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Chapter 4 Control Charts For Variables

Here are the steps to revise control charts: 1. Identify the points that are outside the control limits. These indicate potential changes or issues with the process. 2. Remove these out-of-control points from the dataset. They should not be used to recalculate the control limits. 3. Recalculate the process parameters (mean, range, standard deviation etc.) based only on the in-control points. 4. Recalculate the control limits using the revised process parameters. For example, recalculate the mean and standard deviation to get new values for the UCL and LCL. 5. Redraw the control chart with the revised control limits. 6. Plot all the

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146 views44 pages

Chapter 4 Control Charts For Variables

Here are the steps to revise control charts: 1. Identify the points that are outside the control limits. These indicate potential changes or issues with the process. 2. Remove these out-of-control points from the dataset. They should not be used to recalculate the control limits. 3. Recalculate the process parameters (mean, range, standard deviation etc.) based only on the in-control points. 4. Recalculate the control limits using the revised process parameters. For example, recalculate the mean and standard deviation to get new values for the UCL and LCL. 5. Redraw the control chart with the revised control limits. 6. Plot all the

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geletaw mitaw
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Control charts for

variables: x bar and R


chart; x bar and s chart
Chapter Four Dr. Shimelis Tilahun
• A control chart was first proposed in 1924 by
6. Control W.A Shewhart.
Charts • Aimed at eliminating an abnormal variation by
distinguishing variations due to assignable
causes from those due to chance causes.
• A Control chart is a graphical method for
displaying control results and evaluating
whether a measurement procedure is in-
control or out-of-control.
Control Chart Functions

Control charts are powerful aids to understanding the performance of


a process over time.

Input PROCESS Output

What’s causing variability?


Sources of Variation in Production and Service
Processes
➢ Common causes of variation
– Random causes that we cannot identify
– Unavoidable
– Cause slight differences in process variables like diameter, weight, service
time, temperature, etc.
➢ Assignable causes of variation
– Causes can be identified and eliminated
– Typical causes are poor employee training, worn tool, machine needing
repair, etc.
1. Control charts identify variation
➢ Chance causes - “common cause”
– inherent to the process or random and not controllable
– if only common cause present, the process is considered stable or
“in control”
➢ Assignable causes - “special cause”
– variation due to outside influences
– if present, the process is “out of control”
2. Control Charts Help us Learn More About
Processes

1 2 3
Separate common and Determine whether a Estimate the process
special causes of process is in a state of parameters (mean,
variation statistical control or variation) and assess
out-of-control the performance of a
process or Process
capability
3. Control charts to monitor processes
➢To monitor output, we use a control chart
– we check things like the mean, range, standard deviation
➢To monitor a process, we typically use two control charts
– mean (or some other central tendency measure)
– variation (typically using range or standard deviation)
Uses of Control charts
The main uses of control charts are:
1. It is a proven technique for improving productivity.
2. It is effective in defect prevention.
3. It prevents unnecessary process adjustments.
4. It provides diagnostic information.
5. It provides information about process capability.
• A control chart consists of:
• A central line
• Upper control (Standard) limit = UCL or USL
• Lower control (Standard) limit and =LCL or LSL
• Characteristic values plotted on the chart which
represent the state of a process.
➢ If all these values are plotted within the control limits without any
particular tendency, the process is regarded as being in the controlled
state, otherwise it is out of control.

In - Control

Out of Control
Types of control charts
The quality of a product can be evaluated using either
an attribute of the product or a variable measure.

There are two types of control charts:

1. Control charts for variables

2. Control charts for attributes.


Types of control charts
❖A variable measure is a product characteristic that is
measured on a continuous scale such as length, weight,
volume, pressure, temperature or time.
❖Control charts for attributes summarize the output of a
process, or operation, over time.
❖Attributed data have only two values such as good/bad,
conforming/non-conforming, or acceptable/not
acceptable.
Control Chart for Variables
Two of the most commonly used variable Control charts are :
– The mean chart or X-bar chart, and
– The range or R-chart.
– X –bar and S – Chart
X-bar and R charts
X-bar and R charts
➢ The chart is theoretically based on the normal distribution.
➢ Control charts for variables usually lead to more efficient control procedures and
provide more information about process performance than attributes control charts.
➢ The X-bar chart is developed from the average of each subgroup data.
– used to detect changes in the mean between subgroups.
➢ The R-chart is developed from the ranges of each subgroup data
– used to detect changes in variation within subgroups
X-bar and R
charts
X-bar and R-chart can be used to:
➢ Monitor and control machines and process
performance.
➢ Obtain information about specification and
manufacturability.
➢ Obtain the data about a production run.
➢ Supply information to customers of
conformance to specifications.
X-bar Chart
➢ The x-bar charts are known as control charts for
averages.
➢ The X-bar chart receives its inputs as the mean of
a sample taken from the process under study.
➢ Usually the sample will contain four or five
observations.
➢ X-bar chart: is control chart used to monitor
changes in the mean value of a process.
X-bar Chart
X-bar Chart
R - chart
➢ x-bar charts measure shift in the central
tendency of the process, range charts monitor
the dispersion or variability of the process

➢ Range (R) chart: is a control chart that monitors


changes in the dispersion or variability of process

➢ Both have similar construction method


R - chart
R - chart
Steps to construct X-bar and
R- charts
Step 1 . Collect the data
Step 2. Calculate x-bar (Sample mean)
Step 3. Calculate x-double bar (Process Mean)
Step 4. Calculate R (Sample Range)
Step 5. Calculate R-bar (Average Range)
Step 6. Calculate the control lines(LCL and UCL)
Step 7. Draw the control lines
Step 8. Plot the points
Step 9. Write the necessary items and interpret
Determine centerline(CL)

Central line (CL) for X-bar chart σ𝑚


𝑖=1 X𝑖
X=
𝑛

R = X highest value – X lowest value

Central line (CL) for R- chart


Determine control limits (X-bar chart)

UCL x = x + 3 σ x = x + A 2 R

LCL x = x − 3 σ x = x − A 2 R

Determine control limits (R-chart)

UCL R = R + 3 σ x = D 4 R

LCLR = R − 3 σ x = D3 R
Example 1: Control Charts for Variable Data
Slip Ring Diameter (cm)
Sample 1 2 3 4 5 X R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15
Solution:-
From Table above:

▪ sum of X = 50.09…. For each sample

▪ Sum of R = 1.15…… for each sample

▪ n = 10

Thus;

– X-Double bar = X-D=X = 50.09/10 = 5.009 cm…. For the


whole process

– R-bar=R = 1.15/10 = 0.115 cm…. For the whole process


Control Limit
For X- chart
• UCLx-bar = X-D bar + A2 R-bar = 5.009 + (0.577)(0.115)
= 5.075 cm
• LCLx-bar = X-D bar - A2 R-bar = 5.009 - (0.577)(0.115)
= 4.943 cm
For R-chart
• UCLR = D4R-bar = (2.114)(0.115) = 0.243 cm
• LCLR = D3R-bar = (0)(0.115) = 0 cm
For A2, D3, D4: see Table
n = 5
X-bar Chart
outliers

5.10
UCL
5.08
5.06
5.04
X bar

5.02
5.00 CL
4.98
4.96 LCL
4.94
0 1 2 3 4 5 6 7 8 9 10 11

Subgroup
R - Chart

0.25 UCL

0.20
Range

0.15
CL

0.10

0.05
LCL
0.00
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
Class Work exercise the
following with Excel
Constructing a X-bar
Chart:
A quality control inspector at the Cocoa soft Sampl Sampl Sampl
drink company has taken three samples 1 e2 e3
with four observations each of the volume Time 1 Time 2 Time 3
of bottles filled. If the standard deviation of
the bottling operation is .2 oz, use the data Observation 1 15.8 16.1 16.0
below to develop control charts with limits
of 3 standard deviations for the 16 oz. Observation 2 16.0 16.0 15.9
bottling operation.
Observation 3 15.8 15.8 15.9
Observation 4 15.9 15.9 15.8
Revise the charts

➢ In certain cases, control limits are revised because: During Revising the charts;

– out-of-control points were included in the


➢ Interpret the original charts
calculation of the control limits.
➢ Isolate the causes
– the process is in-control but within subgroup ➢ Take corrective action
variation significantly improves.
➢ Revise the chart
X bar and S chart
X bar and S Charts
X bar and S Charts
X bar and S Charts
X bar and S Charts
Setting
Control
Limits
Three Sigma Capability
➢ Mean output +/- 3 standard deviations falls within the
design specification
➢ It means that 0.26% of output falls outside the design
specification and is unacceptable.
➢ The result: a 3-sigma capable process produces 2600
defects for every million units produced
Six Sigma Capability
➢ Six sigma capability assumes the process is capable of
producing output where the mean +/- 6 standard
deviations fall within the design specifications
➢ The result: only 3.4 defects for every million produced
➢ Six sigma capability means smaller variation and
therefore higher quality
END

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