PRODUCTION AND OPERATIONS MANAGEMENT

CONTROL CHARTS

What Is a Control Chart???

A statistical tool to determine if a process is in control

History of Control Charts

Developed in 1920s By Dr. Walter A. Shewhart
Shewhart worked for Bell Telephone Labs

Basic Principles
A typical control chart has control limits set at values such that if the process is in control, nearly all points will lie within the upper control limit (UCL) and the lower control limit (LCL).

Basic Principles

Why Use Control Charts???

Continually improve of your process Assess effectiveness of changes Communicate process performance Increased profits

Zero defects

Types of Control Charts

There are two main categories of Control Charts, o Those that display attribute data o Those that display variables data.

Variable Control Charts

Displays values resulting from the measurement of a continuous variable. Examples of variables data are elapsed time, temperature, and volume etc

Types of Variable Control Charts

X Bar chart: deals with a average value in a process R chart: takes into count the range of the values

X-Bar and R Control Chart

The X-Bar (arithmetic mean) and R (range) Control Chart is used with variables data when subgroup or sample size is between 2 and 15.

Steps for calculating and plotting an X-Bar and R Control Chart

Step 1 - Collect the data.

Step 2 - Divide the data into sub groups, it is recommended the subgroups be of 4 or 5 data points each. The data should be divided into subgroups in keeping with the following conditions: The data obtained should be from the same grouping of products produced. A sub group should not include data from a different lot or different process.

Steps for calculating and plotting an X-Bar and R Control Chart

STEP 3 - Calculate and enter the average for each subgroup.

Where: X- The average of the measurements within each subgroup xi -The individual measurements within a subgroup
n -The number of measurements within a subgroup, sample size

Steps for calculating and plotting an X-Bar and R Control Chart

Step 4 - Calculate and enter the range for each subgroup.

RANGE =(Largest Value in each Subgroup) - (Smallest Value in each Subgroup)

Steps for calculating and plotting an X-Bar and R Control Chart Step 5 - Calculate the grand mean of the subgroups average. The grand mean of the subgroups average (X-Bar) becomes the centerline

Where: X- The grand mean of all the individual subgroup averages xk- The average for each subgroup k - The number of subgroups

Steps for calculating and plotting an X-Bar and R Control Chart

Step 6 - Calculate the average of the subgroup ranges. The average of all subgroups becomes the centerline.

R = R1+ R2+ R3+ ...+Rk k Where: Ri The individual range for each subgroup R The average of the ranges for all subgroups k The number of subgroups

Steps for calculating and plotting an X-Bar and R Control Chart

Step 7 - Calculate the upper control limit (UCL) and lower control limit (LCL) for the averages of the subgroups.

Steps for calculating and plotting an X-Bar and R Control Chart

Step 8 - Calculate the upper control limit for the ranges. When the subgroup or sample size (n) is less than 7, there is no lower control limit.

Steps for calculating and plotting an X-Bar and R Control Chart

Step 9 - Select the scales and plot the control limits, centerline, and data points, in each plotting area.

Attribute Control Charts

Control charts that factor in the quality attributes of a process to determine if the process is performing in or out of control Displays data that result from counting the number of occurrences or items in a single category of similar items or occurrences. These count data may be expressed as pass/fail, yes/no, or presence/absence of a defect.

Types of Attribute Control Charts

p chart C chart u chart

p Control Charts
A chart of the percent defective in each sample set.

p- Average rate of defective in all sub-group N-Sample size

C Control Charts
A chart of the number of defects per unit in each sample set.

c- Average rate of defects in sub-groups

u Control Charts
A chart of the average number of defects in each sample set.

u- Average rate of defects in sub-groups n-Sample size

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Control Limits:

Control Limits:

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