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Statistical Quality Control PDF
Statistical Quality Control PDF
Statistical Quality Control PDF
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Acceptance Sampling:
Inspection provides a means for monitoring quality. For example, inspection may be performed on
incoming raw material, to decide whether to keep it or return it to the vendor if the quality level is not
what was agreed on. Similarly, inspection can also be done on finished goods before deciding
whether to make the shipment to the customer or not. However, performing 100% inspection is
generally not economical or practical, therefore, sampling is used instead.
Acceptance Sampling is therefore a method used to make a decision as to whether to accept or to
reject lots based on inspection of sample(s). The objective is not to control or estimate the quality of
lots, only to pass a judgment on lots.
Using sampling rather than 100% inspection of the lots brings some risks both to the consumer and to
the producer, which are called the consumer's and the producer's risks, respectively. We encounter
making decisions on sampling in our daily affairs.
Example:
LOT (N)
SAMPLE (n)
STATISTICAL Inference is made on the quality of the lot by inspecting only the small sample drawn
from the lot.
Example:
Suppose n=100 and c=3, which means that if the number of defectives in the sample
(d) is equal to 0, 1, 2, or 3, then the lot will be accepted, and if d is 4 or more, then
the lot will be rejected.
Accept
No Error
Reject
Error
(Producers
Risk)
Bad
Error
(Consumers
Risk)
No Error
In general, both the producer and the consumer want to minimize their risks. The choice of a well
designed sampling plan can help both the producer and the consumer maintain their respective risks at
acceptable levels to both. For example, = 5% for AQL of 0.02 and = 10% for LTPD of 0.08.
Keeping c constant:
X =
UCLx = X + 3 x
where:
LCLx = X 3 x
x is further estimated using the range information (i.e., 3 x = A2 R ); as such the control limit
calculations are much simplified. The simplified control limits are as follows:
UCLx = X + A2 R
LCLx = X A2 R
where A2 is a factor available in tables for different sample sizes (see table below).
R-Charts:
g
R=
where
UCLR = R + 3 R
LCLR = R 3 R
LCLR = D3 R
where D3 and D4 are factors available in tables for different sample sizes (see table below).
n
2
3
4
5
6
R = __________
X = __________
A2 = __________
D3 = __________
D4 = __________
R-Chart:
UCL = D4 R
=
LCL = D3 R
=
Does the R chart show that the process is under control? Yes or No and why?
X -Chart:
UCL = X + A2 R
=
LCL = X - A2 R
=
Does the X chart show that the process is under control? Yes or No and why?
Another Example:
The St. Patrick's Hospital is starting a quality improvement project on the time to admit a patient
using X and R Charts. Determine the limits for the X and R charts and check to see if there are any
out-of-control points.
OBSERVATION
OBSERVATION
Subgroup
Number
X1
X2
X3
1
2
3
4
5
6
7
8
9
10
11
12
6.0
5.2
5.5
5.0
6.7
5.8
5.6
6.0
5.5
4.3
6.2
6.7
5.8
6.4
5.8
5.7
6.5
5.2
5.1
5.8
4.9
6.4
6.9
7.1
6.1
6.9
5.2
6.5
5.5
5.0
5.2
6.0
5.7
6.3
5.0
6.2
Subgroup
Number
X1
X2
X3
13
14
15
16
17
18
19
20
21
22
23
24
6.1
6.2
4.9
7.0
5.4
6.6
4.7
6.7
6.8
5.9
6.7
7.4
6.9
5.2
6.6
6.4
6.5
7.0
6.2
5.4
6.5
6.4
6.3
6.8
7.4
6.8
6.6
6.1
6.7
6.8
7.1
6.7
5.2
6.0
4.6
6.3
n = __________
R = __________
X = __________
A2 = __________
D3 = __________
D4 = __________
R-Chart:
UCL = D4 R
=
LCL = D3 R
=
Does the R chart show that the process is under control? Yes or No and why?
X -Chart:
UCL = X + A2 R
=
LCL = X - A2 R
=
Does the X chart show that the process is under control? Yes or No and why?
p =
p (1 p )
n
LCL = p Z p
or
UCL = p + Z
p (1 p )
n
LCL = p Z
p (1 p )
n
Usually the Z value is equal to 3 (as was used in the X and R charts), since the variations within
three standard deviations are considered as natural variations. However, the choice of the value of Z
depends on the environment in which the chart is being used, and on managerial judgment.
Example:
A computer manufacturer collects data from the final test of its product starting from the end of
January and all through February. Each day a sample of 2000 items are inspected and the number of
items in the sample that do not conform to specifications is recorded. The data is shown below:
Subgroup Number
Number Inspected
(day)
1
2
3
4
5
6
7
8
9
10
11
12
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
Number
Defective
Percent
Defective
55
18
50
42
39
52
47
34
29
53
45
26
n = __________
Subgroup
Number
(day)
Number
Inspected
Number
Defective
13
14
15
16
17
18
19
20
21
22
23
24
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
47
31
38
28
30
113
58
34
19
30
17
46
p = __________
UCL = __________
p = __________
LCL = __________
Percent
Defective