Application of control charts in the diameter of

dowels

Mármol Díaz Ana Hercilia Salazar Roballo Jordanis

Estudiante (Ingeniería industrial) Estudiante (Ingeniería industrial)
Universidad del Atlántico Universidad del Atlántico
Barranquilla, Atlántico, Colombia Barranquilla, Atlántico, Colombia
amarmol@mail.uniatlantico.edu.co jsalazar@mail.uniatlantico.edu.co

Torres Guerrero Julio Cesar

Estudiante (Ingeniería industrial)
Universidad del Atlántico
Barranquilla, Atlántico, Colombia
jcesartorres@mail.uniatlantico.edu.co

1

I. ABSTRACT
In this article we will develop the simulation of the
manufacturing of dowel bs, where the main characteristic of
study of this one will be its diameter. Ten subgroups of 3 data
are initially recorded for a total of 30 data in the first study table
where the first phase will be applied. Based on this data, the
necessary statistical tools will be used to calculate the
parameters, the control charts, and finally the capability index
and then process control is performed. In this way, the
specification limits are calculated and after that the capability
index to know whether or not the process is capable is found.
All this is summarized in an article where the application of the
control letters of Engineer W. A. Shewhart is shown in order to
be analyzed and interpreted; thus generating in the reader an
empowerment on quality control.
Key Words: Tracking and line diagrams, variability and
location measurements, normality tests, confidence intervals,
quality control, specification limits, historical limits, standard
limits, capacity index.
II. INTRODUCTION
In an increasingly competitive system it is necessary for
companies to maintain quality standards in their production, in
order to meet the needs and expectations of their users. In order
to do this, it is necessary to carry out quality control of the
processes and thus prevent the existence of factors that impede
compliance with the minimum quality standards.
According to Walter Shewhart, quality can be understood as "a
problem of variation, which can be controlled and prevented by
eliminating in time the causes that cause it".
Industrial processes are subject to a series of random factors
that make it impossible to manufacture two products that are
exactly alike. In other words, the characteristics of the product
manufactured are not uniform and are variable. This variability
is clearly undesirable and the aim should be to reduce it as much
as possible or at least keep it within limits.
In the production of dowels there are multiple factors that
influence certain quality characteristics that are expressed in
terms of a numerical measurement. For this reason, it is
important to use a tool that contributes to improving the quality
of manufacturing and makes it necessary to monitor the entire
process from the beginning to the end. In this article we will
present the importance of the application of Shewhart control
charts, where their particularity is to take statistical control of
processes and their variability is widely used.
III. THEORETICAL FRAMEWORK
The control cards.
The basic objective of a control chart is to observe and analyze
the behavior of a process over time. Thus, it is possible to
distinguish between variations for common and special
(attributable) causes, which will help to characterize the
functioning of the process and to decide on the best control and
2
improvement actions. When we talk about analyzing the process we are
referring mainly to the output variables (quality characteristics), but the
control charts can also be applied to analyze the variability of input
variables or to control the process itself. [1]
Control limits.
The first thing to be clear about the limits of a control chart is that these
are not the specifications, tolerances or wishes for the process. Instead,
they are calculated from the variation in the statistic (data) represented
in the chart. Thus, the key is to establish the limits to cover a certain
percentage of the natural variation of the process, but care must be taken
to ensure that this percentage is adequate, since if it is too high
(99.99999999%) the limits will be too wide and it will be more difficult
to detect changes in the process; while if the percentage is small, the
limits will be too narrow and thus the standard error 1 will increase (say
that a change occurred when in fact there was no change). [2]
To calculate the control limits, one must act in such a way that, under
statistical control conditions, the data plotted on the chart have a high
probability of falling within such limits. Therefore, one way to proceed
is to find the probability distribution of the variable, estimate its
parameters and locate the limits so that a high percentage (99.73%) of
the distribution is within them (see Duncan, 1989). This is known as
probability limits. [3]
A simpler and more usual way is obtained from the relation between the
mean and the standard deviation of W, which for the case that W is
distributed normal with mean and standard deviation σw, and under
conditions of statistical control it is necessary to enter and
find 99.73% of the possible values of W. In the case that there is no
normal distribution, but there is a unimodal distribution with a shape not
very different from the normal one, then the empirical rule or the
extension of the Chebyshev theorem is applied. Under these conditions,
a general model for a control chart is as follows: W is the statistic to be
plotted on the chart, let us suppose that its mean is and its standard
deviation, then the lower control limit (LCI), the centre line and the
upper control limit (LCS) are given by:
𝐿𝐶𝐼 = 𝜇𝑤 − 3𝜎𝑤
𝑐𝑒𝑛𝑡𝑒𝑟 𝑙𝑖𝑛𝑒 = 𝜇𝑤
𝐿𝐶𝑆 = 𝜇𝑤 + 3𝜎𝑤
Types of control charts.
There are two general types of control charts: for variables and for
attributes. Control charts for variables are applied to continuous quality
characteristics, which intuitively are those that require a measuring
instrument (weight, volume, voltage, length, resistance, temperature,
humidity, etc.). [4]
The most common charts for Shewhart variables are:
 𝑋(𝑀𝑒𝑎𝑛 𝑣𝑎𝑙𝑢𝑒)
 𝑅(𝑅𝑎𝑛𝑔𝑒)
 S (Standard deviation)
 𝑋(𝐼𝑛𝑑𝑖𝑣𝑖𝑑𝑢𝑎𝑙 𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑚𝑒𝑛𝑡)
The different ways of calling a control chart are due to the 𝐿𝐶𝐿 = 𝑋̿ − 𝐴2 𝑅̅
corresponding statistic that is represented in the chart, and
through which an important characteristic of a product or
process is analyzed. Process parameters Formulas (6) and (7)

There are quality characteristics of a product that are not 𝐸(𝑅̅ ) ̅̅̅
𝑅2
measured with a measuring instrument on a continuous scale or 𝜎̂ = =
𝑑2 𝑑2
at least on a numerical scale. In these cases, the product is
𝜇̂ = 𝐸(𝑋̿) = 𝑋̿0
judged as conforming or non-conforming, depending on
𝑤ℎ𝑒𝑟𝑒 𝑑2 𝑖𝑠 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑡ℎ𝑎𝑡 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑜𝑛 𝑡ℎ𝑒 𝑠𝑢𝑏𝑔𝑟𝑜𝑢𝑝
whether or not it has certain attributes; also, the product may be
counted for the number of defects or nonconformities it has.
[5,6] These types of quality characteristics are monitored
through attribute control charts: Control Limits for Average Range Phase II
 𝑝(𝑝𝑟𝑜𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑜𝑟 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑜𝑏𝑗𝑒𝑡𝑠) 𝑈𝐶𝐿 = (𝑑2 + 3𝑑3 )𝜎
 𝑛𝑝(𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑛𝑜𝑛𝑐𝑜𝑛𝑓𝑜𝑟𝑚𝑖𝑛𝑔 𝑢𝑛𝑖𝑡𝑠) 𝐶𝐿 = 𝑑2 𝜎
 𝑐(𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑠) 𝐿𝐶𝐿 = (𝑑2 − 3𝑑3 )𝜎
 𝑢(𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑓𝑒𝑐𝑡𝑠 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡)
Simplifying
What are dowels?
𝑈𝐶𝐿 = 𝐷2 𝜎(𝟖)
The dowels also known as mechanical cleats, dowels or 𝐶𝐿 = 𝑑2 𝜎(𝟗)
anchors, are pieces made of various materials. Household items 𝐿𝐶𝐿 = 𝐷1 𝜎(𝟏𝟎)
are usually made of nylon, a highly elastic material that
maintains pressure for a long time, does not break easily with
the passage of the screw, resists temperatures from -40°C to The values D2 and D1 are constants that depend on the sample size n of
80°C, and has great resistance to aging and oxidation. In the the subgroup and σ = average R/d2.
industry and for more demanding jobs, the iron dowels have had
a significant reception. [7]
Control limits for average X Phase II

X-R control chart. 𝑈𝐶𝐿 = 𝜇 + 𝐴𝜎(𝟏𝟏)

𝐶𝐿 = 𝜇(𝟏𝟐)
Control Limits for Average Range Phase I Formulas (1), (2) and 𝐿𝐶𝐿 = 𝜇 − 𝐴𝜎(𝟏𝟑)
(3) [8]

√𝑉(𝑅) √𝑉(𝑅)
𝑈𝐶𝐿 = 𝑅̅ + 3𝜎
̂𝑅 = 𝑅̅ + 3 𝑅̅ = 𝑅̅ [1 + 3 ]
𝐸(𝑅) 𝐸(𝑅)
𝐶𝐿 = 𝑅̅
√𝑉(𝑅) √𝑉(𝑅)
𝐿𝐶𝐿 = 𝑅̅ − 3𝜎
̂𝑅 = 𝑅̅ − 3 𝑅̅ = 𝑅̅ [1 − 3 ]
𝐸(𝑅) 𝐸(𝑅) Univariate capacity index
Simplifying
𝑈𝐶𝐿 = 𝐷4 𝑅̅ Evaluates the quality of one of the varials of a process.
𝐶𝐿 = 𝑅̅
𝐿𝐶𝐿 = 𝐷3 𝑅̅ 𝐿𝑒𝑠 − 𝑙𝑒𝑖
𝐶𝑝 =
𝐾𝜎

Control limits for average X Phase I Where les and lei are the upper specification limits and lower, the k-value
is usually 6 and 𝐾𝜎 are the limits of the process. That is, traditional
Formulas (3), (4) and (5) formulation is defined as, long-term capability index:

𝐿𝑒𝑠 − 𝑙𝑒𝑖
√𝑉(𝑅) 𝐶𝑝 = (𝟏𝟒)
𝑈𝐶𝐿 = 𝑋̿ + 3𝜎𝑥 = 𝑋̿ + 3 𝑅̅ 6𝜎
𝑅
𝐸( ⁄𝑁 (𝑜, 1))
𝐶𝐿 = 𝑋̿ Other authors define this index as a percentage capacity ratio,
√𝑉(𝑅)
𝐿𝐶𝐿 = 𝑋̿ − 3𝜎𝑥 = 𝑋̿ − 3 𝑅̅ 𝐾𝜎
𝑅
𝐸( ⁄𝑁 (𝑜, 1)) 𝐶𝑝 = × 100%(𝟏𝟓)
𝐿𝑒𝑠 − 𝐿𝑒𝑖
Simplifying

𝑈𝐶𝐿 = 𝑋̿ + 𝐴2 𝑅̅
𝐶𝐿 = 𝑋̿
3
IV. X-R CONTROL LETTER APPLICATION

PHASE I

30 randomly selected dowels were extracted, and for each dowel

the measure "diameter" was taken 3 times. 𝑭𝒐𝒓 𝑹
𝐿𝐶𝑆 = 𝐷4 𝑅̅
For each subgroup of dowels, the R and X ̅ were calculated as 𝐿𝐶𝑆 = (2,575)(0,10) = 0,257
shown in the following table:
𝐿𝐶 = 𝑅̅ = 0,10
Sub- X1 X2 X3 𝑋̅ R
grupos 𝐿𝐶𝑆 = 𝐷3 𝑅̅
1 4,85 4,60 4,65 4,71 0,25 𝐿𝐶𝑆 = (0)(0,10) = 0
2 4,70 4,65 4,60 4,65 0,10
3 4,65 4,70 4,60 4,65 0.05
4 4,70 4,70 4,80 4,73 0,10
5 4,60 4,70 4,70 4,66 0,10 R
6 4,8 4,65 4,60 4,68 0,20
0,300
7 4,65 4,65 4,60 4,63 0,05
8 4,65 4,65 4,60 4,63 0,05
0,200
9 4,65 4,60 4,65 4,63 0,05
10 4,65 4,65 4,65 4,65 0
Table 1. Table of measurements made 0,100

̿ = 𝟒, 𝟔𝟔
𝑿 ̅ = 𝟎, 𝟏𝟎
𝑹 0,000
1 2 3 4 5 6 7 8 9 10
histogram
R UCL CL LCL
𝑭𝒐𝒓 𝑿 Fig 2. Control chart R for phase I
𝐿𝐶𝑆 = 𝑋̿ + 𝐴2 × 𝑅̅
𝐿𝐶𝑆 = 4,66 + 1,023 × 0,10 = 4,76

𝐿𝐶 = 𝑋̿ = 4,66 PHASE II

𝐿𝐶𝐼 = 𝑋̿ − 𝐴2 × 𝑅̅ 𝜇 = 𝑋̅ = 𝐿𝐶 = 4,66
𝐿𝐶𝐼 = 4,66 − 1,023 × 0,10 = 4,55 𝑅̅ 0,10
𝜎= = = 0,0590
𝑑2 1,693
X
𝑭𝒐𝒓 𝑿
4,8
𝐿𝐶𝑆 = 𝜇 + 𝐴𝜎
4,7 𝐿𝐶𝑆 = 4,66 + 1,732 × 0,0590 = 4,76
4,6
𝐿𝐶 = 𝜇 = 4,66
4,5
𝐿𝐶𝐼 = 𝜇 − 𝐴𝜎
4,4 𝐿𝐶𝐼 = 4,66 − 1,732 × 0,0590 = 4,55
1 2 3 4 5 6 7 8 9 10

X UCL CL LCL
X
4,8
Fig 1. Control chart X for phase I
4,7

4,6

4,5

4,4
1 2 3 4 5 6 7 8 9 10

X UCL CL LCL

Fig 3. Control chart X for phase II

4
 Histogram

intervals f Fr F Fr
𝑭𝒐𝒓 𝑹 4,60 – 4,65 24 0,7 21 0,7
𝐿𝐶𝑆 = 𝐷2 𝜎 4,65 – 4,70 6 0,2 27 0,9
𝐿𝐶𝑆 = (4,358)(0,0590) = 0,257 4,70 – 4,75 0 0 27 0,9
4.75 – 4,80 2 0,06 29 0,96
𝐿𝐶 = 𝑑2 𝜎 = (1,693)(0,0590) = 0,10
4.80 – 4,85 1 0,03 30 1
Table 2. frequency table with n=30
𝐿𝐶𝐼 = 𝐷1 𝜎
𝐿𝐶𝐼 = (0)(0,0590) = 0

histogram
R
25
0,300
20
0,200
15
0,100 10

0,000 5
1 2 3 4 5 6 7 8 9 10 0
R UCL CL LCL 1 2 3 4 5
Fig 5. Histogram
Fig 4. Control chart R for phase II

Capacity index

Since the diameter of the jaws follows a normal

distribution, we proceed to look for the indexes LES and
LEI tolerances, with the following equations.

𝐿𝐸𝑆 = 𝜇̂ + 𝐾𝜎̂ (16)

𝐿𝐸𝐼 = 𝜇̂ − 𝐾𝜎̂ (17)

Where K is a constant that depends on data # and %

reliability.

K= 2,140
LES = 4,786
LEI = 4,533

We proceed to calculate the capacity index, with the

equation (14)

𝐂𝒑 = 𝟎, 𝟕𝟏𝟒

It does not comply with the design specifications and non-

conforming units are presented due to the fact that the result
𝐂𝒑 ≥ 𝟏

5

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