Chapter V

(part 4)

QCC Tool: Control Charts

 IMPLEMENTING CONTROL CHARTS

How do we implement control charts?

1. Preparation: how to sample?

2. Retrospective analysis: how to set up control charts?
3. Prospective analysis: how to use control charts?
 1. PREPARATION

How to sample?

▪ Choose quality variable(s)

▪ critical,
▪ controllable,
▪ measurable
▪ Develop a good measuring system
▪ Select sampling strategy
▪ Select subgroup size
▪ Select sampling frequency

Goal: make sure that you have rational subgroups!

 RATIONAL SUBGROUPS

Rational subgroup
= set of observations of a process parameter, taken
together, such that if an assignable cause appears:

1. variation among the items in the subgroup ( within subgroup

variation) is minimized
2. variation between the subgroups (between subgroup variation) is
maximized

Why? Maximize chances of detecting assignable cause, if present.

 SAMPLING FREQUENCY

◾Economic considerations: if cost of producing defective items

is large, then sample more frequently (also if rate of
production is high)

◾Related to subgroup size:

▪ Small samples & short intervals
▪ Large samples & long intervals
= allocate sampling effort
→ compare options based on OC curve, ARL, …

◾Adaptive control chart:

Process out of control: sampling frequency ↑
Process in control: sampling frequency ↓
 COMMON MISTAKES

1. Stratification

2. Mixture

3. Cyclic pattern
 STRATIFICATION

= subgroup has units from different underlying distributions,

systematically represented in the subgroup

Effect on control chart:

points cluster artificially around the center line (lack of natural
variability)

Consequence: process will always seem in control

 STRATIFICATION

Example: filling process for paint spray, 6 nozzles

Use a subgroup size (n) of 6?
 MIXTURE

= subgroup has units from different underlying distributions,

variable representation from subgroup to subgroup

Effect on control chart:

points are near (or outside) the control lines, few points near
the center line

Consequence: process will always seem out of control (risk of

overadjustment)
 CYCLIC PATTERN

= systematic, reoccuring patterns on control charts

Effect on control chart:

Causes:
◾Regular rotation of operators (morning shift/evening shift)
◾Environmental changes (morning, midday temperature)
◾Fatigue
◾…
 CYCLIC PATTERN

= systematic, reoccuring patterns on control charts

Effect on control chart:

Solutions:
◾Avoid differences (e.g. improve work instructions)
◾Adjust sampling strategy
◾Make separate control charts
 IMPLEMENTING CONTROL CHARTS

How do we implement control charts?

1. Preparation: how to sample?

2. Retrospective analysis: how to set up control charts?
3. Prospective analysis: how to use control charts?
 2. RETROSPECTIVE ANALYSIS

How to set up control charts?

▪ Select an appropriate chart type

▪ Collect data (>50 subgroups)
▪ Compute central line, control lines & plot charts
▪ Assess state of control
If out of control: eliminate special cause(s), resample (or remove
samples with special cause), and recalculate until control lines
are based on process in control
▪ Develop out-of-control action plan
▪ Document procedure & provide training

Goal: set up reliable control charts for future use

2. RETROSPECTIVE ANALYSIS
 EXAMPLE

◾Bart is an employee of Volvo

Truck Parts Gent. He produces a
part which has as main quality
characteristic its length.
Specifications for the length are
10.8 – 13.2 mm, with a target
value of 12mm.

◾Volvo Truck Parts Gent is

starting with statistical
processing control to monitor
Bart’s work. Four times a day, a
sample of 6 parts is taken.
 EXAMPLE

Collected data (sample number. sample average/ sample range)

1. 12.14/2.93 9. 11.49/1.17 17. 12.58/1.00 25. 11.85/1.55
2. 11.79/0.99 10. 11.88/1.42 18. 12.74/0.64 26. 11.83/1.71
3. 12.10/1.59 11. 12.00/1.71 19. 12.41/1.93 27. 12.36/1.46
4. 11.95/2.49 12. 12.11/1.62 20. 12.38/0.91 28. 11.96/1.00
5. 12.02/3.39 13. 11.92/0.69 21. 12.01/2.04 29. 11.99/0.64
6. 12.20/2.05 14. 11.92/1.55 22. 12.03/1.95 30. 11.67/1.93
7. 12.35/0.57 15. 12.16/0.86 23. 11.83/0.71 31. 11.60/1.91
8. 12.10/2.46 16. 12.28/2.26 24. 11.99/0.69 32. 12.05/0.88

Notes:
◾ Starting from sample 9, a new supply of raw materials was used from the
same supplier
◾ On Friday afternoon (samples 17 -20 ), it was extremely cold, which may
have had consequences for the production process
◾ Right af ter sample 24, the machine had maintenance
 EXAMPLE

Your task: set up suitable control charts for this process

Which type of control chart?

 EXAMPLE

Your task: set up suitable control charts for this process

Which type of control chart?

variable quality characteristic (length)
n= 6 & subgroup size is constant

-R control chart
 EXAMPLE

Your task: set up suitable control charts for this process

Which type of control chart?

variable quality characteristic (length)
n= 6 & subgroup size is constant

-R control chart

Note: The control chart has to be based on a process in control!

How can we be sure about that?

→ Ignore/ replace samples if good reasons to believe that they are

drawn from a process that was not in control at that time
 EXAMPLE

Your task: set up suitable control charts for this process

Which type of control chart?

variable quality characteristic (length)
n= 6 & subgroup size is constant

-R control chart

Note: The control chart has to be based on a process in control!

How can we be sure about that?

→ Ignore/ replace samples if good reasons to believe that they are

drawn from a process that was not in control at that time

→ Start with R chart

 EXAMPLE: R-CHART

◾Compute control limits

= 1 .522

◾R-chart
▪ D3 = 0 (n=6)
▪ D4 = 2.004 (n=6) UCL(R) = D4
CL(R) =
▪ UCL = 2.004 * 1.522 = 3.050
LCL(R) = D3
▪ CL = 1.522
▪ LCL = 0 * 1.522 = 0

Are these control lines based on a process in control?

 EXAMPLE: R-CHART

3,5

3 UCL
3.051
2,5

1,5 CL
1.522
1

0,5

0 LCL
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
 EXAMPLE: R-CHART

4
Extreme point
Cause? new supply of raw materials (sample 9)
3,5
Remove samples 1 – 8
3 UCL
3.051
2,5

1,5 CL
1.522
1

0,5

0 LCL
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
 EXAMPLE: R-CHART

◾Recompute control limits

= 1 .344

◾R-chart
▪ D3 = 0 (n=6)
▪ D4 = 2.004 (n=6)
▪ UCL = 2.004 * 1.344 = 2.693
▪ CL = 1.344
▪ LCL = 0 * 1.344 = 0

Are these control lines based on a process in control?

 EXAMPLE: R-CHART

3,5

3
UCL
2,5 2.693
2

1,5
CL
1 1.344

0,5

0 LCL
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
76
 EXAMPLE: -CHART

◾Compute control limits

= 1 2.043; = 1 .344

◾ -chart
▪ A2 = 0.483 (n=6)
ന+ A2*R
UCL( ) = X ഥ
▪ UCL = 12.043 + 0.483*1.344 = 12.692
CL( ) = നX
▪ CL = 12.043 ന- A2*R
ഥ
LCL( ) = X
▪ LCL = 12.043 - 0.483*1.344 = 11.394

Are these control lines based on a process in control?

 EXAMPLE: -CHART

13
12,8
12.693
12,6
12.477
12,4
12,2 12.260
12 12.043
11,8 11.826
11,6 11.610
11,4 11.394
11,2
11
10,8
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
 EXAMPLE: -CHART
Extreme point

2 out of 3 in zone A or further

13
12,8 4 out of 5 in zone B or further
12.693
12,6
12.477
12,4
12,2 12.260
12 12.043
11,8 11.826
11,6 11.610
11,4 11.394
11,2
11
Extreme cold: remove
10,8 sample 17 – 20
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
 EXAMPLE: R-CHART (AGAIN)

◾Recompute control limits:

= 1 .388

◾R-chart
▪ D3 = 0 (n=6)
▪ D4 = 2.004 (n=6)
▪ UCL = 2.004 * 1.388 = 2.782
▪ CL = 1.388
▪ LCL = 0 * 1.388 = 0

Are these control lines based on a process in control?

 EXAMPLE : R-CHART (AGAIN)

3,5

3
UCL
2,5 2.782
2

1,5
CL
1 1.388

0,5

0 LCL
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
 EXAMPLE: -CHART

◾Recompute control limits

= 11.947; = 1.388

◾ -chart
▪ A2 = 0.483 (n=6)
▪ UCL = 11.947 + 0.483*1.388 = 12.618
▪ CL = 11.947
▪ LCL = 11.947 - 0.483*1.388 = 11.277

Are these control lines based on a process in control?

 EXAMPLE: -CHART

13
12,8
12,6 12.618
12,4 12.395
12,2
12.171
12
11.947
11,8 11.724
11,6
11.501
11,4
11,2
11.277
11
10,8
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
 EXAMPLE

◾Final result (based on process in control)

▪ -chart
▪ UCL = 12.618
▪ CL = 11.947
▪ LCL = 11.277

▪ R-chart
▪ UCL = 2.782
▪ CL = 1.388
▪ LCL = 0

Note: the control chart is based on only 20 samples (borderline)

 WHAT IF OUT-OF-CONTROL?

◾Out-of-control action plan (OCAP)

Goal: find special cause of variability

and take action

Flow chart, with checkpoints

(assignable causes) and terminators
(actions)

= ‘living’ document

Example: hard-bake process

Controllable variables: time & temperature
 WHAT IF OUT-OF-CONTROL?

◾Pinpointing special causes can be extremely complex

Equipment
People Rotation of machines
Fatigue Lack of maintenance Procedures
Motivation Gradual deterioration Untried proces
Rotation of shifts Badly designed equipment Changes in methods
Lack of training … Changes in inspection
… …
Materials Environment
Different supplier Temperature
Mixing of batches, parts, ... Humidity
Different raw material Noise
… Dusty atmosphere
…
or any combination…

Hints:
◾ Mark relevant changes in process on control chart
◾ Obser ve the data collection, acquire knowledge of the process
 IMPLEMENTING CONTROL CHARTS

How do we implement control charts?

1. Preparation: how to sample?

2. Retrospective analysis: how to set up control charts?
3. Prospective analysis: how to use control charts?
 3. PROSPECTIVE ANALYSIS

How to use control charts?

▪ Monitor process, control & take action

▪ Apply appropriate interpretation rules
▪ Update out-of-control action plan
▪ Continous improvement
▪ Do not remove samples/recompute control lines if process is not in
control!
 EXAMPLE

For each new sample: are we still in control?

-chart

R-chart
 EXAMPLE

For each new sample: are we still in control?

-chart

R-chart
 EXAMPLE

For each new sample: are we still in control?

-chart

R-chart
 EXAMPLE

For each new sample: are we still in control?

-chart

R-chart
 EXAMPLE

For each new sample: are we still in control?

-chart

R-chart
QUIZ TIME!

• Basic knowledge
• 6 small questions

94
 QUESTION 1

◾Sunpower inc. wants to control the number of purified cells in

solar panels. The solar panels differ in size. Which control
chart would you recommend?

A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 1

◾Sunpower inc. wants to control the number of purified cells in

solar panels. The solar panels differ in size. Which control
chart would you recommend?

A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 2

◾Sunpower inc. wants to control the installation time of a

particular type of solar panels for a total installation of 5 Wp.
Each day the company installs one such installation. Which
control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 2

◾Sunpower inc. wants to control the installation time of a

particular type of solar panels for a total installation of 5 Wp.
Each day the company installs one such installation. Which
control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 3

◾Sunpower inc. wants to control the daily production number of

solar panels (of a particular type) that satisfy a minimum
specification limit for voltage output. The number of panels
produced of this type of solar panels differs from day to day.
Which control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 3

◾Sunpower inc. wants to control the daily production number of

solar panels (of a particular type) that satisfy a minimum
specification limit for voltage output. The number of panels
produced of this type of solar panels differs from day to day.
Which control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 4

◾Sunpower inc. wants to control the voltage output of a

particular type of solar panels produced. The company
considers samples of 15 panels as a good sample size. Which
control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 4

◾Sunpower inc. wants to control the voltage output of a

particular type of solar panels produced. The company
considers samples of 15 panels as a good sample size. Which
control chart would you recommend?
A. Xഥ− R
B. 𝐗ഥ− 𝐒
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 5

◾Sunpower inc. wants to control the number of defect cells in

the solar panels of a specific type all having the same
surface. Which control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 5

◾Sunpower inc. wants to control the number of defect cells in

the solar panels of a specific type all having the same
surface. Which control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 6

◾Sunpower inc. wants to control the daily production number of

solar panels (of a particular type) that satisfy a minimum
specification limit for voltage output. The number of panels
produced of this type of solar panels is every day the same.
Which control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u
 QUESTION 6

◾Sunpower inc. wants to control the daily production number of

solar panels (of a particular type) that satisfy a minimum
specification limit for voltage output. The number of panels
produced of this type of solar panels is every day the same.
Which control chart would you recommend?
A
. ഥ− R
X
B
. ഥ− S
X
C. X-R m
D. np
E. p
F. c
G. u