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Number of defects
Variables Data
X-bar and R chart is used to monitor mean
and variance of a process when quality
characteristic is continuous.
Continuous values (variables data) can
theoretically assume an infinite number of
values in some interval.
Time
Weight
Ounces
Diameter
X-bar and R Chart
X-bar chart monitors the process mean by
using the means of small samples taken
frequently
R chart monitors the process variation by
using the sample ranges as the measure of
variability
Range = Maximum value – Minimum value
Notation
X quality characteristic
n sample size
k number of samples
X
n
Notation
X mean of the Xs
X is also called
" X double bar, "
the estimated process mean, or
the overall mean
Notation
R Sample Range
Maximum value - Minimum value
R Mean of ranges
R
k
ˆ
estimated standard error of X
n
Example of Notation
A company monitors the time (in minutes) it
takes to assemble a product.
The company decides to sample 3 units of the
product at three different times tomorrow:
9 AM
12 Noon
3 PM
What is the sample size, n?
What is k, the number of samples?
Suppose the following data are obtained.
Assembly Time
Hour (minutes)
X1 X2 X3
9:00 AM 5 12 4
12 Noon 6 8 10
3:00 PM 9 4 2
How would you compute
X-bar?
R
R-bar
X double bar
Example of Notation
9:00 AM 5 12 4 21/3 = 7 12 – 4 = 8
12 Noon 6 8 10 24/3 = 8 10 – 6 = 4
X
X
n
First Sample
X
X
5 12 4 21
7
n 3 3
Sample Means
Second Sample
X
X
6 8 10 24
8
n 3 3
Third Sample
X
X
9 4 2 15
5
n 3 3
Estimated Process Mean
X
X
k
785
3
20
3
6.7
Sample Ranges
R Maximum Value - Minimum Value
First Sample :
R 12 4 8
Second Sample :
R 10 - 6 4
Third Sample :
R 9-2 7
Mean of R
R
R
k
847
3
19
3
6.3
Underlying Distributions
When constructing an X-bar chart, we
actually have two distributions to consider:
The distribution of the sample means X , and
The process distribution, the distribution of the
quality characteristic itself, X.
The distribution of X is a distribution of
averages.
The distribution of X is a distribution of ???
Underlying Distributions
These distributions have the same mean
Mean of X Mean of X
Their variances (or standard deviations) are
different.
Which distribution has the bigger variance?
Would you expect more variability among
averages or among individual values?
The variability among the individual values
is ???
Underlying Distributions
The standard deviation among the sample
means is smaller by a factor of 1
n
Therefore,
Std of X
1 ˆ
Std of X ˆ
n n
Underlying Distributions
Sampling
distribution
of X Distribution
of X
X
Distribution of X
ˆ
M M UCL
LCL M
M M
X M X
m m
m
The distribution of X is assumed to be normal.
This assumption needs to be tested in practice.
Distribution of X-bar
ˆ
n
M M UCL
LCL M
M M
X M X
m m
m
If the distribution of X is normal, the distribution of
X-bar will be normal for any sample size.
Control Limits for X-bar Chart
Since we are plotting sample means on the X-
bar chart, the control limits are based on the
distribution of the sample means.
The control limits are therefore
ˆ
UCL X 3
n
ˆ
LCL X 3
n
Control Limits for X-bar Chart
Distribution of X
LCL UCL
ˆ ˆ
X 3 X X 3
n n
Control Limits for X-bar Chart
ˆ
LCL X 3
n
ˆ
UCL X 3
n
LCL X A2 R
UCL X A2 R
Control Limits for X-bar Chart
ˆ
3 A2 R
n
LCL X A2 R
UCL X A2 R
Table A: X-bar Chart Factor, A2
n A2
2 1.88
3 1.02
4 0.73
5 0.58
X-bar Chart Control Limits
X 15.33
R 8.5
From Table A in notes or Table 6 - 1, p. 182 of text
n3
A2 1.02
X-bar Chart Control Limits
LCL X A2 R
15.33 1.02(8.5)
6.66
UCL X A2 R
15.33 1.02(8.5)
24.0
X-bar Chart for Sugar Content
30.00
25.00
20.00
15.00
10.00
5.00
0.00
10 1 4 10 1 4
Hour Hour
1 2
Day
Interpretation of X-bar Chart
LCL D3 R
UCL D4 R
Table B: Factors for R Chart
n D3 D4
2 0 3.27
3 0 2.57
4 0 2.28
5 0 2.11
R Chart Control Limits
LCL 0(8.5)
n3
0
D3 0
UCL 2.57(8.5)
D4 2.57
21.85
R Chart for Weight
25
20 R
15 LCL
10 UCL
5 R-bar
0
10 1 4 10 1 4
Hour Hour
1 2
Day
Interpretation of R Chart
Since all of the sample ranges fall within the
control limits, the R chart is in control.
The standard deviation is stable and
predictable and can be estimated—done in
next section.
This does not necessarily mean that the
amount of variation in the process is
acceptable.
Interpretation of R Chart
Continuous improvement means the company
should continuously reduce the variance.
Since the process variation is in control,
management action is required to reduce the
variation.
Expected Pattern in a Stable Process
X-bar Chart
UCL
LCL
Time
Sampling
Distribution (process variability is increasing)
UCL
Does not
x-Chart
LCL
reveal increase
UCL
(process mean is
shifting upward)
Sampling
Distribution
UCL
UCL
Does not
R-chart
LCL
detect shift
Is a Stable Process a Good Process?
“In control” indicates that the process mean is
stable and hence predictable.
A stable process, however, is not necessary a
“good” (defect free) process.
The process mean, although stable, may be far off
target, resulting in the production of defective
product.
In this case, we have, as Deming puts it, “A stable
process for the production of defective product.”
Control Limits vs. Spec. Limits
Control limits apply to sample means, not
individual values.
Mean diameter of sample of 5 parts, X-bar
Spec limits apply to individual values
Diameter of an individual part, X
Control Limits vs. Spec. Limits
Sampling
distribution,
X-bar
Process
distribution,
X
Mean=
Target USL
LSL
Lower Upper
control control
limit limit
Underlying Distributions
Sampling
distribution
X Distribution
of X
of X
LSL
X USL
LCL UCL