Statistical Process Control (Control Chart)

Course: Quality Management

Course Code: TE-4109

Nurul Ahad Choudhury

Lecturer, IPE
NITER
 Sources of Variation in Production and
Service Processes
• Common causes of variation : The common causes of variations occur
regardless of how well the process is designed. Such kind if variations are
uncontrollable, which result from numerous small causes.
– Random causes that we cannot identify
– Unavoidable
– Cause slight differences in process variables like diameter, weight, service time,
temperature, etc.
• Assignable causes of variation : This type of variation may take on large
variation, which may result in ‘out of control’ situation. The variability
may come from one or more number of possible assignable causes
assignable causes related to machine, tools, operators or the materials.
– Causes can be identified and eliminated
– Typical causes are poor employee training, worn tool, machine needing repair, etc.
Traditional Statistical Tools
 Descriptive Statistics include
 Measure of accuracy (centering)
 Measure of central tendency indicating the central
position of the series.
 A measure of the central value is necessary to estimate n
the accuracy or centering of a process.

 The Mean- simply the average of a set of data

x i
 Sum of all the measurements/data divided by the x i 1
number of observations.
 The Median- simply the value of middle item if the n
data are arranged in ascending or descending order.
K 
X
 Applies directly if the number in the series is odd.
 It lies between two middle numbers if the number j
of the series is even.
j 1
 The Mode- value that repeat itself maximum number
of times in the series.

K
 Shape of Distribution of Observed Data
 A measure of distribution of data
 Normal or bell shaped
 Skewed
Traditional Statistical Tools …cont’d
 Measure of Precision or Spread
 Reveals the extent to which numerical data
tend to spread about the mean value.
 The Range- the simplest possible measure
of dispersion.
 Difference between largest and smallest
observations in a set of data.
o Depends on sample size and it tends
to increase as sample size increases.
o Remains the same despite changes
in values lying between two extreme
values.

 Standard Deviation- a measure deviation

 x 
n 2
of the values from the mean.
i  X
 Small values >> data are closely σ  i1
clustered around the mean n 1
 Large values >> data are spread out
around the mean.
 Control Chart
Control Charts are one of the primary tools used in Statistical Process Control or
SPC. Control charts help to graphically represent different aspects of a process and
to assist engineers and technicians with producing a quality product. Control
charts are useful to establish when a process has endured a meaningful
modification; control charts separate the two types of variation in a product
quality characteristic.
A graphical display of data over time (data are displayed in time sequence
in which they occurred/measured) used to differentiate common cause
variation from special cause variation.

All control charts have three basic components:

• a centerline that represents the mean value for the incontrol process
• two horizontal lines, called the upper control limit (UCL) and the lower
control limit (LCL) that define the limits of common variation causes.
• performance data plotted over time.
 Control Chart
Control Charts allow a company’s performance over time to
be analyzed by combining performance data, average, range
and standard deviation. Control charts usually used to
analyze a process the company performs.
 Control Chart
 Interpretation of control chart
 Points between control limits are due to

characteristics
random chance variation

Measured
 One or more data points above an UCL or
below a LCL mark statistically significant
changes in the process
 A process is in control if Time period
 No sample points outside limits
 Most points near process average
 About equal number of points above and below centerline
 Points appear randomly distributed
 A process is assumed to be out of control if
 Rule 1: A single point plots outside the control limits;
 Rule 2: Two out of three consecutive points fall outside the two sigma warning limits on
the same side of the center line;
 Rule 3: Four out of five consecutive points fall beyond the 1 sigma limit on the same
side of the center line;
 Rule 4: Nine or more consecutive points fall to one side of the center line;
 Rule 5: There is a run of six or more consecutive points steadily increasing or
decreasing
Control Chart …Cont’d

 General model for a control chart

 UCL = μ + kσ
 CL = μ
 LCL = μ – kσ

where
 μ is the mean of the variable
 σ is the standard deviation of the variable
 UCL=upper control limit; LCL = lower control limit;
 CL = center line.
 k is the distance of the control limits from the center line,
expressed in terms of standard deviation units.
 When k is set to 3, we speak of 3-sigma control charts.
 Historically, k = 3 has become an accepted standard in
industry.
 Process Control Charts

Control Charts show sample data plotted on a graph with Center Line
(CL), Upper Control Limit (UCL), and Lower Control Limit (LCL).
 Types of the control charts
 Variables control charts: Control chart for variables are used to monitor
characteristics that can be measured, e.g. length, weight, diameter, time, etc.

 Variable data are measured on a continuous scale.

 For example: time, weight, distance or temperature can be
measured in fractions or decimals.
 Applied to data with continuous distribution

 Attributes control charts: Control charts for attributes are used to monitor
characteristics that have discrete values and can be counted, e.g. % defective,
number of flaws in a shirt, number of broken eggs in a box, etc.

 Attribute data are counted and cannot have fractions or decimals.

 Attribute data arise when you are determining only the presence
or absence of something:
 success or failure,
 accept or reject,
 correct or not correct.
 For example, a report can have four errors or five errors, but it
cannot have four and a half errors.
 Applied to data following discrete distribution
 Control Charts for Variables
• Mean (x-bar) charts
– Tracks the central tendency (the average value
observed) over time
• Range (R) charts:
– Tracks the spread of the distribution over time
(estimates the observed variation)
 X-bar chart
 General formulae for a control chart

 UCL = μ + kσx
k = 3,2,1 ; Accepted Standard
 CL =μ
 LCL = μ – kσx
 Constructing a X-bar Chart:

A quality control inspector at the Cocoa Fizz soft drink company has taken
three samples with four observations each of the volume of bottles filled.
If the standard deviation of the bottling operation is .2 ounces, use the
data below to develop control charts with limits of 3 standard deviations
for the 16 oz. bottling operation.

Time 1 Time 2 Time 3

Observation 1 15.8 16.1 16.0

Observation 2 16.0 16.0 15.9

Observation 3 15.8 15.8 15.9

Observation 4 15.9 15.9 15.8

 Step 1:
Calculate the Mean of Each Sample

Time 1 Time 2 Time 3

Observation 1 15.8 16.1 16.0

Observation 2 16.0 16.0 15.9

Observation 3 15.8 15.8 15.9

Observation 4 15.9 15.9 15.8

Sample means 15.875 15.975 15.9

(X-bar)
Step 2: Calculate the Standard Deviation
of the Sample Mean

σ  .2 
σx      .1
n  4
 Step 3: Calculate CL, UCL, LCL

 Center line (x-double bar):

15.875  15.975  15.9
x   15.92
3
 Control limits for ±3σ limits (z = 3):

UCLx  x  zσx  15.92  3 .1  16.22

LCLx  x  zσx  15.92  3 .1  15.62
Step 4: Draw the Chart
 An Alternative Method for the X-bar
Chart Using R-bar and the A2 Factor
Factor for x-Chart Factors for R-Chart
Sample Size
(n) A2 D3 D4
Use this method when sigma 2 1.88 0.00 3.27
for the process distribution 3 1.02 0.00 2.57
is not known. Use factor A2 4 0.73 0.00 2.28
5 0.58 0.00 2.11
from Table 6.1 6 0.48 0.00 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
Step 1: Calculate the Range of Each
Sample and Average Range

Time 1 Time 2 Time 3

Observation 1 15.8 16.1 16.0
Observation 2 16.0 16.0 15.9
Observation 3 15.8 15.8 15.9
Observation 4 15.9 15.9 15.8
Sample ranges 0.2 0.3 0.2
(R)

0.2  0.3  0.2

R   .233
3
 Step 2: Calculate CL, UCL, LCL

 Center line:

15.875  15.975  15.9

CL  x   15.92
3
 Control limits for ±3σ limits:

UCLx  x  A2 R  15.92  0.73 .233  16.09

LCLx  x  A2 R  15.92  0.73 .233  15.75
 Control Chart for Range (R-Chart)

Center Line and Control Limit Sample Size

Factor for x-Chart Factors for R-Chart

calculations:
(n) A2 D3 D4
2 1.88 0.00 3.27
3 1.02 0.00 2.57
0.2  0.3  0.2 4 0.73 0.00 2.28
CL  R   .233 5 0.58 0.00 2.11
3
6 0.48 0.00 2.00
7 0.42 0.08 1.92
UCL  D4R  2.28(.233)  .53 8 0.37 0.14 1.86
9 0.34 0.18 1.82
LCL  D3R  0.0(.233)  0.0 10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
R-Bar Control Chart
 x-bar and R charts
monitor different parameters!
Control Charts for Attributes –P-Charts
Control Chart for Attributes:
• Attributes are discrete events: yes/no or pass/fail
• Construction and interpretation are same as that of variable
control charts.

• Use P-Charts for quality characteristics that are discrete and

involve yes/no or good/bad decisions.
 Uses proportion nonconforming (defective) items in a sample
 Based on a binomial distribution
 Can be used for varying sample size
Example:
Percent of leaking caulking tubes in a box of 48
Percent of broken eggs in a carton
Control Chart: p chart
 Proportion nonconforming or defectives for each sample are plotted on the
p-chart
 The chart is examined to determine whether the process is in control.
 Means to calculate center line and control limits
 No standard or target value of proportion nonconforming is specified
 It must be estimated from sample infromation and
 For each sample, proportion of nonconforming items are
determined as

p  x
 The average
n of these individual sample proportion of
nonconforming items is used as the center line (CLp):

m m

 p x i U C Lp  p  3
p (1  p )
CL  p  i
 i
As true value ofmp is not n
nm known,
p

p-bar is used as an estimate p (1  p )

LC Lp  p  3
n
 Constructing a P-Chart:

A Production manager for 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.

Sample Sample Number

Size (n) Defective
1 20 3
2 20 2
3 20 1
4 20 2
5 20 1
 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
Step 2: Calculate the Standard Deviation
of P.

p(1-p) (.09)(.91)
σp= = =0.064
n 20
 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
Step 4: Draw the Chart
 Constructing a C-Chart:

Week Number of
The number of Complaints
weekly customer 1 3
complaints are 2 2
monitored in a large 3 3
hotel. Develop a 4 1
three sigma control 5 3
limits For a C-Chart 6 3
using the data table 7 2
On the right. 8 1
9 3
10 1
Total 22
Control Chart …Cont’d
 Setting Control Limits
 Type I error
 Concluding a process is not in control when it actually is.
 Type II error
 Concluding a process is in control when it is not.

/2 /2

Mean

Probability LCL UCL

of Type I error

In control Out of control

Type I error
In control No Error
(producers risk)

Type II Error
Out of control No error
(consumers risk)