Quality Control Charts

Control Charts

Primary purpose of control charts is to indicate at a glance when production processes might have changed sufficiently to affect product quality. If the indication is that product quality has deteriorated, or is likely to, then corrective is taken. If the indication is that product quality is better than expected, then it is important to find out why so that it can be maintained. Use of control charts is often referred to as statistical process control (SPC).

Constructing Control Charts

Vertical axis provides the scale for the sample information that is plotted on the chart. Horizontal axis is the time scale. Horizontal center line is ideally determined from observing the capability of the process. Two additional horizontal lines, the lower and upper control limits, typically are 3 standard deviations below and above,

Constructing Control Charts

If the sample information falls within the lower and upper control limits, the quality of the population is considered to be in control; otherwise quality is judged to be out of control and corrective action should be considered. Two versions of control charts will be examined
Control charts for attributes
Control charts for variables

Control Charts for Attributes

Inspection of the units in the sample is performed on an attribute (defective/non-defective) basis. Information provided from inspecting a sample of size n is the percent defective in a sample, p, or the number of units found to be defective in that sample divided by n.

Control Charts for Attributes

Although the distribution of sample information follows a binomial distribution, that distibution can be approximated by a normal distribution with a
mean of p
standard deviation of

p(100 p)/n

The 3s control limits are

p / - 3 p(100 p)/n

Example: Attribute Control Chart

Every check cashed or deposited at State Bank of India must be encoded with the amount of the check before it can begin the clearing process. The accuracy of the check encoding process is of upmost importance. If there is any discrepancy between the amount a check is made out for and the encoded amount, the check is defective.

Example: Attribute Control Chart

Twenty samples, each consisting of 250 checks, were selected and examined. The number of defective checks found in each sample is shown below.
4 2 1 8 5 5 3 3 2 6 7 4 4 2 5 5 2 3 3 6

Example: Attribute Control Chart

The manager of the check encoding department knows from past experience that when the encoding process is in control, an average of 1.6% of the encoded checks are defective. She wants to construct a p chart with 3-standard deviation control limits.

Example: Attribute Control Chart

p(1 p ) .016(1 .016) .015744 sp .007936 n 250 250

UCL = p 3s p =.016+3(.007936)= .039808 or 3.98% LCL = p 3s p =.016-3(.007936)=-.007808= 0%

Example: Attribute Control Chart

p Chart for State Bank of India
0.045 0.040

Sample Proportion p

0.035 0.030 0.025 0.020 0.015 0.010 0.005 0.000

10 15 Sample Number

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Control Charts for Variables

Inspection of the units in the sample is performed on a variable basis. The information provided from inspecting a sample of size n is:
Sample mean, x, or the sum of measurement of each unit in the sample divided by n Range, R, of measurements within the sample, or the highest measurement in the sample minus the lowest measurement in the sample

Control Charts for Variables

In this case two separate control charts are used to monitor two different aspects of the processs output:
Central tendency Variability

Central tendency of the output is monitored using the x-chart. Variability of the output is monitored using the R-chart.

x-Chart

The central line is x, the sum of a number of sample means collected while the process was considered to be in control divided by the number of samples. =
The 3s lower control limit is=x - AR

The 3s upper control limit is x + AR

Factor A is based on sample size.

R-Chart

The central line is R, the sum of a number of sample ranges collected while the process was considered to be in control divided by the number of samples. The 3s lower control limit is D1R.

The 3s upper control limit is D2R.

Factors D1and D2 are based on sample size.

3s Control Chart Factors for Variables

Control Limit Factor Sample for Sample Mean Size n A 2 3 4 5 15 20 25 Over 25 1.880 1.023 0.729 0.577 0.308 0.223 0.180 0.15310
0.75(1/ n)

Control Limit Factor for Sample Range D1 D2

0 3.267 0 2.575 0 2.282 0 2.116 0.223 1.777 0.348 1.652 0.414 1.586 0.459 1.541 0.45+.001n 1.55-.0015n

Statistical Process Control

Quality Control (QC)

Control the activity of ensuring conformance to requirements and taking corrective action when necessary to correct problems Importance

Daily management of processes Prerequisite to longer-term improvements

Designing the QC System

Quality Policy and Quality Manual

Contract management, design control and purchasing Process control, inspection and testing Corrective action and continual improvement Controlling inspection, measuring and test equipment (metrology, measurement system analysis and calibration) Records, documentation and audits

Commonly Used Control Charts

Variables

data

x-bar and R-charts x-bar and s-charts Charts for individuals (x-charts)
Attribute

data

For defectives (p-chart, np-chart) For defects (c-chart, u-chart)

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Inspection/Testing Points
Receiving

inspection In-process inspection Final inspection

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Receiving Inspection
Spot

check procedures 100 percent inspection Acceptance sampling

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Acceptance Sampling
Lot received for inspection

Sample selected and analyzed

Results compared with acceptance criteria

Accept the lot

Reject the lot

Send to production or to customer

Decide on disposition

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In-Process Inspection

What to inspect?
Key quality characteristics that are related to cost or quality (customer requirements)

Where to inspect?
Key processes, especially high-cost and value-added

How much to inspect?

All, nothing, or a sample

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Statistical Process Control (SPC)

A methodology for monitoring a process to identify special causes of variation and signal the need to take corrective action when appropriate SPC relies on control charts

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Common Causes

Special Causes

Histograms do not take into account changes over time. Control charts can tell us when a process changes

Control Chart Applications Establish state of statistical control Monitor a process and signal when it goes out of control Determine process capability

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Commonly Used Control Charts

Variables

data

x-bar and R-charts x-bar and s-charts Charts for individuals (x-charts)
Attribute

data

For defectives (p-chart, np-chart) For defects (c-chart, u-chart)

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SPC Implementation Requirements

Top

management commitment Project champion Initial workable project Employee education and training Accurate measurement system

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