1

Statistical Quality Control

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OBJECTIVES
• Process Control Procedures
– Variable data
– Attribute data
• Acceptance Sampling
– Operating Characteristic Curve
 3

Process Control
• It is concerned with monitoring quality while
the product or service is being produced.

• Statistical Process Control:

It tests a random sample of output from a
process to determine whether the process is
producing output within a preselected range.
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Basic Forms of Variation

Assignable variation is Example:

Example:AApoorly
poorlytrained
trained
caused by factors that employee
employeethat
thatcreates
creates
variation
variationin
infinished
can be clearly identified product
finished
productoutput.
output.
and possibly managed

Common variation is Example:

Example:AAmolding
molding
inherent in the process
processthat
thatalways
alwaysleaves
leaves
“burrs”
“burrs”ororflaws
flawson
onaa
production process molded
moldeditem.
item.
 5

Taguchi’s View of Variation

Traditional
Traditionalview
viewisisthat
thatquality
qualitywithin
withinthetheLS
LSand
andUS USisisgood
good
and
andthat
thatthe
thecost
costof
ofquality
qualityoutside
outsidethis
thisrange
rangeisisconstant,
constant,where
where
Taguchi
Taguchiviews
viewscosts
costsasasincreasing
increasingas
asvariability
variabilityincreases,
increases,so
soseek
seek
to
toachieve
achievezero
zerodefects
defectsand
andthat
thatwill
willtruly
trulyminimize
minimizequality
qualitycosts.
costs.
High High

Incremental Incremental
Cost of Cost of
Variability Variability

Zero Zero

Lower Target Upper Exhibits Lower Target Upper

Exhibits
Spec Spec Spec TN8.1 Spec Spec Spec
TN8.1&&
TN8.2
TN8.2
Traditional View Taguchi’s View
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Types of Statistical Sampling

• Attribute (Go or no-go information)
– Defectives refers to the acceptability of product across
a range of characteristics.
– Defects refers to the number of defects per unit which
may be higher than the number of defectives.
– p-chart application

• Variable (Continuous)
– Usually measured by the mean and the standard
deviation.
– X-bar and R chart applications
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Statistical UCL

Process Normal
NormalBehavior
Behavior

Control
LCL

(SPC) Charts 1 2 3 4 5 6 Samples

over time
UCL

Possible
Possibleproblem,
problem,investigate
investigate

LCL

1 2 3 4 5 6 Samples
over time
UCL

Possible
Possibleproblem,
problem,investigate
investigate

LCL

1 2 3 4 5 6 Samples
over time
 8

Control Limits are based on the Normal

Curve

x
m
z
-3 -2 -1 0 1 2 3

Standard
Standard
deviation
deviation
units
unitsoror“z”
“z”
units.
units.
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Control Limits
We establish the Upper Control Limits (UCL) and the Lower
Control Limits (LCL) with plus or minus 3 standard
deviations from some x-bar or mean value. Based on this
we can expect 99.7% of our sample observations to fall
within these limits.

99.7%
x
LCL UCL
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Example of Constructing a p-Chart:

Required Data
Sample No. of Number of
defects found
No. Samples in each sample
1 100 4
2 100 2
3 100 5
4 100 3
5 100 6
6 100 4
7 100 3
8 100 7
9 100 1
10 100 2
11 100 3
12 100 2
13 100 2
14 100 8
15 100 3
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Statistical Process Control Formulas:

Attribute Measurements (p-Chart)

Given: Total Number of Defectives

p=
Total Number of Observations

p (1 - p)
sp =
n
Compute control limits:

UCL = p + z sp
LCL = p - z sp
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Example of Constructing a p-chart: Step 1

Sample n Defectives p
1.
1. Calculate
Calculatethe
the 1 100 4 0.04
sample 2 100 2 0.02
sampleproportions,
proportions,pp 3 100 5 0.05
(these
(theseare
arewhat
whatcan
canbe
be 4 100 3 0.03
plotted
plottedon
onthe
thep-chart)
p-chart) 5 100 6 0.06
for
foreach
eachsample
sample 6 100 4 0.04
7 100 3 0.03
8 100 7 0.07
9 100 1 0.01
10 100 2 0.02
11 100 3 0.03
12 100 2 0.02
13 100 2 0.02
14 100 8 0.08
15 100 3 0.03
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Example of Constructing a p-chart: Steps

2&3
2.
2. Calculate
Calculatethe
theaverage
averageof
ofthe
thesample
sampleproportions
proportions

55
p= = 0.036
1500
3.
3.Calculate
Calculatethe
thestandard
standarddeviation
deviationof
ofthe
thesample
sample
proportion
proportion

p (1 - p) .036(1 - .036)
sp = = = .0188
n 100
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Example of Constructing a p-chart: Step 4

4.
4. Calculate
Calculate the
the control
control limits
limits
UCL = p + z sp
LCL = p - z sp

.036  3(.0188)

UCL
UCL == 0.0924
0.0924
LCL
LCL == -0.0204
-0.0204 (or
(or 0)
0)
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Example of Constructing a p-Chart: Step 5

5.
5. Plot
Plotthe
theindividual
individualsample
sampleproportions,
proportions,the
theaverage
average
of
ofthe
theproportions,
proportions,and
andthe
thecontrol
controllimits
limits
0.16

0.14

0.12

0.1 UCL
p 0.08

0.06

0.04

0.02

0 LCL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Observation
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Basic Forms of Statistical Sampling for Quality

Control

• Acceptance Sampling is sampling to

accept or reject the immediate lot of
product at hand
• Statistical Process Control is sampling to
determine if the process is within
acceptable limits
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Acceptance Sampling
• Purposes
– Determine quality level
– Ensure quality is within predetermined level
• Advantages
– Economy
– Less handling damage
– Fewer inspectors
– Upgrading of the inspection job
– Applicability to destructive testing
– Entire lot rejection (motivation for improvement)
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Acceptance Sampling (Continued)

• Disadvantages
– Risks of accepting “bad” lots and rejecting
“good” lots
– Added planning and documentation
– Sample provides less information than 100-
percent inspection
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Acceptance Sampling:
Single Sampling Plan

A simple goal

Determine (1) how many units, n, to

sample from a lot, and (2) the
maximum number of defective items,
c, that can be found in the sample
before the lot is rejected
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Risk
• Acceptable Quality Level (AQL)
– Max. acceptable percentage of defectives defined
by producer
• The a (Producer’s risk)
– The probability of rejecting a good lot
• Lot Tolerance Percent Defective (LTPD)
– Percentage of defectives that defines consumer’s
rejection point
• The  (Consumer’s risk)
– The probability of accepting a bad lot
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Operating Characteristic Curve

The
TheOCC
OCCbrings
bringsthe
theconcepts
conceptsof
ofproducer’s
producer’srisk,
risk,consumer’s
consumer’s
risk,
risk,sample
samplesize,
size,and
andmaximum
maximumdefects
defectsallowed
allowedtogether
together
1
The
Theshape
shape
0.9 a = .05 (producer’s risk)
Probability of acceptance

0.8 or
orslope
slopeof
of
0.7 the
thecurve
curveisis
n = 99
0.6 c=4
dependent
dependent
0.5 on
onaa
0.4 particular
particular
0.3  =.10 combination
combination
(consumer’s risk) of
0.2 ofthe
thefour
four
0.1 parameters
parameters
0
1 2 3 4 5 6 7 8 9 10 11 12
AQL LTPD
Percent defective
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