L4 - Control Chart Principles

Quality
Management
Techniques: AEM 6102
By
Dr. Prianka Binte Zaman
Assistant Professor
Department of IPE, BUET
Control Chart Principles
What is a Control Chart?
 A statistical tool used to distinguish between process variation
resulting from common causes and variation resulting from
special causes.
 What Does a Control Chart Do?
 Focuses attention on detecting and monitoring process
variation over time;
 Distinguishes between special cause and common causes of
variation.
 Helps improve a process to perform consistently and
predictably for higher quality, lower cost, and higher
effective capacity;
 Provides a common language for discussing process
performance.
Types of Data
 Variable data
 Product characteristic that can be measured
 Length, size, weight, height, time, velocity
 Attribute data
 Product characteristic evaluated with a discrete choice
• Good/bad, yes/no
Developing Control Charts
 A control chart (also called process chart or quality control chart) is a graph
with CL, UCL, and LCL that shows whether a sample of data falls within the
common or normal range of variation.
 The common range of variation is defined by the use of control chart limits.
We say that a process is out of control when a plot of data reveals that one
or more samples fall outside the control limits. If a sample of observations
falls outside the control limits we need to look for assignable causes.
5
Control Chart Limits
The upper and lower control limits (UCL, and LCL ) on a control chart are usually set at
±3s from the mean. If we assume that the data exhibit a normal distribution, these
control limits will capture 99.74 % of the normal variation. Control limits can be set at
±2s from the mean. In that case, control limits would capture 95.44 % of the values.
Errors in Control Chart
Process reality
Process from sample
Process in control Process out of control
Process in control Right signal Type II error
Process out of control Type I error Right signal
This type of wrong signaling happens because of sampling error.
From the process control view Type II error is more serious than Type I error.
Basics of Control Chart
Two important criteria:

1. The pattern of plots of points must be random.
2. There must not be any increasing or decreasing pattern, or any other specific
trend.
Basics of Control Chart
Shift in mean value Increasing trend
Fig: Out of Control Indications

Example: 3sigma Limits
A glass manufacturing company produces flat glass sheets, with target final
thickness of 0.130 inch and a known standard deviation of 0.0078 inch. The
company decided to plot a 3-sigma control chart to know in and out of control
situation. The following values, in table are obtained for sample size 5, in 10
consecutive days.
Days Average thickness of samples (inch)
1 0.1196
2 0.1351
3 0.1260
4 0.1192
5 0.1212
6 0.1250
7 0.1275
8 0.1195
9 0.1295
10 0.1248
Improvement
Types of control charts
Types of Control Charts
Control chart for variables are used to monitor characteristics that can be
measured, e.g. length, weight, diameter, time
X and R charts: for sample averages and ranges.

X and s charts: for sample means and standard deviations.
MR and R charts: for sample medians and ranges.
X charts: for individual measures; uses moving ranges.
Control charts for attributes are used to monitor characteristics that have discrete
values and can be counted, e.g. % defective
p charts: proportion of units nonconforming.

np charts: number of units nonconforming.
c charts: count of nonconformities.
u charts: count of nonconformities per unit.
Control Charts for Variables
 Use x-bar charts to monitor the changes in the
mean of a process (central tendencies)
 Use R charts to monitor the dispersion or variability
of the process
 System can show acceptable central tendencies but
unacceptable variability or
 System can show acceptable variability but
unacceptable central tendencies
Specification Limits vs. Control Limits
 The specification limits of a process reflect our need.
These limits are set by the management as objectives.
 The control limits of a process tell us what the process
can do when it is operating properly. These limits are
set by the quality of the machinery and the skills of
the operators.
 Process Capability is a figure of merit that tells us
whether a process is suitable for our manufacturing
objectives.
The center line of the control data is the average of the samples:
Another way to construct the control limits is to use the sample range as an estimate of the
variability of the process. Remember that the range is simply the difference between the largest
and smallest values in the sample. The spread of the range can tell us about the variability of
the data. In this case control limits would be constructed as follows:
Factors for three-sigma contro limits of and R-charts
[Source: Factors adapted from the ASTM Manual on Quality Control of Materials.]
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
R-Bar Control Chart
Control Charts for Variables
 Use x-bar and R charts

together
 Used to monitor different
variables
 X-bar & R Charts reveal
different problems
 Is statistical control on one
chart, out of control on the
other chart? OK?
© Wiley 2010 24
Control Charts for Attributes
 Many quality characteristics cannot be conveniently

represented numerically.
 In such cases, each item inspected is classified as
either conforming or nonconforming to the
specifications on that quality characteristic.
 Quality characteristics of this type are called
attributes.
 Examples are nonfunctional semiconductor chips,
warped connecting rods, etc,.
Type of Attribute Charts
p charts
 This chart shows the fraction of nonconforming or defective
product produced by a manufacturing process.
 It is also called the control chart for fraction nonconforming.
np charts
 This chart shows the number of nonconforming. Almost the
same as the p chart.
c charts
 This shows the number of defects or nonconformities
produced by a manufacturing process.
u charts
 This chart shows the nonconformities per unit produced by a
manufacturing process.
Control Charts for Attributes –P-Charts
& C-Charts
Attributes are discrete events: yes/no or 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
P-Charts
P-charts are used to measure the proportion that is defective in a sample.
C-Charts
 C-charts are used to monitor the number of defects per unit. Examples are the
number of returned meals in a restaurant, the number of trucks that exceed their
weight limit in a month, the number of discolorations on a square foot of carpet, and
the number of bacteria in a millilitre of water.

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Quality

Process in control Process out of control

Process in control Right signal Type II error

Process out of control Type I error Right signal

This type of wrong signaling happens because of sampling error.

Two important criteria:

Shift in mean value Increasing trend

Fig: Out of Control Indications

X and R charts: for sample averages and ranges.

p charts: proportion of units nonconforming.

Factor for x-Chart Factors for R-Chart

 Use x-bar and R charts

 Many quality characteristics cannot be conveniently

Attributes are discrete events: yes/no or pass/fail

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