Quality Control

Quality Control
Chapter 9- Lot-by-Lot
Acceptance Sampling
By Attributes
PowerPoint presentation to accompany
Besterfield
Quality Control, 8e
PowerPoints created by Rosida Coowar
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
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Outline
 Fundamental Aspects
 Statistical Aspects
 Sampling Plan Design
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Learning Objectives
When you have completed this chapter you should
be able to:
 Know the advantages and disadvantages of
sampling; the types of sampling plans and selection
factors; criteria for formation of lots; criteria for
sampling selection; and decisions regarding
rejected lots.
 Determine the OC Curve for a single sampling plan.
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Learning Objectives-cont’d.
be able to:
 Determine the equations needed to graph the OC
Curve for a double sampling plan.
 Know the properties of OC Curves.
 Know the consumer-producer relationships of risk,
AQL, and LQ.
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Learning Objectives-cont’d.
be able to:
 Determine the AOQ curve and the AOQL for a single
sampling plan.
 Determine single sampling plans for stipulated
producers risk and for stipulated consumers risk.
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Fundamental Aspects
Acceptance Sampling is a form of

inspection applied to lots or batches of
items before or after a process to
judge conformance to predetermined
standards.
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Acceptance Sampling
Acceptance Sampling is very useful when:
 Large numbers of items must be processed in a
short amount of time.
 The cost of “passing defectives” is low.
 Fatigue/boredom is caused by inspecting large
numbers of items.
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Acceptance Sampling
Acceptance Sampling is very useful when:
Destructive testing is required
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Acceptance Sampling
 Three important aspects of sampling:
 Involves random sampling of the entire lot
 Accept and Reject Lots (does not improve
the quality) “Lot Sentencing”
 Audit Tool
 Three approaches to “lot sentencing”:
 Accept with no inspection
 100% inspection
 Acceptance Sampling
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Acceptance Sampling
 Advantages
 Less expensive
 Reduced damage
 Reduces the amount of inspection error
 Disadvantages
 Risk of accepting “bad” lots and rejecting
“good” lots
 Less information generated
 Requires planning and documentation
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Sampling Plans
Sampling Plans specify the lot size, sample size,
number of samples and acceptance/rejection
criteria.
Sampling plans involve:
 Single sampling
 Double sampling
 Multiple sampling
Random
Lot
sample
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Sampling Plans
Single Sampling Plan
N = lot size
n = sample size
C=acceptance number
If c or less non-conforming units are found in the
sample, the lot is accepted, else it is rejected.
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Single Sampling Plan
A single sampling plan is one where:
 A representative sample of n items is drawn
from a lot size of N items
Each item in the sample is examined and
classified as good/defective
If the number of defective exceeds a specified
rejection number (c) the whole lot is rejected;
otherwise the whole lot is accepted
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Double Sampling Plan
A Double Sampling Plan allows to take a second

sample if the results of the original sample are
inconclusive.
 Specifies the lot size, size of the initial sample, the
accept/reject/inconclusive criteria for the initial sample
(N, n1, c1 (Ac), r1(Re))
 Specifies the size of the second sample and the
acceptance rejection criteria based on the total number
of defective observed in both the first and second
sample (n2,c2,r2)
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Lot First Random
sample
First sample inconclusive,

Accept Lot Reject Lot
take second sample
C1 r1
Compare number of defective found in the first random sample to C1
and r1 and make appropriate decision.
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Lot First Random sample
Second Random sample
Accept Lot Reject Lot
C2
Compare the total number of defective in both lots to C2 and make the
appropriate decision
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A Multiple Sampling Plan is similar to the
double sampling plan in that successive trials
are made, each of which has acceptance,
rejection and inconclusive options.
Which Plan you choose depends on:

Cost and time
Number of samples needed and number
of items in each sample
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Lot Formation
Considerations before inspection:
 Lots should be homogeneous
 Larger lots are more preferable than
smaller lots
 Lots should be conformable to the
materials-handling systems used in both
the vendor and consumer facilities
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Random Sampling
 Units selected for inspection should be

chosen at random
 If random samples are not used, bias can
be introduced
 If judgment methods are used to select
the sample, the statistical basis of the
acceptance-sampling procedure is lost
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Statistical Aspects
The Operating Characteristic Curve:
 Measures the performance of an
acceptance sampling plan
 Plots the probability of accepting the lot
versus the lot fraction defective
 Shows the probability that a lot submitted
with a certain fraction defective will be
either accepted or rejected
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Acceptable Quality Level (AQL)

The AQL is a percent defective that is the
base line requirement for the quality of
the producer's product. The producer
would like to design a sampling plan such
that there is a high probability of
accepting a lot that has a defect level less
than or equal to the AQL.
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Lot Tolerance Percent Defective

The Lot Tolerance Percent Defective LTPD
or LQ is a designated high defect level
that would be unacceptable to the
consumer. The consumer would like the
sampling plan to have a low probability of
accepting a lot with a defect level as high
as the LTPD.
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Type I Error (Producer’s Risk)

This is the probability, for a given (n,c)
sampling plan, of rejecting a lot that has a
defect level equal to the AQL. The
producer suffers when this occurs,
because a lot with acceptable quality was
rejected. The symbol α is commonly used
for the Type I error and typical values for
range from 0.2 to 0.01.
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Type II Error (Consumer’s Risk)
This is the probability, for a given (n,c)
sampling plan, of accepting a lot with a
defect level equal to the LTPD. The
consumer suffers when this occurs,
because a lot with unacceptable quality
was accepted. The symbol β is commonly
used for the Type II error and typical
values range from 0.2 to 0.01.
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Operating Characteristic Curve
This curve plots the probability of
accepting the lot (Y-axis) versus the lot
fraction or percent defectives (X-axis).
The OC curve is the primary tool for
displaying and investigating the properties
of a Lot Acceptance Sampling Plan.
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OC Curves
There are two types of OC curves:
 Type A
Gives the probability of acceptance
of an individual lot coming from
finite production
 Type B
Gives the probability of acceptance
for lots coming from a continuous
production
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OCCs for Single Sampling Plans
An Operating Characteristic Curve (OCC) is a probability
curve for a sampling plan that shows the probabilities of
accepting lots with various lot quality levels (% defectives).
1
0.9 Under this sampling plan, if the lot has 3% defective
Probability of accepting lot
. the probability of
0.8
accepting the lot is 90% . the probability of
0.7 rejecting the lot is 10%
0.6
0.5 If the lot has 20% defective
0.4 . it has a small probability (5%) of being accepted
0.3 . the probability of rejecting the lot is 95%
0.2
0.1
0
0 .05 .10 .15 .20 Lot quality (% defective)
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OCC, AQL and Producer’s Risk
1
0.9 Producer’s Risk = probability acceptable lot is rejected
0.8
0.7
0.6
0.5 AQL - percentage level of defects at which
0.4 a customer is willing to accept
0.3
0.2
0.1
0
“Acceptable Lot”
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OCC, LTPD and Consumer’s Risk
1
0.9
0.8
0.7
LTPD - upper limit on the percentage of
0.6 defectives that a customer is willing to
0.5 accept.
0.4
0.3
0.2
0.1 Consumer’s Risk = probability unacceptable is accepted
0
“Unacceptable Lot”
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OCC for Double Sampling Plan
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Inspect a sample
of 150 from lot
of 2400
If 1 or less If 4 or more
Nonconforming Nonconforming units
units accept lots and If 2 or 3 nonconforming the lot is not accepted
stop units, inspect a second and stop
sample of 200
If 5 or less If 6 or more
Nonconforming units Nonconforming units
On both samples, On both samples
Accept the lot The lot is not accepted
Figure 9-5 Graphical description of the double sampling plan: N=2400,n1=150,c1=1
r1=4, n2=200, c2=5, and r2=6
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OCC for a Multiple Sampling Plan
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Average Outgoing Quality (AOQ)
A common procedure, when sampling
and testing is non-destructive, is to
100% inspect rejected lots and replace
all defectives with good units. In this
case, all rejected lots are made perfect
and the only defects left are those in lots
that were accepted.
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Average Outgoing Quality
The Average Outgoing Quality (AOQ) is the

average of rejected lots (100% inspection) and
accepted lots ( a sample of items inspected)
N -n
AOQ = Pac * p( ) where
N
Pac = Probability of accepting a lot
p = Fraction defective
n = sample size
N = Lot size
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AOQ and Acceptance Sampling
15 lots 11 lots
2% nonconforming N=3000 2% nonconforming
Producer n=89 Consumer
c=2
4 lots
2% nonconforming
4 lots
0% nonconforming
Figure 9-15 How acceptance Sampling works
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AOQ and Acceptance Sampling
Total Number Number
Nonconforming
11 lots- 11(3000)=33,000 33,000(0.02)=660
2%
Nonconforming
4 lots- 4(3000) 0
0% (0.98)=11,760
Nonconforming
44,760 660
Percent Nonconforming (AOQ) =

660/44,760 X 100 =1.47%
Figure 9-15 cont’d.

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Average Quality of Inspected Lots
Typically the term (N-n)/N is very close to 1;
therefore, the equation most often used is:
AOQ = Pac * p where

Pac = Probability of accepting a lot
p = Fraction defective
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Average Outgoing Quality Level
 A plot of the AOQ (Y-axis) versus the

incoming lot p (X-axis) will start at 0 for
p = 0, and return to 0 for p = 1 (where
every lot is 100% inspected and
rectified). In between, it will rise to a
maximum. This maximum, which is the
worst possible long term AOQ, is called
the Average Outgoing Quality Level
AOQL.
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Average Total Inspection (ATI)
When rejected lots are 100% inspected,
it is easy to calculate the ATI if lots come
consistently with a defect level of p. For
a LASP (n,c) with a probability pa of
accepting a lot with defect level p, we
have:
ATI = n + (1 - pa) (N - n)
where N is the lot size.
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Average Sample Number (ASN)
For a single sampling (n,c) we know each and
every lot has a sample of size n taken and
inspected or tested. For double, multiple and
sequential plans, the amount of sampling
varies depending on the number of defects
observed.
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Average Sample Number (ASN)
For any given double, multiple or
sequential plan, a long term ASN
can be calculated assuming all lots
come in with a defect level of p. A
plot of the ASN, versus the
incoming defect level p, describes
the sampling efficiency of a given
plan scheme.
ASN = n1 + n2 (1 – P1) for a double
sampling plan.
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Sampling Plan Design
Suppose α is known and the AQL is
also known then :
 Sampling plan with stipulated producer’s
risk
 Sampling plan with stipulated consumer’s
risk
 Sampling plan with stipulated producer’s
and consumer’s risk
can be designed.
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 Stipulated Producer’s Risk
α
= 0.05 AQL = 1.2%
 Pa=0.95 P0.95= 0.012
 Assume values for C, find np0.95 for this
c value, calculate n
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 Stipulated Consumer’s Risk
β
= 0.10 LQ = 6.0%
 Pa=0.10 P0.10= 0.060
 Assume values for C, find np0.95 for this
c value, calculate n
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 Stipulated Producer’s and Consumer’s
risk
 α = 0.10 β = 0.10
 AQL=0.9 LQ= 7.8
 Find the ratio of P0.10/P0.95. From table
9-4 C is between 1 and 2. Find n for c
=1 and n for c =2 .
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 Have 4 plans.
 Select plan based on:
 Lowest sampling size
 Greatest sampling size
 Plan exactly meets consumer’s
stipulation and is as close as possible to
producer’s stipulation
 Plan exactly meets producer’s stipulation
and is as close as possible to consumer’s
stipulation
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Quality Control

PowerPoints created by Rosida Coowar

Acceptance Sampling is a form of

A Double Sampling Plan allows to take a second

First sample inconclusive,

Second Random sample

Accept Lot Reject Lot

Which Plan you choose depends on:

 Units selected for inspection should be

The Average Outgoing Quality (AOQ) is the

Figure 9-15 How acceptance Sampling works

Percent Nonconforming (AOQ) =

Figure 9-15 cont’d.

AOQ = Pac * p where

 A plot of the AOQ (Y-axis) versus the

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