Control Charts for Variables

Contd……..

Department of Industrial Engineering

UET Peshawar

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 State Of Control
Process in Control
 When assignable causes eliminated and points
plotted are within C.L.- process is in state of
control
 What are the characteristics of process in
control? (natural pattern of variation)
 34% within 1 from Center Line
 13% between 1 & 2
 2.5% of plotted points - 2  3
 Points located back & forth across the center line
randomly
 No point out of control
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 Choice of 3 limits
 Subgroup averages forms frequency distribution which is
normal distribution and limits are established at 3 from
center line
 Choice of 3 is economic decision with respect to 2 types of
error
 Type I - occurs when looking for assignable cause but in
reality chance cause present. Also called as Producers risk.
 When limits set  3 Type I error probability = 0.27% or
3/1000.

 Type II - assume chance cause present, but in fact assignable

cause present.
 Records indicate 3 limits balance between 2 errors.

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What if Process In Control

 Individual parts will be more uniform – less

variation and fewer rejects
 Cost of inspection will decrease as fewer parts will
be inspected due to uniformity of the process.
 Process capability easily attained
 Trouble can be anticipated before it occurs
 Percentage of parts fall between two values can be
predicted with highest degree of accuracy.
 X-R charts can be used as statistical evidence for
process control

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 When Process is in Control
Predictable and stable process only when chance causes are present

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Process - Out Of Control

1. A point falls outside control

limits
 assignable cause present
 process producing
subgroup avg. not from
stable process
 must be investigated &
corrected

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What else make process out of control
Unnatural runs of variation even
within 3 limits
 7 or more points above or
below center line (in a row)
 10 out of 11 points on one
side
 12 out of 14 points on one
side
 6 points
increasing/decreasing
 2 out of 3 in Zone A
 4 out of 5 in Zone B

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 Analysis of Out Of Control
Patterns
1. Change/Jump in level
Shift in mean (a step or sudden
change in the mean of
population)
 Causes –(For X bar chart)
 Process parameters change,
diff / new operator, change
in raw material, minor
failure of machine part.
 Causes (R charts)
 Inexperienced operator,
sudden increase in gear play
, greater variation in
incoming material.

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 ANALYSIS OF OUT-OF-CONTROL

2. Trend or steady change in level

 Drifting mean (a gradual
change of a mean or average of
a population)
 Common, upward or
downward direction
 Causes for X bar chart
 Tool wear, gradual change

in temp. viscosity of
chemical used, build up of
chips in a work holding
device.
_ Causes for (R charts)
 An improvement in worker

skill (downward trend), a

decrease in worker skill
due to fatigue etc(upward
skill) etc.

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ANALYSIS OF OUT-OF-CONTROL

3. Recurring cycles
 Wavy, periodic high & low
points
 Seasonal effects of mtl.
 Recurring effects of temp.,
humidity (morning vs
evening)
4. Two populations (mixture)
 many points near or
outside control limits
 Reasons;
 large difference in material
quality
 2 or more machines
 different test method
 mtls from different supplier

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ANALYSIS OF OUT-OF-CONTROL

 5. Mistakes.
Mistakes are also there to give data out of
control limits. Some causes are given below
a) Measuring equipment out of calibration
b) Errors in calculations
c) Taking samples from different populations

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Specification and Control Limits
 I often hear control limits and specification
limits discussed as if they are
interchangeable. But control limits and
specification limits are completely different
values and concepts. What is the relationship
between control limits and specification
limits? Usually there is no relationship
whatsoever.

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Specification and Control Limits
Control limits Specification limits

Voice of the Process Voice of the Customer

Calculated from data Defined by Customer

Guide for process action Separate good items from

bad
What the process is doing What we want the process
to do
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Specification and Control Limits
 Control limits are a function of a averages
where as specification are the permissible
variations in the size of the parts and are
therefore for individual values.
 Control limits cannot determine if the process
is meeting specifications.

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Process Capability and Tolerance
 Process spread will be referred as process capability
and is equal to 6 б.
 The difference between upper and lower specification
limits is called as Tolerance.
 Three situations are there
 Case 1 : when process capability is less than the
tolerance
 Case 2 : when the process capability is equal to the
tolerance.
 Case 3:when the process capability is equal to the
tolerance.

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 Process Capability and Tolerance
 Case 1;6б<USL –L SL.
It is a situation where process
capability is less than the
tolerance and is more desirable
even when there is little shift in
the data but still it is in
specification limits. although
corrective action is required as
the process is out of control.

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 Process Capability and Tolerance
 Case 2; 6б=USL – LSL
 In this particular case
process capability is equal
to the tolerance.
 Any shift in the process will
result in waste due to
presence of assignable
causes.

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 Process Capability and Tolerance
 Case 3: 6б>USL – LSL
 In this particular case process capability is greater than the tolerance, an undesirable
situation exist.
 Although the process will be in control but nonconforming product will be produced i.e. the
process is not capable of manufacturing that product.
 It is the situation that require 100% inspection of parts.
 Discussion required with design engineer regarding the manufacturing of part and part
specification limits. Process change, material change, experienced operator, retraining,
new machine purchase etc.

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Questions

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