
The P Chart
cont’d.
3. Collect the data:
 At least 25 subgroups.
 Different sources (Check sheet).
 For each subgroup the proportion
nonconforming is calculated by the formula
P = np/n
18
The P Chart
4. Calculate the trial central line and the control
limits:
p  np
n
p (1  p )
UCL  p  3
n
p (1  p )
LCL  p  3
n
19
FIGURE 9-2 A p Chart to Illustrate the Trial Central Line and
Control Limits Using the Data from Table 9-1
20
The P Chart
cont’d.
5. Establish the revised central line and control limits.
pnew  p0 
 np  np d
n  n d
p0 (1  p0
UCL  p0  3
n
p0 (1  p0 )
LCL  p0  3
n
21
FIGURE 9-3 Continuing Use of the p Chart for Representative
Values of the Proportion Nonconforming, p
22
The P Chart
 The P Chart is most effective if it is posted
where operating and quality personnel can
view it.
 The control limits are usually three standard
deviations from the central value. Therefore,
approximately 99% of the plotted points, P,
will fall between the upper and lower control
limits.
23
The P Chart
 A P Chart will also indicate long-range
trends in quality, which will help to evaluate
changes in personnel, methods, equipment,
tooling, materials, and inspection
techniques.
 P-chart is based on the binomial
distribution.
24
FIGURE 9-4 Various Techniques for Presenting p -Chart Information
25
The P Chart
P Chart Construction for Variable Subgroup Size
1. Collect the data.
2. Determine the trial central line and control
limits: Since the subgroup size changes each
day, limits must be calculated for each day.
26
FIGURE 9-5 Preliminary Data, Central
Line, and Trial Control Limits
FIGURE 9-5 Preliminary Data, Central Line, and Trial Control Limits
27
The P Chart
cont’d.
2. As the subgroup size gets larger, the control
limits are closer together.
3. Establish revised central line and control limits:
28
The P Chart
cont’d.
 If Po is known, the process of data collection
and trial control limits is not necessary.
 P is the proportion (fraction) nonconforming
in a single subgroup.
 Pbar is the average proportion (fraction)
nonconforming of many subgroups.
29
The P Chart
cont’d.
 Po is the standard or reference value of the
proportion (fraction) nonconforming based
on the best estimate of PBar.
 Φ is the population proportion (fraction)
nonconforming.
30
The P Chart
Minimizing the Effect of Variable Subgroup Size
1. Control limits for an average subgroup size: By using an average
subgroup size, one limit can be calculated and placed on the
control chart.
nav 
 n
g
p0 (1  p0
UCL  p0  3
nav
p0 (1  p0 )
LCL  p0  3
nav 31
FIGURE 9-7 Chart for May Data Illustrating Use of an
Average Subgroup Size
32
The P Chart
Minimizing the Effect of Variable Subgroup Size cont’d.
Case I: This case occurs when a point (subgroup
fraction nonconforming) falls inside the limits and
its subgroup size is smaller than the average
subgroup size.
Case II: This case occurs when a point (subgroup
fraction nonconforming) falls inside the average
limits and its subgroup size is larger than the
average subgroup size.
33
The P Chart
Minimizing the Effect of Variable Subgroup Size cont’d.
Case III: This case occurs when a point (subgroup
fraction nonconforming) falls outside the limits and
its subgroup size is larger than the average
subgroup size.
Case IV: This case occurs when a point (subgroup
fraction nonconforming) falls outside limits and its
subgroup size is less than the average subgroup
size.
34
FIGURE 9-8 p Chart Illustrating Central Line and Control
Limits for Different Subgroup Sizes
35
The np Chart
Number Nonconforming Chart (np):
 The np chart is easier for operating personnel
to understand than the p chart.
 The limitation that this chart has is that the
subgroup size needs to be constant.
36
The np Chart
Central Line = np0

Control Limits = np0  3 np0 (1  p0 )
37
The np Chart
Number Nonconforming Chart (np):
 If the fraction nonconforming po is unknown,
then it must be determined by collecting
data, calculating trial control limits, and
obtaining the best estimate of po.
38
FIGURE 9-9 Number Nonconforming Chart ( np Chart)
39
Process Capability
 For an attribute this process is much simpler.
 The process capability is the central line of
the control chart.
 Management is responsible for the capability.
 When the plotted point is outside the control
limit, operating personnel are usually
responsible.
40
FIGURE 9-10 Process Capability Explanation and Responsibility
41
Control Charts for Count of Non-
conformities
 The nonconformities chart controls the count
of nonconformities within the product or
service.
 An item is classified as a nonconforming unit
whether it has one or many nonconformities.
 Count of nonconformities (c) chart.
 Count of nonconformities per unit (u) chart.
42
conformities
 Since these charts are based on the Poisson
distribution, two conditions must be met:
1. The average count of nonconformities
must be much less than the total possible
count of nonconformities.
2. The occurrences are independent.
43
conformities
Objectives:
1. Determine the average quality level: This
information gives the initial process capability.
2. Bring to the attention of management any
changes in the average.
3. Improve the product quality: Ideas for quality
improvement.
44
conformities
Objectives cont’d.:
4. Evaluate the quality performance of
operating and management personnel.
5. Suggest places to use Xbar and R chart.
6. Determine acceptance criteria of a
product before shipment to the customer.
45
conformities
C Chart construction:
1. Select the quality characteristic(s):
a) Single quality characteristic.
b) Group of quality characteristics.
c) A part.
d) An entire product.
e) A number of products.
f) It can be established for performance control of
an: operator, work center, department, shift, plant,
or corporation
46
conformities
C Chart construction cont’d:
2. Determine the subgroup size and method:
3. Collect the data:
 At least 25 subgroups.
 Different sources.
47
conformities
c-Chart Construction cont’d:
4. Calculate the trial central line and the control

limits:
c
c
g
UCL  c  3 c
LCL  c  3 c
48
FIGURE 9-11 Control Chart for Count of Nonconformities ( c Chart), Using
Preliminary Data
49
conformities
5. Establish the revised central line and control

limits
c ne w = c 0 =
c - cd
g - gd
UCL = c 0 + 3 c0
LCL = c 0 - 3 c0
50
51
conformities
C chart construction cont’d:
6. Achieve the objectives: The reason for the

control chart is to achieve one or more of the
previously stated objectives.
52
conformities/Unit
Chart for Count of Nonconformities/Unit (u Chart)
u 
c
u 
c
n n
u
UCL  u  3
n
u
LCL  u  3
n
53
FIGURE 9-13 u Chart for Errors on Waybills
54
conformities
Chart for Count of Nonconformities/Unit
(u Chart)
 Scale selected is continuous for the u chart. For
the c chart is discrete.
 Subgroup size for the u chart can vary. For the c
chart is 1.
 The u chart is limited in that we do not know the
location of the nonconformities.
55
A Quality Rating System
Nonconformity Classification:
1. Critical nonconformities: Unsafe conditions for
individuals using, maintaining, or depending upon the
product.
2. Major nonconformities: Result in failure or reduce
materially the usability of the product for its intended
purpose.
3. Minor nonconformities: Reduce materially the usability
of the product for its intended purpose.
56
Control Chart Selection
Quality Characteristic
Variable Attribute
Defective Defect
no
n>1? x and MR
constant yes Sampling

yes p or
sample Unit one
np
no size?
n>=10? x and R
yes no
no
yes
p-chart with c u
x and s variable sample
size
59
Computer Program
 EXCEL/Minitab program files on the
website will solve for:
 p chart
 np chart
 c chart
 U chart
60
Homework
 5, 7, 16b, 23
61

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Quality

PowerPoint presentation to accompany

When you have completed this chapter you should:

1. Where measurements are not possible.

Central Line = np0

4. Calculate the trial central line and the control

5. Establish the revised central line and control

6. Achieve the objectives: The reason for the

constant yes Sampling

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