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Control Charts for Variables

Introduction

• Variable- a single quality characteristic that

can be measured on a numerical scale.
• When working with variables, we should
monitor both the mean value of the
characteristic and the variability associated
with the characteristic.

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Subgroup Data with Unknown µ and σ

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Phase I Application of and R Charts

• Eqns 6.4 and 6.5 are trial control limits
– Determined from m initial samples
• Typically 20-25 subgroups of size n between 3 and 5
– Any out-of-control points should be examined for assignable causes
• If assignable causes are found, discard points from calculations and
revise the trial control limits
• Continue examination until all points plot in control
• Adopt resulting trial control limits for use
• If no assignable cause is found, there are two options
1. Eliminate point as if an assignable cause were found and revise limits
2. Retain point and consider limits appropriate for control
– If there are many out-of-control points they should be examined for
patterns that may identify underlying process problems

Example 6.1 The Hard Bake Process

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Phase II Operation of Charts

• Use of control chart for monitoring future
production, once a set of reliable limits are
established, is called phase II of control chart
usage (Figure 6.4)
• A run chart showing individuals observations
in each sample, called a tolerance chart or tier
diagram (Figure 6.5), may reveal patterns or
unusual observations in the data

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Control vs. Specification Limits

• Control limits are derived
from natural process
variability, or the natural
tolerance limits of a process

• Specification limits are

determined externally, for
example by customers or
designers

• There is no mathematical or
statistical relationship
between the control limits
and the specification limits

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Rational Subgroups
• charts monitor between-sample variability
• R charts measure within-sample variability
• Standard deviation estimate of σ used to construct
control limits is calculated from within-sample
variability
• It is not correct to estimate σ using

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Guidelines for Control Chart Design

• Control chart design requires specification of sample size,
control limit width, and sampling frequency
– Exact solution requires detailed information on statistical
characteristics as well as economic factors
– The problem of choosing sample size and sampling frequency is one of
allocating sampling effort
• For chart, choose as small a sample size is consistent with
magnitude of process shift one is trying to detect.
– For moderate to large shifts, relatively small samples are effective.
– For small shifts, larger samples are needed.
• For small samples, R chart is relatively insensitive to changes
in process standard deviation. For larger samples (n > 10 or
12), s or s2 charts are better choices.

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If the shift is 1.0σ and the sample

size is n = 5, then β = 0.75.

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Chapter 7: Methods and Philosophy of

Statistical Process Control (Part III)
Agenda
•Control Charts for X-Bar and S
•The S2 control charts
•The control charts for individual measurements

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Development of the control limits:

Thus produces the control limits in equation (6.27)

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This produces the control limits in equation (6.28)

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Chapter 7: Methods and Philosophy of

Statistical Process Control (Part III)
Agenda
•Control Charts for Attributes
•Control Charts for Fraction Non Conforming P-Chart
•Control Charts for Number Non Conforming NP-Chart
•Control Charts for Non Conformities (Defects) C-Chart
•Control Charts for Average Number of Non Conformities U-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Control Charts for Fraction Non

Conforming : P-Chart

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Design of the Fraction Nonconforming Chart

• Three parameters must be specified

1. The sample size
2. The frequency of sampling
3. The width of the control limits
• Common to base chart on 100% inspection
of all process output over time
• Rational subgroups may also play role in
determining sampling frequency

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Control Charts for Number Non Conforming

NP-Chart

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Average sample size approach

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Non Conformities (Defects)

C-Chart

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Control Charts for Average Number of Non Conformities

U-Chart

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Control Charts for Average Number of Non Conformities

U-Chart

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Control Charts for Average Number of Non Conformities

U-Chart

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