STATISTICAL

QUALITY
CONTROL

Chapter Thirteen
McGraw-Hill/Irwin Copyright © 2014 by The McGraw-Hill Companies, Inc. All rights reserved.
Learning Objectives
 LO13–01: Illustrate process variation and explain
how to measure it.
 LO13–02: Analyze process quality using statistics.
 LO13–03: Analyze the quality of batches of items
using statistics.

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Statistical Quality Control (SQC)
 The
quantitative Assignable variation
• Variation that is caused by
aspects of factors that can be identified
and managed
quality
management
 Processes Common variation
usually exhibit • Variation that is inherent in
the process itself
some variation
in their output

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Measuring Variation
    

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Variation and Specifications
 Upper specification – the maximum acceptable
value for a characteristic
 Lower specification – the minimum acceptable
value for a characteristic
Traditional View of Variability Costs Taguchi’s View of Variability Costs

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Process Capability
 The ability of a process to consistently produce a
good or deliver a service with a low probability of
generating a defect
 Specification limits – range of variation that is
considered acceptable by the designer or customer
 Process limits – range of variation that a process is
able to maintain with a high degree of certainty

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Process Capability

Process control limits exceed specification limits – process is not

capable of meeting requirements

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Process Capability

Specification control limits exceed process limits (for improved

process) – process is capable of meeting requirements

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Process Capability Index (Cpk)
 Ratio of the range of values
produced divided by the range of
values allowed
 Shows how well the parts being
produced fit into the range specified
by the design specifications  

 Cpk larger than one indicates process

is capable
 When the two numbers are not
close, indicates mean has shifted
Excel: Process Cap
ability

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Example 13.1
The quality assurance manager is assessing the capability
of a process that puts pressurized grease in an aerosol
can. The design specifications call for an average of 60
pounds per square inch (psi) of pressure in each can with
an upper specification limit of 65 psi and a lower
specification limit of 55 psi. A sample is taken from
production and it is found that the cans average 61 psi
with a standard deviation of 2 psi.
 What is the capability of the process?

 What is the probability of producing a defect?

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 Example 13.1: Solution

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 Process Control Procedures
 Concerned with monitoring quality while the
product or service is being produced
 Statistical process control - testing a sample

of output to determine if the process is

producing items within a preselected range
 Attributes - quality characteristics that are

classified as either conforming or not

conforming
 Variable - characteristics that are measured

using an actual value Excel: Statistical P

rocess Control

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 Process Control Measurements –
p-Charts

 Used when an item (or service) is either good or

bad (a yes-no decision)  

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Creating p-Charts

Calculate the sample proportions p for each sample.

Calculate the average of the sample proportions.

Calculate the standard deviation of the sample proportion.

Calculate the control limits.

Plot the individual sample proportions, the average of the

proportions, and the control limits.

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Process Control Measurements –
c-Charts

 Used when an item (or service) may have multiple

defects
 

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Variable Measurement Process Control Charts – X-
bar and R-Charts

 Size of samples
 Preferable to keep small (usually 4 or 5 units)
 Number of samples
 Once chart set up, each sample compared to chart
 Use about 25 samples to set up chart
 Frequency of samples
 Trade-off between cost of sampling and benefit of adjusting the
system
 Control limits
 Generally use z = 3

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 X-bar and R-Charts

   

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Process Control Charts – Interpretation

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Acceptance Sampling
 Performed on goods that already exist to determine
what percentage of the products conform to
specifications
 Executed through a sampling plan
 Results include accept, reject, or retest

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Acceptance Sampling – Purposes
 Determine quality level
 Ensure quality is within predetermined

level

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 Acceptance Sampling
Disadvantages Advantages

 Risks of accepting  Economy

“bad” lots and  Less handling damage
rejecting “good” lots  Fewer inspectors
 Added planning and
 Upgrading of the
inspection job
documentation  Applicability to
 Sample provides less
destructive testing
information than 100  Entire lot rejection
percent inspection (motivation for
improvement)

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Acceptance Sampling – Designing a Sampling Plan

 Determine (1) how many units, n, to sample from a

lot, and (2) the maximum number of defective items,
c, that can be found in the sample before the lot is
rejected
Acceptable quality Lot tolerance percent
level (AQL) defective (LTPD)
• Maximum acceptable • Percentage of defectives
percentage of defectives that defines consumer’s
defined by producer rejection point

 (producer’s risk)  (consumer’s risk)

• The probability of • The probability of
rejecting a good lot accepting a bad lot

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Operating Characteristic Curve

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