UNIT 2

Quality Control

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Statistical Process Control

UCL

LCL

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CONTROL CHART

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Control Charts W.A. Sehwart

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Where to Use Control Charts

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Control Charts

• Types of charts
– Attributes
• p-chart
• c-chart
– Variables
• range (R-chart)
• mean (x bar – chart)

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Control Charts for Variables

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X BAR and R Chart

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UCL  X  3x   R / d2

LCL  X  3x x   / n

 = Std. Deviation of universe

x = Std. Deviation of expected frequency

11

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 X AND R CHART EXAMPLE

• The following collection of data represents samples of the amount of force

applied in a gluing process:

• Determine if the process is in control

by calculating the appropriate upper and lower
control limits of the X-bar and R charts.

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X AND R CHART EXAMPLE

Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5

1 10.68 10.689 10.776 10.798 10.714
2 10.79 10.86 10.601 10.746 10.779
3 10.78 10.667 10.838 10.785 10.723
4 10.59 10.727 10.812 10.775 10.73
5 10.69 10.708 10.79 10.758 10.671
6 10.75 10.714 10.738 10.719 10.606
7 10.79 10.713 10.689 10.877 10.603
8 10.74 10.779 10.11 10.737 10.75
9 10.77 10.773 10.641 10.644 10.725
10 10.72 10.671 10.708 10.85 10.712
11 10.79 10.821 10.764 10.658 10.708
12 10.62 10.802 10.818 10.872 10.727
13 10.66 10.822 10.893 10.544 10.75
14 10.81 10.749 10.859 10.801 10.701
15 10.66 10.681 10.644 10.747 10.728

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Step 1: Calculate sample means, sample ranges, mean of means, and
mean of ranges

Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5 Avg Range

1 10.68 10.689 10.776 10.798 10.714 10.732 0.116
2 10.79 10.86 10.601 10.746 10.779 10.755 0.259
3 10.78 10.667 10.838 10.785 10.723 10.759 0.171
4 10.59 10.727 10.812 10.775 10.73 10.727 0.221
5 10.69 10.708 10.79 10.758 10.671 10.724 0.119
6 10.75 10.714 10.738 10.719 10.606 10.705 0.143
7 10.79 10.713 10.689 10.877 10.603 10.735 0.274
8 10.74 10.779 10.11 10.737 10.75 10.624 0.669
9 10.77 10.773 10.641 10.644 10.725 10.710 0.132
10 10.72 10.671 10.708 10.85 10.712 10.732 0.179
11 10.79 10.821 10.764 10.658 10.708 10.748 0.163
12 10.62 10.802 10.818 10.872 10.727 10.768 0.250
13 10.66 10.822 10.893 10.544 10.75 10.733 0.349
14 10.81 10.749 10.859 10.801 10.701 10.783 0.158
15 10.66 10.681 10.644 10.747 10.728 10.692 0.103

Averages 10.728 0.220400

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Step 2: Determine Control Limit Formulas and
Necessary Tabled Values

n A2 D3 D4
x Chart Control Limits 2 1.88 0 3.27
3 1.02 0 2.57
UCL = x + A 2 R 4 0.73 0 2.28
5 0.58 0 2.11
LCL = x - A 2 R 6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
R Chart Control Limits 9 0.34 0.18 1.82
10 0.31 0.22 1.78
UCL = D 4 R 11 0.29 0.26 1.74
LCL = D 3 R

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Steps 3&4: Calculate limits and Plot Values

UCL = x + A2 R  10.728  .58( 0.2204 )=10.856

LCL = x - A2 R  10.728-.58( 0.2204 )=10.601
10.900

10.850

10.800

10.750
Means

Sample
10.700 mean
UCL

10.650 LCL

10.600 grand
mean of x

10.550
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

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Steps 5&6: Calculate R-chart and Plot Values

UCL = D 4 R  ( 2.11)( 0.2204 )  0.46504

LCL = D 3 R  ( 0)( 0.2204 )  0
0.800
0.700
0.600
0.500 Range
UCL
R 0.400
LCL
0.300 R-bar

0.200
0.100
0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

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Limitations of Chart for variable

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Control charts for attributes

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GO NO GO Gauge

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 Types of Attribute Control Charts

• P chart
• C Chart
• U Chart

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Attribute Control Charts

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Control Charts for Attributes –P-Charts & C-
Charts

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Constructing a P-Chart:

A Production manager of a tire company has inspected the number

of defective tires in five random samples with 20 tires in each
sample. The table below shows the number of defective tires in each
sample of 20 tires. Check whether the process is in control or not.

Sample Sample Number

Size (n) Defective
1 20 3
2 20 2
3 20 1
4 20 2
5 20 1
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Step 1:
Calculate the Percent defective of Each Sample and the
Overall Percent Defective (P-Bar)

Sample Number Sample Percent

Defective Size Defective
1 3 20 .15
2 2 20 .10
3 1 20 .05
4 2 20 .10
5 1 20 .05
Total 9 100 .09

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Step 2: Calculate the Standard Deviation of P.

p(1-p) (.09)(.91)
σp= = =0.064
n 20

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Step 3: Calculate CL, UCL, LCL

 Center line (p bar):

CL  p  .09
 Control limits for ±3σ limits:

UCL  p  z σ p   .09  3(.064)  .282

LCL  p  z σ p   .09  3(.064)  .102  0

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Step 4: Draw the Chart

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 Constructing a C-Chart:
Week Number of
The number of Complaints
weekly customer 1 3
complaints are 2 2
monitored in a 3 3
large hotel. 4 1

Develop a three 5 3
6 3
sigma control
7 2
limits For a C-Chart
8 1
using the data
9 3
table On the right.
10 1
Total 22
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Calculate CL, UCL, LCL

No. of defects in all sample/

 Center line (c bar): total no. of samples

#complaints 22
CL    2.2
# of samples 10

 Control limits for ±3σ limits:

UCL  c  z c  2.2  3 2.2  6.65
LCL  c  z c  2.2  3 2.2  2.25  0

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Quality Measures

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 U-Chart
A u-chart is an attributes control chart used with data
collected in subgroups of varying sizes. U-charts show
how the process, measured by the number of
nonconformities per item or group of items, changes
over time. Nonconformities are defects or occurrences
found in the sampled subgroup.

Defect per unit

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U-Chart

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U-Chart
• A car company monitors the number of paint
defects per car by taking a sample of 5 cars each
day over the next 6 days.
• The results are shown on next slide.

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u-Chart

u 
 u
k

u 
 u 63.2
  10.5
k 6

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u-Chart

u
LCL  u  3
n
u
UCL  u  3
n
where u is the central line and equal to
Total Defects
Total Units

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U-Chart

Day n c u=c/n u-bar LCL UCL

1 5 45 9.0 10.5 6.18 14.888
2 5 58 11.6 10.5 6.18 14.888
3 5 48 9.6 10.5 6.18 14.888
4 5 53 10.6 10.5 6.18 14.888
5 5 68 13.6 10.5 6.18 14.888
6 5 44 8.8 10.5 6.18 14.888
Sum u 63.2
u-bar 10.5

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u-Chart

u
LCL  u  3
n
10.5
 10.5  3  6.18
5
u
UCL  u  3
n
10.5
 10.5  3  14.89
5
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u-Chart
u-Chart
Number of Paint Defects Per Car

c, number of defects 16
14
12 LCL
10
UCL
8
u
6
4 u-bar
2
0
1 2 3 4 5 6

Car

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