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Statistical
Quality
Control
PREPARED BY
SEELAM SRINIVASA REDDY.
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What is SQC ?

 Statistical quality control (SQC) is the

term used to describe the set of
statistical tools used by quality
professionals.
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History
 SQC was pioneered by Walter A. Shewhart at
Bell Laboratories in the early 1920s.

 Shewhart developed the control chart in 1924 and

the concept of a state of statistical control.

 Shewhart consulted with Colonel Leslie E. Simon in

the application of control charts to munitions
manufacture at the Army's Picatinney Arsenal in
1934.
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History
 W. Edwards Deming invited Shewhart to speak at the
Graduate School of the U.S. Department of Agriculture, and
served as the editor of Shewhart's book Statistical
Method
from the Viewpoint of Quality Control (1939) which
was the result of that lecture.

 Deming was an important architect of the quality

control short courses that trained American industry in
the new techniques during WWII.
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 Deming traveled to Japan during the Allied Occupation and met

with the Union of Japanese Scientists and Engineers(JUSE)in an
effort to introduce SQC methods to Japanese industry
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SQC Categories
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Descriptive Statistics
 Descriptivestatistics are used to
describe quality characteristics
and relationships.
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Descriptive Statistics
 The Mean- measure of central tendency

 The
Range- difference between largest/smallest
observations in a set of data

 StandardDeviation measures the amount of

data dispersion around mean
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The Mean
 To compute the mean we simply sum all the observations and
divide by the total no. of observations.
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The Range
 Range, which is the difference between
the largest and smallest observations.
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Standard Deviation
 Standard deviation is a measure of dispersion of a
curve.

 It measures the extent to which these values are

scattered around the central mean.
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Statistical process
control

• Extend the use of descriptive statistics to monitor

the quality of the product and process

• Statistical process control help to determine the

amount of variation

• To make sure the process is in a state of control

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Variation in Quality
 No two items are exactly alike.

 Some sort of variations in the two items is bound to be there. In

fact it is an integral part of any manufacturing process.

 This difference in characteristics known as variation.

 This variation may be due to substandard quality of raw

material, carelessness on the part of operator, fault in
machinery system etc..
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Types Of Variations
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Variation due to chance
causes/common causes

 Variation occurred due to chance.

 This variation is NOT due to defect in machine, Raw

material or any other factors.
 Behave in “random manner”.
 Negligible but Inevitable
 The process is said to be under the state of statistical
control.
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Variation due to assignable
causes

Non – random causes like:

 Difference in quality of raw material

 Difference in machines
 Difference in operators
 Difference of time
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Specification and control limits

 No item in the world can be a true copy of another item.

 It is not expressed in absolute values but in terms of a range.

 For Eg:
The diameter of a pen is expected by its
manufacturer not as 7mm but as 7mm ± 0.05.

Thus, the diameter of a pen produced by the

manufacturer can vary from 6.95 mm to 7.05 mm.
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Setting Control Limits
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HOW CONTROL LIMITS ARE
USEFUL… ?
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SPC Methods- Control Charts
 Control Charts show sample data plotted on a
graph with CL, UCL, and LCL

 Control chart for variables are used to

monitor characteristics that can be measured, e.g.
length, weight, diameter, time

 Control charts for attributes are used to

monitor characteristics that have discrete values
and can be counted, e.g. % defective, number of
flaws in a shirt, number of broken eggs in a box
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Control Charts for Variables

x-bar charts
It is used to monitor the changes in the mean of a
process (central tendencies).

R-bar charts
It is used to monitor the dispersion or variability of the
process
Constructing a X-bar chart 23

( sigma is not given)

 A factory produces 50 cylinders per hour. Samples of 10

cylinders are taken at random from the production at
every hour and the diameters of cylinders are measured.
Draw X-bar and R charts and decide whether the
process is under control or not.

(For n=4 A2= 0.73 D3= 0, D4=2.28)

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Sample x1 x2 x3 x4
no.
1 230 238 242 250
2 220 230 218 242
3 222 232 236 240
4 250 240 230 225
5 228 242 235 225
6 248 222 220 230
7 232 232 242 242
8 236 234 235 237
9 231 248 251 271
10 220 222 224 231
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Sample x1 x2 x3 x4 Sigma Mean Range
no. Xi X-bar R
1 230 238 242 250 960 240.00 20
2 220 230 218 242 910 227.50 24
3 222 232 236 240 930 232.50 18
4 250 240 230 225 945 236.25 25
5 228 242 235 225 930 232.50 17
6 248 222 220 230 920 230.00 28
7 232 232 242 242 948 237.00 10
8 236 234 235 237 942 235.50 3
9 231 248 251 271 1001 250.25 40
10 220 222 224 231 897 224.25 11
Total 2345.75 196
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Calculation of x-bar and R-bar

 Now,

x 2345 .75
x 234 .75
m 10

R 196
R 19.6
m 10
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Factor for x-Chart Factors for R-Chart

Sample Size
(n) A2 D3 D4
2 1.88 0.00 3.27
3 1.02 0.00 2.57
4 0.73 0.00 2.28
5 0.58 0.00 2.11
6 0.48 0.00 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
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Control limits of X-Bar Chart

 Central line C.L = x 234 .75

 U.C.L = x A2 * R
=234.75 + (0.73) (19.6)
=249.06

 L.C.L= x A2 * R
=234.75- (0.73) (19.6)
=220.72
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X-Bar Chart
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Control limits of R-Bar Chart

 Central Line = R 19.6

 U.C.L = D4R (2.28) * (19.96)

=45.50

 L.C.L = D3R (0)* (19.96)

=0
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R-Bar Chart
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Constructing a X-bar Chart
(Sigma is given)
 A quality control inspector at the Coca-Cola soft drink
company has taken twenty-five samples with four observations
each of the volume of bottles filled. The data and the
computed means are shown in the table. If the standard
deviation of the bottling operation is 0.14 ounces, use this
information to develop control limits of three standard
deviations for the bottling operation.
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Equations
UCL X z x s
x
n
LCL X z x R
s
d2
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X-Bar Control Chart

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Control Charts for Attributes
 Attributes are discrete events; yes/no, pass/fail

Use P-Charts for quality characteristics that are

discrete and involve yes/no or good/bad decisions
 Number of leaking caulking tubes in a box of 48
 Number of broken eggs in a carton

Use C-Charts for discrete defects when there can

be more than one defect per unit
 Number of flaws or stains in a carpet sample cut from a
production run
 Number of complaints per customer at a hotel
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P-Chart Example
 A Production manager of a BKT tire company has
inspected the number of defective tires in five random
samples with 20 tires in each sample. The table below
shows the number of defective tires in each sample of 20
tires. Calculate the control limits.
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P- Control Chart
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C - Chart Example
 The number of weekly customer complaints are
monitored in a large hotel using a c-chart. Develop
three sigma control limits using the data table below.
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C - Control Chart
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Process Capability
 Evaluating the ability of a production process to meet or
exceed preset specifications. This is called process
capability.

 Product specifications, often called tolerances, are

preset ranges of acceptable quality characteristics, such
as product dimensions.
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Two parts of process capability

 1) Measure the variability of the output of a process, and

 2) Compare that variability with a proposed specification or

product tolerance.
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Measuring Process Capability

 Toproduce an acceptable product, the
process must be capable and in control
before production begins.

USL LSL
Cp
6
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Example
 Let’s
say that the specification for
the acceptable volume of liquid is
preset at 16 ounces ±.2 ounces,
which is 15.8 and 16.2 ounces.
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Figure (a)
 The process produces 99.74 percent (three sigma) of the
product with volumes between 15.8 and 16.2 ounces.

Cp 1
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Figure (b)
 The process produces 99.74 percent (three sigma)
of the product with volumes between 15.7 and 16.3
ounces.

Cp 1
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Figure (c)
 the production process produces 99.74 percent (three
sigma) of the product with volumes between 15.9 and
16.1 ounces.

Cp 1
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Process capability ratio 55
(off centering process)

 There is a possibility that the process mean may shift over a

period of time, in either direction, i.e., towards the USL or the
LSL. This may result in more defective items then the expected.
This shift of the process mean is called the off-centering of the
process.

USL LSL
Cp k min ,
3 3
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Example
 Process mean: 15.9

 Process standard deviation: 0.067

 LSL = 15.8
 USL = 16.2

0.4
Cp 1
6(0.067 )
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USL LSL
Cpk min ,
3 3

C min 16.2 15.9 , 15.9 15.8

pk
3(.1) 3(.1)

C pk min 1.00, 0.33

C pk 0.33
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Thank You…