X-Bar and S Charts
X-Bar and S Charts
X-Bar and S Charts
com
Chapter 243
Introduction
This procedure generates X-bar and s (standard deviation) control charts for variables. The format of the
control charts is fully customizable. The data for the subgroups can be in a single column or in multiple
columns. This procedure permits the defining of stages. For the X-bar chart, the center line can be entered
directly or estimated from the data, or a sub-set of the data. Similarly sigma may be estimated from the data
or a standard sigma value may be entered. A list of out-of-control points can be produced in the output, if
desired, and means and standard deviation values may be stored to the spreadsheet.
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∑𝑛𝑛𝑗𝑗=1 𝑥𝑥𝑖𝑖𝑖𝑖
𝑥𝑥̅𝑖𝑖 = ,
𝑛𝑛
2
∑𝑛𝑛𝑗𝑗=1�𝑥𝑥𝑖𝑖𝑖𝑖 − 𝑥𝑥̅𝑖𝑖 �
𝑠𝑠𝑖𝑖 = � .
𝑛𝑛 − 1
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𝑛𝑛𝑖𝑖
∑𝑘𝑘𝑖𝑖=1 ∑𝑗𝑗=1 𝑥𝑥𝑖𝑖𝑖𝑖
𝑥𝑥̿ = .
∑𝑘𝑘𝑖𝑖=1 𝑛𝑛𝑖𝑖
If the subgroups are of equal size, the above equation for the grand mean reduces to
∑𝑘𝑘𝑖𝑖=1 𝑠𝑠𝑖𝑖
𝑠𝑠̅ =
𝑘𝑘
𝐸𝐸(𝑠𝑠) 𝜇𝜇𝑠𝑠
𝑐𝑐4 = =
𝜎𝜎 𝜎𝜎
The calculation of E(s) requires the knowledge of the underlying distribution of the xij’s. Making the
assumption that the xij’s follow the normal distribution with constant mean and variance, the values for c4
are obtained from
𝑛𝑛
2 Γ �2 �
𝑐𝑐4 = �
𝑛𝑛 − 1 Γ �𝑛𝑛 − 1�
2
1/2
∑𝑘𝑘𝑖𝑖=1(𝑛𝑛𝑖𝑖 − 1)𝑠𝑠𝑖𝑖2
𝜎𝜎� = 𝑠𝑠̅ = � �
∑𝑘𝑘𝑖𝑖=1 𝑛𝑛𝑖𝑖 − 𝑘𝑘
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𝜎𝜎�
𝐿𝐿𝐿𝐿𝐿𝐿 = 𝑥𝑥̿ − 𝑚𝑚 � �
√𝑛𝑛
𝜎𝜎�
𝑈𝑈𝑈𝑈𝑈𝑈 = 𝑥𝑥̿ + 𝑚𝑚 � �
√𝑛𝑛
where m is a multiplier (usually set to 3) chosen to control the likelihood of false alarms (out-of-control
signals when the process is in control).
If the standard deviation is estimated from a series of subgroups, the s chart center line is given by 𝑠𝑠̅,
whether computed by the mean of standard deviations approach, or by the weighted approach.
s Chart Limits
The lower and upper control limits for the s chart are calculated using the formula
where m is a multiplier (usually set to 3) chosen to control the likelihood of false alarms, and c4 is defined
above, and is based on the assumption of normality.
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Runs Tests
The strength of control charts comes from their ability to detect sudden changes in a process that result from
the presence of assignable causes. Unfortunately, the X-bar chart is poor at detecting drifts (gradual trends) or
small shifts in the process. For example, there might be a positive trend in the last ten subgroups, but until a
mean goes above the upper control limit, the chart gives no indication that a change has taken place in the
process.
Runs tests can be used to check control charts for unnatural patterns that are most likely caused by
assignable causes. Runs tests are sometimes called “pattern tests”, “out-of-control” tests, or “zones rules”.
While runs tests may be helpful in identifying patterns or smaller shifts in the mean, they also increase the
likelihood of false positive indications. The rate of false positives is typically measured using the average run
length (the average length of a run before a false positive is indicated). When several runs tests are used the
average run length of the control chart becomes very short. Two alternatives to consider before using runs
tests are the CUSUM and EWMA control charts. Runs tests are generally advised against when there is only
one observation per subgroup. In this case, the rate of false positives is quite high (average run length is
short).
In order to perform the runs tests, the control chart is divided into six equal zones (three on each side of the
centerline). Since the control limit is three sigma limits (three standard deviations of the mean) in width,
each zone is one sigma wide and is labeled A, B, or C, with the C zone being the closest to the centerline.
There is a lower zone A and an upper zone A. The same is true for B and C. The runs tests look at the
pattern in which points fall in these zones.
The runs tests used in this procedure are described below.
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Subgroup Size
How many items should be sampled for each subgroup? Some common values are 5, 10, and 20. How does
the subgroup size affect my use of control charts? What about unequal subgroup sizes?
Startup Time
How many subgroups should be used to establish control for my process?
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Normality Assumption
How important is the assumption of normality? How do I check this? Should I consider a transformation?
(See also the Box-Cox Transformation and Capability Analysis procedures in NCSS.)
Data Structure
In this procedure, the data may be in either of two formats. The first data structure option is to have the
data in several columns, with one subgroup per row.
Example Dataset
S1 S2 S3 S4 S5
2 6 3 8 5
8 8 7 7 9
6 2 2 4 3
5 6 7 6 10
48 2 6 5 0
. . . . .
. . . . .
. . . . .
The second data structure option uses one column for the response data, and either a subgroup size or a
second column defining the subgroups.
Response Subgroup
2 1
6 1
3 1
8 1
5 1
8 2
8 2
7 2
7 2
9 2
6 3
2 3
. .
. .
. .
In the alternative example dataset, the Subgroup column is not needed if every subgroup is of size 5 and the
user specifies 5 as the subgroup size. If there are missing values, the Subgroup column should be used, or
the structure of the first example dataset.
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Symbols Section
You can modify the attributes of the symbols using the options in this section.
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A wide variety of sizes, shapes, and colors are available for the symbols. The symbols for in-control and out-
of-control points are specified independently. There are additional options to label out-of-control points.
The label for points outside the primary control limits is the subgroup number. The label for points that are
out-of-control based on the runs test is the number of the first runs test that is signaled by this point.
The user may also specify a column of point labels on the procedure variables tab, to be used to label all or
some of the points of the chart. The raw data may also be shown, based on customizable raw data symbols.
Lines Section
You can specify the format of the various lines using the options in this section. Note that when shading is
desired, the fill will be to the bottom for single lines (such as the mean line), and between the lines for pairs
of lines (such as primary limits).
Lines for the zones, secondary limits, and specification limits are also specified here.
Titles, Legend, Numeric Axis, Group Axis, Grid Lines, and Background Tabs
Details on setting the options in these tabs are given in the Graphics Components chapter. The legend does
not show by default but can easily be included by going to the Legend tab and clicking the Show Legend
checkbox.
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Setup
To run this example, complete the following steps:
Variables Tab
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
This section displays the center line values that are to be used in the X-bar and s charts.
s-bar
This is the average of the standard deviations.
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This report gives the lower and upper limits for each of the charts, corresponding to a specific subgroup
size.
This report gives the estimation of the population standard deviation (sigma) based on three estimation
techniques. The estimation technique used for the plots in this procedure is based on the ranges.
Estimation Type
The two formulas for estimating sigma based on the standard deviation are shown earlier in this chapter in
the Control Chart Formulas section. The formulas for the Ranges method are shown in the X-bar and R
Charts chapter.
Estimated Value
This column gives the R-bar and s-bar estimates based on the corresponding formulas.
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Estimated Sigma
This column gives estimates of the population standard deviation (sigma) based on the corresponding
estimation type.
The first plot shows the sample means, as well as the centerline and control limits for the process mean,
based on the 50 subgroups. This process appears to be in control. The second plot shows the sample
standard deviations for each subgroup, as well as the corresponding centerline and limits. The s chart
seems to indicate the variation is also in control.
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Out-of-Control List
This report provides a list of the subgroups that failed one of the runs tests (including points outside the
control limits). The report shows that subgroup 30 is the final point of 4 out of 5 points in Zone B. This run
does not appear to indicate a clear shift in the process variation.
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Setup
To run this example, complete the following steps:
Variables Tab
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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Since the first 50 subgroups are the same as those of Example 1, and since only the first 50 subgroups are
used in the calculations for this run, the results for these sections are the same as those of Example 1.
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These plots have the same limits as those of Example 1. It appears there may have been a shift in process
for the last 30 or 40 subgroups, as evidenced by the large majority of points above the center line and out-
of-control signal from subgroup 142.
Out-of-Control List
This list indicates a large number of out-of-control signals (by Runs tests) for subgroups 121 and beyond.
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X-bar Chart
As shown here, a variety of enhancements can be made to the formatting of the control charts to make the
chart as easy to read as possible. The numbers above the points near the end represent the number of the
first runs test that is signaled by that point.
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Setup
To run this example, complete the following steps:
Variables Tab
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
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Primary Control Limit Section for Subgroups 71 to 120 where CalcRows equals 1
─────────────────────────────────────────────────────────────────────────
These limits are based on a subgroup of size 5.
─────────────────────────────────────────────────────────────────────────
Primary Control Limits
───────────────
Chart Type Lower Upper
─────────────────────────────────────────────────
X-bar 40.18144 52.29652
s 0 8.865826
─────────────────────────────────────────────────────────────────────────
This report shows the center line, limit, and sigma estimates for each of the two stages. The center line
estimate changes from about 51 to about 46. There also appears to be a change in sigma of about 6.3 to
about 4.5.
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The change in process mean and variation from the first stage to the second is reflected in the X-bar and s
charts.
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