Control Chart For Attributes.

Control Chart For Attributes

Control Chart Control Chart For Defects

For Defectives

Control Chart For Control Chart For

Control chart for Control chart for
Fraction Defective Number of Defective
np-Chart Defects / sample Defects / Unit
P-Chart
C-Chart U-Chart

Constant
Constant
Sample
Sample
Size Constant Variable
Variable Constant Size
Sample Sample
Sample Sample Size
Size 87
Size Size
 Control Chart For Defectives

Control Chart
For Defectives

Control Chart For Control Chart For

Fraction Defective Number of Defective
P-Chart np-Chart

Constant
Sample
Size
Constant
Variable
Sample
Sample
Size
Size

88
 Defect and Defective

Defects :- Is a flaw or Single Quality Characteristics that

does not meet customer Requirement
• Defect are the one which makes an product defective.
• Also Known as Non Conformity.
• There can be One or More defects in an defective
product Example:- Cracks, Blow holes
Defects in Defective Garment.
Defective :- A defective is an item that is considered to
be unacceptable for use
• An item is said to be defective if it is having one or
More defects.
• An items categorized in to two things conforming or
Non conforming

89
 Control Chart Decision Tree

X bar , R

X bar, S

Start
P (fraction defective) or
np (number def. Per sample)

P(fraction defective)

C (defects per sample)

or
U ( Defects per unit)

U chart (defects Per unit)

90
 Procedure For Construction for construction of P-Chart

Fraction Defective Chart(P-Chart)

I. Variable Sample Size.
Sub Group Number of Items Inspected Number of Defective
Number Items
1 n1 m1
2 n2 m2
. . .
. . .
. . .
k nk mk
n m

91
Step 1 Calculation of Fraction Defective for Each Subgroup
Sub Group Number Number of Items Number of Fraction Defective
Inspected Defective Items
1 n1 m1 p1=m1/n1
2 n2 m2 P2=m2/n2
. . . .
. . . .
. . . .
k nk mk pk
n m P

Fraction Defective = Number of Defectives found in sample / Total number of Items Inspected

Calculation of Average Sample Size

navg = n /K

Step 2 Calculation of Average Fraction Defective.

= P/K OR = m/ n 92
Step 3 Calculation of 3-Sigma Control Limits

avg

avg

Step 4 Plot the control chart.

93
Conclusion:-
• If all the Points in the chart within control limit We
conclude that Process is Prevailing With
Unassignable(Chance)Causes of Variation and Process is
under statistical Control
• If any one of the Points is going out of control limit We
conclude that Process is Prevailing With assignable
Causes of Variation and Process is Not under statistical
Control

94
 Procedure For Construction for construction of Fraction Defective
Chart(P-Chart )
2.Constant Sample Size
Sub Group Number of Items Inspected Number of Defective
Number Items
1 n m1
2 n m2
. . .
. . .
. . .
k nk mk
n m

95
Step 1 Calculation of Fraction Defective for Each Subgroup
Sub Group Number Number of Items Number of Fraction Defective
Inspected Defective Items
1 n m1 p1=m1/n
2 n m2 P2=m2/n
. . . .
. . . .
. . . .
k nk mk pk
n m P

Fraction Defective = Number of Defectives found in sample / Total number of Items Inspected

Step 2 Calculation of Average Fraction Defective.

= P/K OR = m/ n

96
Step 3 Calculation of 3-Sigma Control Limits

Step 4 Plot the control chart.

97
Conclusion:-
• If all the Points in the chart within control limit We conclude that Process
is Prevailing With Unassignable(Chance)Causes of Variation and Process is
under statistical Control
• If any one of the Points is going out of control limit We conclude that
Process is Prevailing With assignable Causes of Variation and Process is Not
under statistical Control

98
Problem 1:
Following are the inspection results of Magnets for Nineteen Observations

Construct the appropriate control chart and comment on the process.

99
Step1: Calculation of Fraction Defective for each of the Subgroup

100
 navg = n / K = 14091 /19 = 741.63 =742
Step 2:- Calculation of Average Fraction Defective

Avg Fraction Defective = Number of Defectives found in sample / Total number of Items Inspected
= m / n = 1030 / 14091 =0.0731

Step 3 :- Calculation of 3-Sigma Control limits

avg

avg

101
Step 4:- Plot the control chart

4:- Comment on the process

As the sample number 2 , 4 are going out of control limit and
sample number 19 is going below control limit hence the process is
prevailing with assignable causes of variation and process is not under
statistical control

102
Problem 2:
In a Manufacturing process the number of defective found in the inspection of 20 lots of
100 samples is given below
Lot Nuber Number of Defctives Lot Nuber Number of Defctives
1 5 11 7
2 4 12 6
3 3 13 3
4 5 14 5
5 4 15 4
6 6 16 2
7 9 17 8
8 15 18 7
9 11 19 6
10 6 20 4

i. Construct the appropriate control chart and comment on the process.

ii. What would be the control limits which you suggest for the future.

103
Step 1 calculation of Fraction defective for Each subgroup
Lot Nuber Number of Defctive Fraction defective
1 5 0.05
2 4 0.04
3 3 0.03
4 5 0.05
5 4 0.04
6 6 0.06
7 9 0.09
8 15 0.15
9 11 0.11
10 6 0.06
11 7 0.07
12 6 0.06
13 3 0.03
14 5 0.05
15 4 0.04
16 2 0.02
17 8 0.08
18 7 0.07
19 6 0.06
20 4 0.04
120 1.2
104
Conclusion :- From the control chart it shows that lot number 8 with fraction defective
0.15 is falling outside the control limit hence the process is prevailing with assignable
causes and process is not under statistical control

105
106
 Procedure For Construction for construction of Number of Defective
Chart(np-Chart)
Constant Sample Size
Lot Number Number of Items Number of Defectives
Inspected
1 n m1
n m2
2 . .
. . .
. . .
. . mk
K nk np
n np
np = Total Number of defective

Step 1 . Calculation of Average fraction defective = np / n

107
Step 2 :- Calculation of : n
Step 3 :- Calculation of control limit for np chart Step 4 :- Construction of control

Step 5 :- Conclusion
• If all the Points in the chart within control limit We conclude that Process is
Prevailing With Unassignable(Chance)Causes of Variation and Process is under
statistical Control
• If any one of the Points is going out of control limit We conclude that Process is
Prevailing With assignable Causes of Variation and Process is Not under
statistical Control 108
Problem 1:- In a manufacturing the number of defectives found in the inspection
of 15 lots of 400 items each are given below.
i. Determine the trail control limits for number of defective chart and comment
on the process.
ii. What value of new control limit would you suggest for the future

Lot Number Number of Defctives Lot Number Number of Defctives

1 2 11 6
2 5 12 0
3 0 13 3
4 14 14 0
5 3 15 6
6 0
7 1
8 0
9 18
10 8
109
110
111
Problem 2:- An item is made in lots of 200 each. The record sheet for the first 25 lots inspected showed
that a total of 75 items were defective
a. Determine the trail control limits for np chart.
b. Assume that all points fall within the control limits. What is your estimate average Fraction
defective.
c. If the P is unchanged what is the probability that the 26th Lot will contain exactly 7 defectives?
That it will contain 7 or more defectives?

112
113
114
Procedure for construction of control charts for Defects /sample(C-chart)

Lot Number Sample Size (n) Defects

1 n c1
2 n c2
. n .
. n .
. n .
. n .
k nk Ck

K nk Ck
C

115
Step 1 : Calculation of Average Defects

Number of Defects in all Sample / Total Number of Samples

Step 2: Calculation of Control Limits Step 3: Plot the control limits

LCL =

Step 4: Conclusion:-
If all the Points in the chart within control limit We conclude that Process is Prevailing
With Unassignable(Chance)Causes of Variation and Process is under statistical Control
If any one of the Points is going out of control limit We conclude that Process is Prevailing With
assignable Causes of Variation and Process is Not under statistical Control
116
351 / 25 = 14.04

117
118
 Procedure for construction of control charts for Defects /unit
(U-chart)
Lot number Sample Size Defects
/sample
1 n1 c1
2 n2 c2
. . .
. . .
. . .
. . .
K nk ck

119
Step1 Determination of Defects/unit for each subgroup
Lot number Sample Size Defects Defects /Unit
/sample
1 n1 c1 U1=c1/n1
2 n2 c2 U2= c2/ n2
. . . .
. . . .
. . . .
. . . .
K nk ck UK = ck /nk

Step 2 Determination of Average Defects/unit

120
Step 3 Calculation of 3-Sigma Control Limits Step 4 Construction of Control chart

avg

avg

Step 5 :- If all the Points in the chart within control limit We conclude that Process is
Prevailing With Unassignable(Chance)Causes of Variation and Process is under statistical
Control
If any one of the Points is going out of control limit We conclude that Process is Prevailing With
assignable Causes of Variation and Process is Not under statistical Control

121
122
Step 1 :- Calculation of Defects /unit for each subgroup
Lot 100s of Square yard Defects Defects /unit
1 2 5 2.50
2 2.5 7 2.80
3 1 3 3.00
4 0.9 2 2.22
5 1.2 4 3.33
6 0.8 1 1.25
7 1.4 0 0.00
8 1.6 2 1.25
9 1.9 3 1.58
10 1.5 0 0.00
11 1.7 2 1.18
12 1.7 3 1.76
13 2 1 0.50
14 1.6 2 1.25
15 1.9 4 2.11
23.7 39 24.73
123
 =24.73 /15 =1.64 navg = n / k = 23.7/15 = 1.58= 2.0

=4.35

= -1.07=0

Since all the Points in the control chart are within control limit We conclude that
Process is Prevailing With Unassignable(Chance)Causes of Variation and Process is
under statistical Control

124
125
Since all the Points in the control chart are within control limit We conclude that
Process is Prevailing With Unassignable(Chance)Causes of Variation and
Process is under statistical Control

126
Comparison of Control chart for variables and Attributes

127
 Acceptance Sampling

• Methods of Inspection
1. 100% Inspection
– 100% inspection – inspect every item in the lot, remove all defectives
– Costly Process
– It is not Suited for Destructive Testing
– Some time Inspector Reject Good Product and accept defective
product.

128
2.Sampling Inspection.
– It is Process were the sample is drawn from lot and inspect those
items based on that we accept lot or Reject a lot
– Less costly and Less time consuming.
– Smaller Inspection staff is necessary.

129
 Acceptance sampling

• A form of inspection applied to lots or batches of items before or after a process to

judge conformance to predetermined standards

• It is a decision making tool by which a conclusion is reached regarding the

acceptability of lot.

• Acceptance sampling – sample is taken from lot, a quality characteristic is inspected;

then on the basis of information in sample, a decision is made regarding lot
disposition

130
Acceptance Sampling Used

– When testing is destructive

– When the cost of 100% inspection is extremely high and it is

not technologically feasible

131
 Symbols used In Acceptance sampling

1-Pa = probablity of rejection

132
 Types of Acceptance Sampling Plan

1. Single Sampling Plan (SSP)

2. Double Sampling Plan(DSP)

3. Multiple Sampling Plan (MSP)

133
1. Single Sampling Plan

Lot of Size N

134
2.Double Sampling Plan.
Lot of Size N

135
A single Sampling plan uses a sample size of 15, and an acceptance number 1.. Using
hyper geometric compute the probability of acceptance of lots of 50 articles and 2%
defective.

136
137
2. Calculating Probability of Acceptance using Poisson Distribution
Table

np’ =15 x 0.02 =0.30 From Table G

Pa= P(0) + P(1) P(0)= 0.741 P(1) = 0.963-0.741 = 0.222

Pa=0.741+0.222 = 0.963

OR

Pa(1 or Less) =0.963

138
139
140
141
142
143
144
Pa = PI(exactly 0) + PI( exactly 1) x PII (exactly 0)
From Table G
To calculate PI Probabilities of acceptance use n1 x p’ and PII
Probabilities use n2X P’
n1 X p’ = 0.5 n2 X p’ = 1x0.25 =0.25
Pa = PI(exactly 0) + PI( exactly 1) x PII (exactly 0)
Pa = 0.607+0.303 x0.779 =0.843
1-Pa = 0.157

145
2. Calculation of probability of acceptance using hypergeometric
distribution

146
A Double sampling plan With N=300 n1=50 and n2=50 C1=1 and
c2=3 if the submitted lot is 1% defective Determine the
Probability of Acceptance.

147
148
149
 Operating Characteristic(OC) Curve

• A graph that describes how well an acceptance plan discriminates between good and bad
lots.
• A graph which shows the probability of Acceptance(Pa) for various values of Fraction
defective (p’)

150
Problem :- Construct an OC curve For Single sampling Plan N=1500 ,
n=200 and C=5. and also determine AOQL

To construct an OC curve either P’ or Pa should be known assuming

Value of P’ as 0.5%,1.0%,1.5%,2.0%,3.0%,3.5%,4.0%, and 5.0%
n nP' P' Pa AOQ=Pa*P'
200 0.01
200 0.015
200 0.02
200 0.025
200 0.03
200 0.035
200 0.04
200 0.045
200 0.05

151
 n nP' P' Pa AOQ=Pa*P'
200 2 0.01 0.983 0.00983
200 3 0.015 0.916 0.01374
200 4 0.02 0.785 0.0157
200 5 0.025 0.616 0.0154
200 6 0.03 0.446 0.01338
200 7 0.035 0.301 0.010535
200 8 0.04 0.191 0.00764
200 9 0.045 0.116 0.00522

152
 1.2
Pa
1
Producer Risk (α) =1- 0.983 =0.017

0.8

0.6

0.4
Indifferent Quality
0.2 Region
β =0.10 0
0 0.01 0.02 0.03 0.04 0.05 0.06
AQL LTPD or RQL

P’

153
Pa P’ AOQL
0.018

0.016

0.014

0.012

0.01

0.008

0.006

0.004

0.002

0
0 0.01 0.02 0.03 0.04 0.05 0.06

P’

154