Professional Documents
Culture Documents
Stat 100410144230 Phpapp02
Stat 100410144230 Phpapp02
Chapter 19
McGraw-Hill/Irwin
GOALS
Discuss the role of quality control in production and service operations. Define and understand the terms chance cause, assignable cause, in control, out of control, attribute, and variable. Construct and interpret a Pareto chart. Construct and interpret a fishbone diagram. Construct and interpret mean and range charts. Construct and interpret percent defective and a c-bar charts. Discuss acceptance sampling. Construct an operating characteristic curve for various sampling plans.
Control Charts
Statistical Quality Control emphasizes in-process control with the objective of controlling the quality of a manufacturing process or service operation using sampling techniques. Statistical sampling techniques are used to aid in the manufacturing of a product to specifications rather than attempt to inspect quality into the product after it is manufactured. Control Charts are useful for monitoring a process.
Causes of Variation
There is variation in all parts produced by a manufacturing process. There are two sources of variation:
Chance Variation is random in nature and cannot be entirely eliminated. Assignable Variation is nonrandom in nature and can be reduced or eliminated.
Diagnostic Charts
There are a variety of diagnostic techniques available to investigate quality problems. Two of the more prominent of these techniques are Pareto charts and fishbone diagrams.
Pareto Charts
Pareto analysis is a technique for tallying the number and type of defects that happen within a product or service. The chart is named after a nineteenth-century Italian scientist, Vilfredo Pareto. He noted that most of the activity in a process is caused by relatively few of the factors. Paretos concept, often called the 8020 rule, is that 80 percent of the activity is caused by 20 percent of the factors. By concentrating on 20 percent of the factors, managers can attack 80 percent of the problem.
6
Fishbone Diagrams
Another diagnostic chart is a causeand-effect diagram or a fishbone diagram. It is called a cause-andeffect diagram to emphasize the relationship between an effect and a set of possible causes that produce the particular effect. This diagram is useful to help organize ideas and to identify relationships. It is a tool that encourages open brainstorming for ideas. By identifying these relationships we can determine factors that are the cause of variability in our process. The name fishbone comes from the manner in which the various causes and effects are organized on the diagram. The effect is usually a particular problem, or perhaps a goal, and it is shown on the right-hand side of the diagram. The major causes are listed on the left-hand side of the diagram. 9
The purpose of quality-control charts is to portray graphically when an assignable cause enters the production system so that it can be identified and corrected. This is accomplished by periodically selecting a random sample from the current production.
10
R is
11
12
13
150.60 9.413 16
102 R 6.375 16
14
15
16
17
102 R 6.375 16
18
LCL D3 R 0(6.375) 0
19
20
In-Control Situation
21
22
23
The percent defective chart is also called a p-chart or the p-bar chart. It graphically shows the proportion of the production that is not acceptable. The proportion of defectives is found by:
Total Number of Defectives Number of samples
24
p(1 p) n
25
p-Chart Example
Jersey Glass Company, Inc., produces small hand mirrors. Jersey Glass runs a day and evening shift each weekday. Each day, the quality assurance department (QA) monitors the quality of the mirrors twice during the day shift and twice during the evening shift. After each four-hour period, QA selects and carefully inspects a random sample of 50 mirrors. Each mirror is classified as either acceptable or unacceptable. Finally QA counts the number of mirrors in the sample that do not conform to quality specifications. List below is the result of these checks over the last 10 business days. Construct a percent defective chart for this process. What are the upper and lower control limits? Interpret the results. Does it appear the process is out of control during the period?
26
27
28
The c-chart or the c-bar chart is designed to control the number of defects per unit. The UCL and LCL are found by:
29
c-Chart Example
The publisher of the Oak Harbor Daily Telegraph is concerned about the number of misspelled words in the daily newspaper. It does not print a paper on Saturday or Sunday. In an effort to control the problem and promote the need for correct spelling, a control chart will be used. The number of misspelled words found in the final edition of the paper for the last 10 days is: 5, 6, 3, 0, 4, 5, 1, 2, 7, and 4. Determine the appropriate control limits and interpret the chart. Were there any days during the period that the number of misspelled words was out of control?
37 3.7 10 UCL and LCL 3.7 3 3.7 UCL 3.7 5.77 9.47 LCL 3.7 5.77 2.07 0 c
30
c-Chart in Minitab
31
Acceptance Sampling
Acceptance sampling is a method of determining whether an incoming lot of a product meets specified standards. It is based on random sampling techniques. A random sample of n units is obtained from the entire lot. c is the maximum number of defective units that may be found in the sample for the lot to still be considered acceptable.
32
If the number of defects in the sample of size n is less than or equal to c, the lot is accepted. If the number of defects exceeds c, the lot is rejected and returned to the supplier, or perhaps submitted to 100 percent inspection.
33
Type II Error
Type I Error
34
Operating Characteristic Curve An OC curve, or operating characteristic curve, is developed using the binomial probability distribution in order to determine the probabilities of accepting lots of various quality level.
35
36
Let X be the number of defects in the sample. The decision rule is:
37
38
39
40
41
End of Chapter 19
42