Target IX-MR Charts

Target charts show multiple characteristics that have different nominal or target values,
with a zero point representing the target value of each characteristic. Target individual X
and moving range (IX-MR) charts enable you to spot variation in a characteristic and
plot several characteristics in the same chart. Review the following example—an
excerpt from Innovative Control Charting1—to get a sense of how a target IX-MR chart
works.

Figure 1. Target percent solids from five different paint specifications.

Case Description
Solids content in paint is a key characteristic. To obtain a measure of solids content, a
paint sample of known weight is taken from a mixing tank—one sample per paint batch.
The sample is baked in an oven until only solids remain. The remaining solids are
weighed and a percent solids is calculated. In this example, a mixing tank is used to
produce five different types of paint: A, B, C, D, and E. Each paint type requires a
different percent solids content. Long production runs rarely occur with any one paint.
The production manager is monitoring the solids content from all five paints on the
same SPC chart.

Sampling Strategy
A target IX-MR chart is used to monitor this process because

1. Only one characteristic is being controlled (solids content).

2. One measurement is representative of each batch.
3. The user prefers to construct a single chart to track multiple paint specs.
Data Collection Sheet
Table 1. Data collection sheet for constructing target IX-MR chart.

Target IX-MR Chart

Figure 2. Percent solids target IX-MR chart.

Calculations for the MR Chart

Calculation 1. Calculations for MR chart.

MR Chart Interpretation and Recalculation

An upward spike occurs on the MR chart when the new supplier’s products begin to be
used. Because the MR chart is out of control, this means that the value of MR is
unreliable and cannot be used to calculate control limits for the target IX chart. This is
why no control limits were placed on the target IX chart in Figure 2.
After removing the out-of-control plot point (subgroup number 14) from the MR chart,
the MR was recalculated using the remaining 18 MR values (see Calculation 2).

Calculation 2. Revised MR chart calculations after removing subgroup number 14.

Note that all of the remaining moving range values fall within the new MR chart control
limits (see Figure 3). There appears to be no indication of assignable causes of
variation. Given this situation, it is now appropriate to complete the control chart
calculations for the target IX chart.
Figure 3. Target IX-MR chart with revised control limits. Subgroup number 14 has
been removed from calculations for the MR chart.

Calculations for the Target IX Chart

Calculation 3. Calculations for the percent solids target IX chart.

Target IX Chart Interpretation

It appears that, after the supplier change, the percent solids contents increased across
paints A, B, and C. The run above the centerline between plot points 14 and 20 was
determined to be the result of changing the supplier. The run below the centerline
between points 4 and 9 is, in part, due to the upward shift in the centerline between
points 14 and 20.
Note: When analyzing target charts, also look for patterns unique to each characteristic
represented on the chart. For example, look to see if all of paint A plot points were
above or below the centerline or trending upward or downward. In this example, all paint
B plot points are above the centerline, but there are only two plot points. This does not
qualify as an assignable cause. However, if eight or more plot points from the same
paint were above the centerline, it would indicate an out-of-control condition unique to
that paint. This would be true regardless of how many different paints were
manufactured between those points.

Recommendation
Supplier changes should not be introduced into the line without first knowing how the
change will affect the producibility and/or the finished product. If the effects are known in
advance, prior adjustments can possibly be made without affecting the production line.
In many cases, the costs associated with changing suppliers exceed the benefits of a
lower price.

Estimating the Process Average

The coded IX on the control chart (–0.02 percent) has been upwardly influenced
because of the supplier change assignable cause. Because of the presence of an
assignable cause, the overall average of –0.02 percent is not a reliable estimate of the
centering of the process.

To accurately estimate the overall process average, we will evaluate only the data from
the old supplier (the first 13 subgroups). This data by itself proved to be in control on a
separate target IX-MR chart (not shown here).

Calculation 4. Estimate of the process average based upon old supplier data (first
13 subgroups).

The coded IX from Calculation 4 shows that, on average, each old supplier batch of
paint is approximately 0.15 percent below targets. If enough data were gathered from
the new supplier data, it might be interesting to evaluate the old supplier’s coded IX with
the new supplier’s IX.

Estimating Sigma
The MR chart for the first 13 subgroups (not shown) proved to be in control. The
calculation for MR is shown in Calculation 5.
Calculation 5. Average moving range calculation from first 13 subgroups.

Calculation 6. Estimating sigma using MR from Calculation 5.

Note that the first 13 subgroups represent only old supplier data. Therefore,
the sigma found in Calculation 6 can be thought of as the estimated standard deviation
for the old supplier. Notice, though, that the first 13 subgroups also are representative of
process performance from paint specs A, D, and E. No data representing paint specs B
or C are found. Therefore, paint specs A, D, and E will be used in calculating Cp and
Cpk values. There will be no calculation of Cp or Cpk values for paint specs B or C.

Calculating Process Capability and

Performance Ratios
Capability ratios will be calculated for each paint specification found in the first 13
subgroups. Because the MR chart is in control, the same sigma may be used in
calculating process capability and performance ratios for paint specifications A, D, and
E. The Cp calculation for paint specification A (assuming the old supplier’s materials are
used) is found in Calculation 7.

Calculation 7. Process capability ratio for paint spec A using old supplier data.

In order to calculate CpkA, the process average must first be estimated for paint spec A.
The estimate of the paint spec A process average is given in Calculation 8.
Calculation 8. Estimate of the process average for paint spec A.

Calculation 9. Cpk upper calculation for paint spec A.

Calculation 10. Cpk lower calculation for paint spec A.

Because the Cp value is greater than 1, the process is more than capable of producing
almost 100 percent acceptable output. Because the Cpk value is smaller than the Cp
value, it means that the process is a little off center, but because the Cpk value is larger
than 1, the process is performing to specifications.
The Cp and Cpk ratios for paint specs D and E can be found in Table 2.
Note: To ensure reliable estimates of sigma and the process average, one needs about
20 data points. Therefore, the calculations on these pages and those in Table 2 are
used for illustration purposes only.

Target IX-MR Chart Advantages

 Multiple parts, specifications, or characteristics can be plotted on the same chart
(provided they all have similar variability as exhibited by an in-control MR chart).
 Cp and Cpk can be calculated for each characteristic on the chart.
 Statistical control can be assessed for both the process and each unique part
and/or characteristic on the chart.

Target IX-MR Chart Disadvantages

 When interpreting the target IX chart, both the zero line and the coded X must be
taken into account.
 The MR plot points are dependent on the IX plot points. In other words, changes
in the MR chart are directly related to changes from one individual measurement
to the next.
  Variation in the individual measurements could be caused by a shift in the
average or the inherent standard deviation of the process; however, the IX-MR
charts cannot efficiently separate the effects of the two.
 Reliable control limits require the distribution of the individual measurements to
be approximately normal.
 The target IX-MR chart is not as sensitive to changes in the process average or
standard deviation as would be a target Xbar-R chart.

Additional Comments About the Case

Cp and Cpk for paint specifications D and E are shown in Table 2.

Table 2. Cp and Cpk values for paint specifications D and E.

When you use SPC software from InfinityQS, consuming the information provided by
target IX-MR charts becomes faster and easier than ever. See how this type of analysis
is surfaced in InfinityQS solutions.

FOOTNOTE:
1 Wise, Stephen A. and Douglas C. Fair. Innovative Control Charting: Practical SPC
Solutions for Today’s Manufacturing Environment. Milwaukee, WI: ASQ Quality Press.
Group Target IX-MR Charts
Group target individual X and moving range (IX-MR) charts combine the insights of
a group IX-MR chart and a target IX-MR chart to provide statistically valid information
from multiple part numbers or characteristics that have a common process. Review the
following example—an excerpt from Innovative Control Charting1—to get a sense of
how a group target IX-MR chart works.

Figure 1. Three generic key characteristics for the seat product line.

Case Description
Three generic key characteristics are monitored on several different seat products. All seats
share three common key characteristics and tolerances.

 Key a, inside diameter (nominal + 0.001)

 Key b, length (nominal + 0.001)
 Key c, OD (nominal + 0.005)

Seats are manufactured in many different sizes. In this example, three different seat product
series (the -400, -800, and -900) will be evaluated. Each of the three seat series is machined on
the same lathe but with different tools. Each characteristic is a different size, but the standard
deviations are expected to be similar. The shop supervisor wants to analyze the stability of all
three key characteristics, regardless of series number, on one chart (see Table 1).

Table 1. Key target values for the three different seat product series.

Sampling Strategy
Given low production volume and multiple characteristics of different sizes, a group target IX-
MR chart is selected. This chart will help operators evaluate the variation due to the lathe and
variation specific to each characteristic/product series combination. The data in Table 2
represent measurements taken at the lathe every hour in subgroup sizes of one.

Data Collection Sheet

Table 2. Group target IX-MR data and plot points (shown in bold) for the three seat
product line characteristics.
Plot Point Calculation
Group MR chart: Moving range values are calculated by taking the absolute value
between individual measurements from consecutive groups for the same location. For
example, location a in group 2 is 0.4455 and location a in group 1 is 0.4448, so the MR
between the two groups is 10.4455 — 0.44481 = 0.0007. MAX and MIN values within
each group are used as plot points.
Note: Because the same part series was not evaluated in any previous group, no MR values
exist for groups 1, 4, or 7.

Group Target IX-MR Chart

Figure 2. Group target IX-MR chart used to evaluate three different key
characteristics from three similar parts.

Chart Interpretation
Note: There are only three groups per part series in this example, therefore, any plot point
patterns unique to a part series should be considered only when more data become available.

Group MR chart: MAX and MIN plot points from consecutive groups appear to be descending
over time. This could be the result of either

1. The standard deviation getting smaller over time regardless of part number
2. The -400 series parts exhibiting more variability than either the -800 or -900 series seats

With more data, this initial observation could be confirmed or rejected.

Note: The centerline on the group moving range chart is the average of all the moving ranges in
the data set.

Group target IX chart: Key characteristic c appears in the MAX position six out of nine times.
Because this is true across all three part series, it may indicate a condition inherent to the
process instead of one specific to a part series. Operators speculate it has to do with the lathe’s
apparent difficulty in machining the ODs. There might be something unique about why the lathe
tends to run ODs a little higher than specified. Or the problem may be attributed to the
programmer having written the program to intentionally manufacture the diameters on the high
side. Additional investigation will be required to pinpoint the reason for this nonrandom pattern.
Note: The centerline on the group target IX chart is the average of all the coded IX plot points in
the data set.

Recommendations
 As more data are collected, the operator should pay close attention to key
characteristic c (the ODs). Look for reasons why the diameters on all part series might
be a little high.
 Look to see if the moving range plot points continue to decrease over time. It is possible
that the -400 series key characteristics have larger standard deviations than the -800 or -
900 series key characteristics. (The -800 and -900 series are larger parts, which could
explain their smaller standard deviations.)

Estimating the Process Average

If all the part series and their characteristics on the IX chart appear to be behaving randomly, a
single average of all coded individual values could be used to estimate the overall process
average. However, because this was not the case for the seat products here, process averages
will need to be estimated for each seat characteristic across all part series. This is done by
calculating a coded IX value for each characteristic for all part series. An example for
characteristic a is shown in Calculation 1.
Calculation 1. Estimate of the process average for key characteristic a.

Estimating Sigma
Estimates of sigma are also calculated separately for each characteristic on the group chart.
Continuing with key characteristic a, see Calculations 2 and 3.

Calculation 2. Calculation of MR for key characteristic a across all seat series.

Calculation 3. Estimate of the process standard deviation for key characteristic a.

Note: To ensure reliable estimates, the number of groups should be at least 20. In this example,
the number of groups is only 9. Therefore, these estimates and those found in Table 3 are
shown only for illustration purposes.

Calculating Process Capability and Performance

Ratios
These ratios are calculated using coded data. The coded target for each characteristic is zero.
Calculations for key characteristic a across all three-part series are shown in Calculations 4, 5,
and 6.

Calculation 4. Cp calculation for seat key characteristic a.

Calculation 5. Cpk upper calculation for seat key characteristic a.

Calculation 6. Cpk lower calculation for seat key characteristic a.

Group Target IX-MR Chart Advantages

 Graphically illustrates the variation of multiple products and their characteristics
simultaneously on the same chart
 Separates sources of variation unique to the process, unique to the product, and unique
to a characteristic on a single chart
 Separates variation due to changes in the average from variation due to changes in the
standard deviation

Group Target IX-MR Chart Disadvantages

 No visibility of the characteristics that fall between the MAX and MIN plot points
 The use of negative numbers can be confusing
 Cannot detect certain out-of-control conditions because the group charts described here
have no control limits

Additional Comments About the Case

Additional statistics and process capability and performance values for key
characteristics b and c are shown in Table 3.

Table 3. Additional statistics and process capability and performance values for key
characteristics b and c.

When you use SPC software from InfinityQS, consuming the information provided by group
target IX-MR charts becomes faster and easier than ever. See how this type of analysis is
surfaced in InfinityQS solutions.

FOOTNOTE:
1 Wise, Stephen A. and Douglas C. Fair. Innovative Control Charting: Practical SPC Solutions
for Today’s Manufacturing Environment. Milwaukee, WI: ASQ Quality Press.