Quality Management Tools

Presented by
Dr. Tien Minh Do
Department of Industrial Management
School of Economics and Management
University of Science and Technology
 Control chart (Continued)
• chart
- The - s chart is a method of looking at two different sources of variation. One
source is the variation in sample averages. The other source is the variation
within a sample.

- - s chart actually consists of two charts. One chart is for sample averages ().
The other chart is for sample ranges (s).

• When to use  −s chart

- Data are variable

- Monitor variation in a process and detect changes in either the average or the
amount of variation in the process.

- Sample size n ≥ 10
 Control chart (Continued)
• Steps in constructing chart
- Gather the data
a. Select the sample size (n). Normally n ≥ 10

b. Select the frequency (time interval) with which the data will be collected.
Data should be collected in the order in which it is generated (in most
cases).

c. Select the number of samples (k) to be collected before control limits are
calculated. It is advised that the calculation of initial control limits should
be started after ten samples, but recalculate the limits each time until
number of samples reach twenty.
 Control chart (Continued)
• Steps in constructing chart
- Calculate the overall process averages and control limits.
a. Calculate average range of the process ()

Where:
- Average range of the process
k – Number of samples
- Standard deviation of the sample ith
Where:

Where:

- individual data in the sample

n – sample size
 Control chart (Continued)
• Steps in constructing chart
- Calculate the overall process averages and control limits.
b. Calculate control limits for the s chart

Where:
- Average range of the process
, - Control chart constants that depend on sample size (see the table
below)
 Control chart (Continued)
• Steps in constructing chart
- Calculate the overall process averages and control limits.
c. Calculate the overall process mean value ():

Where:
k – number of samples
- Mean value of the sample ith

Where:
n – Sample size
- individual data in the sample ith

d. Calculate the control limits for the chart

Where: A3 Control chart constants that depend on sample size (see the table
below)
 Control chart (Continued)

Subgroup (sample) size

(n) A3 B3 B4
2 2.659 - 3.267
3 1.954 - 2.568
4 1.628 - 2.266
5 1.427 - 2.089
6 1.287 0.030 1.970
7 1.182 0.118 1.882
8 1.099 0.185 1.815
9 1.032 0.239 1.761
10 0.975 0.284 1.716
15 0.789 0.428 1.572
25 0.9896 0.565 1.435
   Hệ số cho Control
biểu đồ kiểmchart (Continued)
Để ước lương Hệ số cho biểu đồ kiểm Hệ số cho biểu đồ kiểm
Cỡ mẫu soát X δ soát R soát S
(n) A2 A3 d2 D3 D4 B3 B4

2 1.880 2.659 1.128 0 3.267 0 3.267

3 1.023 1.954 1.693 0 2.574 0 2.568
4 0.729 1.628 2.059 0 2.282 0 2.266
5 0.577 1.427 2.326 0 2.114 0 2.089
6 0.483 1.287 2.534 0 2.004 0.030 1.970
7 0.419 1.182 2.704 0.076 1.924 0.118 1.882
8 0.373 1.099 2.847 0136 1.864 0.185 1.815
9 0.337 1.032 2.970 0.184 1.816 0.239 1.761
10 0.308 0.975 3.078 0.223 1.777 0.284 1.716
11 0.285 0.927 3.173 0.256 1.744 0.321 1.679
12 0.266 0.886 3.258 0.283 1.717 0.354 1.646
13 0.249 0.850 3.336 0.307 1.693 0.382 1.618
14 0.235 0.817 3.407 0.328 1.672 0.406 1.594
15 0.223 0.789 3.472 0.347 1.653 0.428 1.572
16 0.212 0.763 3.532 0.363 1.637 0.448 1.552
17 0.203 0.739 3.588 0.378 1.622 0.466 1.534
18 0.194 0.718 3.640 0.391 1.608 0.482 1.518
19 0.187 0.698 3.689 0.403 1.597 0.497 1.503
20 0.180 0.680 3.735 0.415 1.585 0.510 1.490
21 0.173 0.663 3.778 0.425 1.575 0.523 1.477
22 0.167 0.647 3.819 0.434 1.566 0.534 1.466
23 0.162 0.633 3.858 0.433 1.557 0.545 1.455
24 0.157 0.619 3.895 0.451 1.548 0.555 1.445
 Control chart (Continued)
• Steps in constructing chart
- Plot the data
a. Select the scales for the x and y axes for both the and s charts.

b. Put on the s chart

c. Plot the individual sample ranges ( ) on the s chart and connect

consecutive points with a straight line

d. Put on the chart

e. Plot mean values (averages) of the individual samples on the chart and
connect consecutive points with a straight line
 Control chart (Continued)
• Exercise
- Company A produces LCD panel monitor. Quality of the LCD is represented
by the brightness. Low or unsteady brightness indicates poor quality, so LCD
manufacturers keep track of monitor brightness of the monitors during the
developmental and testing process.
- In order to inspect the LCD panel monitor – Brand of 17” TPF, 25 samples
with 12 units each were taken for testing its brightness. The test results were
presented in the table below.
- The specification limits of brightness are between 150 and 200 cd/(meter
square).
- You are required to construct -s charts for controlling the LCD
manufacturing process of the Company A.
 Control chart (Continued)
Number of samples Individual value
• Exercise 1 188 184 178 192 182 168 176 178 172 173 179 179
2 178 179 180 187 179 183 182 175 176 185 178 176
3 179 181 177 188 174 181 180 183 178 183 178 173
4 191 180 179 181 178 181 171 174 168 181 180 187
5 185 189 182 176 184 182 177 179 178 180 180 188
6 177 185 172 185 181 178 181 175 182 173 178 183
7 188 178 179 185 172 179 183 183 184 184 181 181
8 177 181 177 182 174 178 179 182 181 189 173 175
9 180 175 165 177 190 181 176 179 180 180 179 184
10 175 176 178 177 176 178 182 173 176 171 178 174
11 182 186 179 190 182 186 170 174 174 183 177 173
12 190 175 182 187 183 183 180 180 184 176 180 178
13 183 179 171 181 190 182 182 177 188 176 186 184
14 181 177 179 180 187 180 180 187 188 181 180 169
15 179 181 178 178 185 177 178 186 176 185 175 170
16 183 175 185 174 179 184 183 182 185 180 182 173
17 175 183 177 180 186 179 174 188 181 177 176 177
18 195 177 187 183 180 180 179 177 183 190 177 179
19 175 172 186 181 183 172 169 183 184 184 182 184
20 179 173 187 175 186 173 182 178 185 185 172 183
21 181 184 175 178 175 185 180 168 181 177 176 183
22 181 184 188 174 178 187 181 177 174 170 184 184
23 180 174 178 185 183 187 189 180 176 174 173 180
24 176 176 181 177 182 183 181 174 177 176 174 181
25 190 183 175 184 174 178 180 188 188 174 184 183
 Number of
Control chart (Continued)
• Exercise samples
Individual value i si
1 188 184 178 192 182 168 176 178 172 173 179 179 179.1 6.7
2 178 179 180 187 179 183 182 175 176 185 178 176 179.8 3.7
3 179 181 177 188 174 181 180 183 178 183 178 173 179.6 4.1
4 191 180 179 181 178 181 171 174 168 181 180 187 179.3 6.3
5 185 189 182 176 184 182 177 179 178 180 180 188 181.7 4.2
= 179.9 6 177 185 172 185 181 178 181 175 182 173 178 183 179.2 4.4
7 188 178 179 185 172 179 183 183 184 184 181 181 181.4 4.1
= 4.9 8 177 181 177 182 174 178 179 182 181 189 173 175 179.0 4.4
9 180 175 165 177 190 181 176 179 180 180 179 184 178.8 5.9
10 175 176 178 177 176 178 182 173 176 171 178 174 176.2 2.8
11 182 186 179 190 182 186 170 174 174 183 177 173 179.7 6.2
12 190 175 182 187 183 183 180 180 184 176 180 178 181.5 4.3
13 183 179 171 181 190 182 182 177 188 176 186 184 181.6 5.3
14 181 177 179 180 187 180 180 187 188 181 180 169 180.8 5.1
15 179 181 178 178 185 177 178 186 176 185 175 170 179.0 4.7
16 183 175 185 174 179 184 183 182 185 180 182 173 180.4 4.3
17 175 183 177 180 186 179 174 188 181 177 176 177 179.4 4.4
18 195 177 187 183 180 180 179 177 183 190 177 179 182.3 5.7
19 175 172 186 181 183 172 169 183 184 184 182 184 179.6 5.9
20 179 173 187 175 186 173 182 178 185 185 172 183 179.8 5.6
21 181 184 175 178 175 185 180 168 181 177 176 183 178.6 4.8
22 181 184 188 174 178 187 181 177 174 170 184 184 180.2 5.6
23 180 174 178 185 183 187 189 180 176 174 173 180 179.9 5.3
24 176 176 181 177 182 183 181 174 177 176 174 181 178.2 3.2
25 190 183 175 184 174 178 180 188 188 174 184 183 181.8 5.6
 Control chart (Continued)
• Exercise
- With sample size n =12, B3 = 1.679, B4 = 0.354 and A3 = 0.886
- For the s chart:

- For the chart:

 Control chart (Continued)
• Exercise
 Control chart (Continued)
• p chart
- p-chart is an attributes control chart used for monitoring and controlling
proportion of non-conforming of the production process.

- p-chart shows how the process changes over time. The process attribute (or
characteristic) is always described in a yes/no, pass/fail, go/no go form.
- p-chart is used to determine if the process is stable and predictable, as well as
to monitor the effects of process improvement theories.

• When to use the p chart

- Attribute data
- Sample size changes overtime
- Monitoring and controlling non-conforming fraction
 Control chart (Continued)
• Steps in constructing the p chart
- Gather the data
a. Sample size: Sampling requires some careful consideration:
 If the organization selects to use 100% inspection on a process, the production
rate determines an appropriate sampling rate which in turn determines the
sample size
 If the organization selects to only inspect a fraction of units produced, the
sample size should be chosen large enough so that the chance of finding at
least one nonconforming unit in a sample
 One technique is to fix sample size so that there is a 50% chance of detecting a
process shift of a given amount (for example, from 1% defective to 5%
defective). That is:

Where: - process mean or process average

b. Select the number of samples (k) to be collected before control limits are
calculated. It is advised that the calculation of initial control limits should be started
after ten samples, but recalculate the limits each time until number of samples reach
twenty.
 Control chart (Continued)
• Steps in constructing the p chart
- Calculate the overall process average and control limits.
 Calculate the center line or process mean :

Where:
- Process mean (average fraction of defect)
- Number of defect in the sample i
- ith Sample size
k – number of samples

 Calculate control limits

(If LCL < 0 give it value of 0)

Where: - Process mean
- ith Sample size
 Control chart (Continued)
• Steps in constructing p chart
- Plot the data
a. Select the scales for the x and y axes for the p chart.

b. Put on the p chart

c. Plot the individual sample defect fraction () on the p-chart and connect
consecutive points with a straight line
 Control chart (Continued)
• Exercise
- Company A produces plastic bag. The company wants to control its product
quality through fraction of defect. You are required to provide the company with
advice on what control chart to be used in this production process if the data on
the plastic bag production process are given in the table below

Sample size 120 120 120 100 100 100 100 115 115 115 110 110 110 110 110 100 100 100 100 100

Number of 3 1 1 1 2 1 1 1 3 1 1 2 1 1 2 1 3 2 1 4
defect
 Control chart (Continued)
• Calculation results of process mean and control limits are given in the table below
Number of Sample
Sample size defect defect CL UCL LCL
fraction
120 3 0.025 0.015439 0.049204 0
120 1 0.008333 0.015439 0.049204 0
120 1 0.008333 0.015439 0.049204 0
100 1 0.01 0.015439 0.052426 0
100 2 0.02 0.015439 0.052426 0
100 1 0.01 0.015439 0.052426 0
100 1 0.01 0.015439 0.052426 0
115 1 0.008696 0.015439 0.04993 0
115 3 0.026087 0.015439 0.04993 0
115 1 0.008696 0.015439 0.04993 0
110 1 0.009091 0.015439 0.050705 0
110 2 0.018182 0.015439 0.050705 0
110 1 0.009091 0.015439 0.050705 0
110 1 0.009091 0.015439 0.050705 0
110 2 0.018182 0.015439 0.050705 0
100 1 0.01 0.015439 0.052426 0
100 3 0.03 0.015439 0.052426 0
100 2 0.02 0.015439 0.052426 0
100 1 0.01 0.015439 0.052426 0
100 4 0.04 0.015439 0.052426 0
Control chart (Continued)
 Control chart (Continued)
• np-chart
- np-chart is an attributes control chart used for monitoring and controlling
number of defects of the production process.

- np-chart shows how the process changes over time. The process attribute (or
characteristic) is always described in a yes/no, pass/fail, go/no go form.
- np-chart is used to determine if the process is stable and predictable, as well as
to monitor the effects of process improvement theories.

• When to use the np chart

- Attribute data
- Sample size is constant overtime
- Monitoring and controlling number of defects
 Control chart (Continued)
• Steps in constructing an np chart
- Gather the data
a. Select the subgroup size (n). Attributes data often require large subgroup
sizes (50 - 200). The subgroup size should be large enough to have several
defective items. The subgroup size must be constant.
b. Select the frequency with which the data will be collected. Data should be
collected in the order in which it is generated.
c. Select the number of subgroups (k) to be collected before control limits are
calculated. You can start a control chart with as few as five to six points but you
should recalculate the average and control limits until you have about 20
subgroups.
d. Inspect each item in the subgroup and record the item as either defective or
non-defective. If an item has several defects, it is still counted as one
defective item.
e. Determine npi for each subgroup.
npi = number of defective items found
f. Record the data.
 Control chart (Continued)
• Steps in constructing an np chart
- Calculate the process mean (process average) and control limits
a. Calculate the process mean (Average number of defects per sample)

Where:
n – Sample size
k – Number of sample
pi – Fraction of defect in sample i
npi – Number of defects in sample i
- Average faction of defect per sample
b. Calculate control limits

(if LCL < 0 give it value of 0)

 Control chart (Continued)
• Steps in constructing np chart
- Plot the data
a. Select the scales for the x and y axes for the np-chart.

b. Put on the np-chart

c. Plot the individual sample number of defects (npi) on the np-chart and
connect consecutive points with a straight line
 Control chart (Continued)
• np-chart Exercise
- A golf club shaft manufacturing company inspects one sample size of 100
everyday for 25 consecutive days. The observation results are shown in the
table below. You are required to construct a np chart in order to help the
company to control its production process.

Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Number of 5 2 1 3 4 2 1 3 1 2 1 3 1 4 3 4 2 5 3 4 2 3 1 2 1
defects
 Control chart (Continued)
• Calculation of the process mean and control limits
npi Sample size (n) Sample’s fraction of defect (pi) Average fraction of defect ( UCL CL = n LCL
5 100 0.05 0.0252 7.221964 2.52 0
2 100 0.02 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
3 100 0.03 0.0252 7.221964 2.52 0
4 100 0.04 0.0252 7.221964 2.52 0
2 100 0.02 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
3 100 0.03 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
2 100 0.02 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
3 100 0.03 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
4 100 0.04 0.0252 7.221964 2.52 0
3 100 0.03 0.0252 7.221964 2.52 0
4 100 0.04 0.0252 7.221964 2.52 0
2 100 0.02 0.0252 7.221964 2.52 0
5 100 0.05 0.0252 7.221964 2.52 0
3 100 0.03 0.0252 7.221964 2.52 0
4 100 0.04 0.0252 7.221964 2.52 0
2 100 0.02 0.0252 7.221964 2.52 0
3 100 0.03 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
2 100 0.02 0.0252 7.221964 2.52 0
1 100 0.01 0.0252 7.221964 2.52 0
Control chart (Continued)