Statistical Process Control

for Attribute Data

(SPC)

1
 Module Objectives

By the end of this module, the participant

will be able to:
• Apply SPC rules
• Interpret run and trend patterns in
control charts
• Create and interpret
- np-charts
- p-charts
- c-charts
- u-charts
2
 Why Learn About
SPC for Attribute?

SPC for variable data will

• Keep process centered
• Minimize variation
• Reduce excursions
• Validate improvements
• Focus six sigma process activity

3
 What is SPC for Attributes?

SPC for attribute data is

• Industry standard control language
• Reliable, easy method of determining
- Common cause variation
- Special cause variation
• Graphical communication
• Set of statistical tools for analyzing
variables performance data

4
Attribute Control Charts

5
 Control Chart Roadmap

Attribute

Defectives Defects
Defects or
defective?

No Yes No Yes
Constant area of
n = const
opportunity

p-chart np-chart u-chart c-chart

6
 np-charts

Constant subgroup size

7
 np-chart Principles

np-charts
• Measure the proportion non-conforming
- uses binomial distribution
- good/bad, accept/reject, yes/no
• Each proportion is a subgroup of samples
- large subgroups required (50 minimum)
• Subgroup size must be constant
• Control limits will be constant
• 20 or more subgroups suggested for analysis

8
 np-charts and Uniform
Subgroup Size

Day Orders Errors

1 125 14
2
3
125
125
5
7
The sourcing department
4 125 17 measures 125 purchase orders
5 125 4
6 125 3 daily and records the number of
7
8
125
125
14
5
entry errors.
9 125 10
10 125 6 Is the order entry process in
11 125 5
12 125 26 control?
13 125 6
14 125 14
15 125 6 Since the data has a constant
16 125 7
17 125 8 subgroup size (orders processed) of
18 125 11
19 125 13 defectives (error/no error) an np-chart
20 125 10
will be used

9
 Constructing an np-chart
Graph

Day Orders Errors Prop np

1 125 14 0.112 14 Out of control
2 125 5 0.040 5
point
3 125 7 0.056 7
4 125 17 0.136 17
5 125 4 0.032 4
6 125 3 0.024 3
7 125 14 0.112 14
8 125 5 0.040 5
9 125 10 0.080 10
10 125 6 0.048 6
11 125 5 0.040 5
12 125 26 0.208 26
13 125 6 0.048 6
14 125 14 0.112 14
15 125 6 0.048 6
16 125 7 0.056 7
17 125 8 0.064 8
18 125 11 0.088 11
19 125 13 0.104 13
20 125 10 0.080 10
Total 191
pbar 0.076
npbar 9.55
10
 Defining the np-chart
UCL and LCL

UCLn p  n p  3 n p (1  p )

LCLn p  n p  3 n p (1  p )
where n is subgroup size
k k

X i X i
p i 1
 np  i 1

nk k
where k is number of subgroups

Control limits are constant; subgroup size must

also be constant
11
 Calculating the np-
chart UCL and LCL

191
p  0.0764
125* 20
n p  125*0.0764  9.550

UCLn p  9.55  3 9.55(1  0.0764)

 18.46
LCLn p  9.55  3 n p(1  0.0764)
 0.640
Calculated values
agree with Minitab® Manual calculations may differ
slightly from Minitab® due to
rounding and binomial estimates

12
 np-charts in Minitab®
Step 1

Copy or enter the data by subgroups

into the worksheet
Open file SPC Attribute np-chart.MTW
Stat>Control Charts>np

Either 125 or
Column

13
np-charts in Minitab®
Step 2

14
 np-chart Class Exercise

Using “np-chart Data” tab of file SPC Attribute

Class Exercises.xls
For Shipment Number subgroups
1. Calculate UCL and LCL
2. Copy the data into Minitab®
3. Verify your calculations
4. Determine if process is in control
5. If you have done SPC Variables Data module
run an I-MR chart on this data
• What does I-MR show?
• Why is it wrong?
6. Prepare for discussion
15
 p-charts

Varying Subgroup Size

16
 p-chart Principles

p-charts
• Measure the proportion non-conforming
• Uses binomial distribution
• Good/bad, accept/reject, yes/no
• Each proportion is a subgroup of samples
• Large subgroups required (50 minimum)
• Subgroup size does not have to be constant
• Control limits may vary from subgroup to
subgroup based upon subgroup size
• 20 or more subgroups suggested for analysis
17
 p-charts and Varying
Subgroup Size

Day Orders Errors

1 123 14
2 102 5 The sourcing department
3 87 7
4 119 17
measures the number of entry
5 88 4 errors on a daily basis.
6 72 3
7 100 14
8 94 5 Is the order entry process in
9 111 10
10 103 6 control?
11 92 5
12 155 26
13 47 6
14 116 14
15 97 6 Since the data has varying subgroup
16 102 7
17 117 8 sizes (orders processed) of defectives
18 101 11
19 89 13
(error/no error) a p-chart will be used
20 103 10

18
 Constructing a p-chart Graph

Day Orders Errors Prop

1 123 14 0.114
2 102 5 0.049 Out of control
3 87 7 0.080 point
4 119 17 0.143
5 88 4 0.045
6 72 3 0.042
7 100 14 0.140
8 94 5 0.053
9 111 10 0.090
10 103 6 0.058
11 92 5 0.054
12 155 26 0.168
13 47 6 0.128
14 116 14 0.121
15 97 6 0.062
16 102 7 0.069
17 117 8 0.068
18 101 11 0.109
19 89 13 0.146
20 103 10 0.097

Total 2018 191 0.09465

19
 Defining the p-chart
UCL and LCL

p (1  p )
UCL p  p  3
n
p (1  p )
LCL p  p  3
n

p (1  p)
UCL pi  p  3
n
p(1  p)
LCLpi  p  3
n

Control limits are dependent upon subgroup size

and are individually calculated for each point
20
 Calculating the p-chart
UCL and LCL

Average over subgroups

0.09465(1  0.09465)
UCL p  0.09465  3
2018 / 20
 0.1821
0.09465(1  0.09465)
LCL p  0.09465  3
2018 / 20
 0.0072

Individual subgroup
0.9465(1  0.09465)
UCLp13  0.9465  3
47
 0.223
0.9465(1  0.09465)
UCLp13  0.9465  3
Calculated values 47
agree with Minitab®  0.0335  0.0

Manual calculations may differ

slightly from Minitab® due to
rounding and binomial estimates 21
 p-charts in Minitab®
Step 1

Copy or enter the data by subgroups

into the worksheet
Open file SPC Attribute p-chart.MTW
Stat>Control Charts>p

22
p-charts in Minitab®
Step 2

23
 p-chart Class Exercise

Using “p-chart Data” tab of file SPC Attribute

Class Exercises.xls
For “Daily Tests” subgroups
1. Calculate UCL and LCL for overall Pbar
2. Calculate UCL and LCL for point 11
3. Copy the data into Minitab®
4. Verify your calculations
5. Determine if process is in control
6. Copy the “Is this the same?” data in Minitab®?
7. Determine if process is in control
8. Prepare for discussion
24
 c-charts

Constant Area of Opportunity

25
 c-chart Principles

c-charts
• Measure the count of non-conforming defects
- uses Poisson distribution
- good/bad, accept/reject, yes/no
• Each count is a subgroup of samples
• Area of opportunity must be constant
- lot, unit, invoice
• Control limits will be constant
• 20 or more subgroups suggested for analysis

26
 c-chart Subgroups

PaneNo White Specs

1 31
2 39
3 38 Final inspection grades the tinted
4
5
5
22 glass on the number of “white specs.”
6
7
34
10
Product is priced by grade.
8 23
9 11 Is the process in control?
10 36
11 25
12 4
13 4
14 11
15 25
16 4 White specs are defects, not defectives,
17 38
18 36
and are measured over a constant
19
20
36
17
sample area; a c-chart will be used
Average 22.45

27
 Constructing a c-chart Graph

PaneNo White Specs One out of

1 31 control point
2 39
3 38
4 5
5 22
6 34
7 10
8 23
9 11
10 36
11 25
12 4
13 4
14 11
15 25
16 4
17 38
18 36
19 36
20 17
Average 22.45

28
 Defining the c-chart
UCL and LCL

UCLc  c  3 c
LCLc  c  3 c

Control limits are constant; subgroup size must

also be constant, i.e. piece, lot, shipment etc.
29
 Calculating the c-chart
UCL and LCL

UCLc  22.45  3 22.45

 36.66
LCLc  22.45  3 22.45
 8.236

Calculated values
agree with Minitab®
Manual calculations may differ
slightly from Minitab® due to
rounding and Poisson estimates30
 c-charts in Minitab®
Step 1

Copy or enter the data by subgroups

into the worksheet
Open file SPC Attribute c-chart.MTW
Stat>Control Charts>c

31
c-charts in Minitab®
Step 2

32
 c-chart Class Exercise

Using “c-chart Data” tab of file SPC Attribute

Class Exercises.xls
For CSR subgroups of complaints
1. Calculate UCL and LCL
2. Copy the data into Minitab®
3. Verify your calculations
4. Determine if process is in control
5. Prepare for discussion

33
 u-charts

Varying Area of Opportunity

34
 u-chart Principles

u-charts
• Measure the count of non-conforming defects
- Uses Poisson distribution
- Good/bad, accept/reject, yes/no
• Each count is a subgroup of samples
• Area of opportunity may vary
- Lot, unit, invoice
• Control limits may vary
• 20 or more subgroups suggested for analysis

35
 u-chart Subgroups

Count of
Run Produced Defects
1 159 17
2
3
138
120
6
9
The plastics operation counts defects
4
5
148
127
21
5
after a “run”, which is undetermined
6
7
98
136
4
17
in length (once started continues until
8
9
134
139
6
12
all material is used).
10 127 7
11
12
125
161
6
23
Is the process in control?
13 75 7
14 161 17
15 139 7
16 143 9
17 163 10 The count of defect has a varying area
18 192 32
19 119 16 of opportunity since the lengths of runs
20 134 12
Total 2738 243 are not constant. A u-chart will be used.
Ubar 0.08875

36
 Constructing a u-chart Graph

Out of
Count of Count/
Run Produced Defects area
control point
1 159 17 0.107
2 138 6 0.043
3 120 9 0.075
4 148 21 0.142
5 127 5 0.039
6 98 4 0.041
7 136 17 0.125
8 134 6 0.045
9 139 12 0.086
10 127 7 0.055
11 125 6 0.048
12 161 23 0.143
13 75 7 0.093
14 161 17 0.106
15 139 7 0.050
16 143 9 0.063
17 163 10 0.061
18 192 32 0.167
19 119 16 0.134
20 134 12 0.090
Total 2738 243
Ubar 0.088751

37
 Defining the u-chart
UCL and LCL

u
UCLu  u  3
a
u
LCLu  u  3
a

u
UCLui  u  3
ai

u
LCLui  u  3
ai

Control limits are dependent upon subgroup area

and are individually calculated for each point
38
 Calculating the u-chart
UCL and LCL

Average over subgroups

0.08875
UCLu  0.08875  3
136.9
 0.165
0.08875
LCLu  0.08875  3
136.9
 0.012

Individual subgroup
0.08875
UCLu12  0.08875  3
161
 0.159
0.08875
LCLu12  0.08875  3
Calculated values 161
agree with Minitab®  0.0183
Manual calculations may differ
slightly from Minitab® due to
rounding and Poisson estimates 39
 u-charts in Minitab®
Step 1

Copy or enter the data by subgroups

into the worksheet
Open file SPC Attribute u-chart.MTW
Stat>Control Charts>c

40
u-charts in Minitab®
Step 2

41
 u-chart Class Exercise

Using “u-chart Data” tab of file SPC Attribute

Class Exercises.xls
For errors from line items ordered
1. Calculate overall UCL and LCL
2. Calculate UCL and LCL for point 3
3. Copy the data into Minitab®
4. Verify your calculations
5. Determine if process is in control
6. Prepare for discussion

42
 Departing Note on SPC and
Control Charts

Clearly the last class exercise for u-charts

showed the process is in control. But is control
an acceptable level of performance? Certainly
not in this case.
SPC and control charting will point the Black
Belt in the right direction to solve the problem.
The u-chart shows that focus should be applied
to the systemic common cause variation. The
process random variation is the culprit.

43
 Module Key Learning Points

•
•
•
•
•
•
•

44
 Objectives Review

The participant will be about to:

• Apply SPC rules
• Interpret run and trend patterns in
control charts
• Create and interpret
- np-charts
- p-charts
- c-charts
- u-charts
45