2023/10/23

品質計劃與管制 (Quality Planning and Control)

Ch07-Attributes Control Charts

課程老師：王姿惠

Outline
 Introduction
 The Control Chart for Fraction Nonconforming (p Chart)
 The Control Chart for Number Nonconforming (np Chart)
 The Control Charts for Nonconformities (Defectives) (c and u Charts)
 Choice Between Attributes and Variables Control Charts
 Guideline for Implementing Control Charts

CHAPTER 07 2

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7.1 Introduction

Two Types of Data in Quality Control

 ___________ data: continuous variables; measurement data
• Example: A dimension, weight, or volume
 ___________ data: discrete or categorical variables; go/no-go data
• Example: Pass or fail assessment, clothing sizes

25 35
mm mm

No-Go Go
Spec. = (25 mm, 35 mm)

CHAPTER 07 4

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 Go/No-Go量具 (Gauge)
• 目的：比起量測精準尺寸數值 (計量值)，Go/No-Go量具可快速地篩選
出符合尺寸規格的良品與不良品。
• 作法：
1) ____________
2) _________________
• 舉例：
零件 A 1. 間隙不可超過 1.0 mm
(____________)

零件 B
2. 間隙應介於 0.8-1.0 mm
(____________)

影片來源: https://www.youtube.com/watch?v=P7FMwEY3_iI (Go nogo usage)

https://www.youtube.com/watch?v=uN0ZTmhsH1w (Go No Go Gage Application 厚薄規)

CHAPTER 07 5

1. 間隙不可超過 1.0 mm (Go or No-go)

? mm ? mm

1.0 mm

0.6 mm

1.5 mm

CHAPTER 07 6

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2. 間隙應介於 0.8-1.0 mm (Go/No-go)

? mm ? mm

1.0 mm
0.8 mm

1.3 mm
0.5 mm

CHAPTER 07 7

Chapter Overview (p288)

 Many quality characteristics cannot be conveniently numerically.

 In such cases, we usually classify each item inspected as either
conforming or nonconforming to the specifications on that quality
characteristic.
• 許多品質特性無法方便地用數值表示。
• 通常將檢查項目對應規格，區分為 _____ 或 _____ 之結果。

 Quality characteristics of this type are called _____________.

• 優點：計數型資料蒐集上較為 _______ 且 _________________。

CHAPTER 07 8

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Chapter Overview
 Examples:
• The number of nonfunctional semiconductor chips on a wafer.
• The number of errors or mistakes made in completing a loan application
(一週內銀行員處理貸款申請過程中發生失誤的件數)。
• The number of medical errors made in a hospital.
(每年某醫院內發生醫療爭議案件數)

CHAPTER 07 9

Chapter Overview
 Three widely used attributes control charts:
• The control chart for fraction nonconforming, or p chart
• The control chart for nonconformities, or the c chart
• The control chart for nonconformities per unit, or the u chart

 Types of Charts with Values

1. Standard value is given (with known p / c / u )
2. Standard value is not given(with unknown p / c / u )

CHAPTER 07 10

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Chapter Overview
 以管制圖監控製程目的：用來監控製程，以「統計方法」確認當前
製程狀態與過去相比是否有顯著變化，以防止任何變化對產品品質
造成影響。
300
25%-
250
23%-
200 UCL
20%-
150
100
18%-
15%-50 LCL
0
13%-

CHAPTER 07 11

7.2 The Control Chart for Fraction

Nonconforming (p Chart)

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The Control Chart for Fraction

Nonconforming (p Chart) (p289)

 Fraction nonconforming is the ratio of the number of nonconforming items

in a population to the total number of items in that population.
• 不良率指母體中________________與母體__________的比率。

• 舉例：9:00-10:00 某機台生產產品數為 1000 個，不合格品數為 20 個。

 Items may have several quality characteristics that are examined

simultaneously by the inspector.
• 產品可同時依據多個品質特性一起檢查。

CHAPTER 07 13

The Control Chart for Fraction

Nonconforming (p Chart) (p289)

 名詞補充：
• 若有某項品質特性不符合標準或規格，稱之為 _____________________
或 _______________。
• 若產品具有一項或多項缺點，使得___________________，即是
___________________ (Nonconforming Item) 或 __________
(Defective Item) 。

CHAPTER 07 14

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The Control Chart for Fraction

Nonconforming (p Chart)
 How to develop the control chart based on fraction nonconforming?
 Control charts for fraction nonconforming are based on the
Binomial distribution.
• All trials are independent.
• Each outcome is either a “success” or “failure”.
• The probability of a success is constant.
 The probability of success on any trial is given as p.
 The probability of a failure is 1-p.

CHAPTER 07 15

The Binomial Distribution (p290)

 The binomial distribution with parameters 𝑛 ≠ 0 and 0 < 𝑝 < 1, is

given by

 The mean and variance of the binomial distribution are

CHAPTER 07 16

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The Control Chart for Fraction

Nonconforming (p Chart)
 Assume
• n = number of units of product selected at random (____________)
• D = number of nonconforming units from the sample (樣本中__________)
• p = probability that any unit will not conform to specifications (_________)

Example: assume the p = 0.10, what is the P(D = 3) when the n = 10?

CHAPTER 07 17

The Control Chart for Fraction

Nonconforming (p Chart) (p290)

 The sample fraction nonconforming is defined as

• where 𝑝̂ is a random variable with mean and variance

• 推導過程

CHAPTER 07 18

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The Control Chart for Fraction

Nonconforming (p Chart) (p291)

 1. Standard value is  2. Standard value is not given

given (with known p) (with unknown p)

CHAPTER 07 19

 p Chart example:

Machine 9:00-10:00 …

機台生產產品數共 1000 個，採 _____ 檢驗方式，

檢查出的不合格品數共計 20 個。

Machine 9:00-10:00 …

機台生產產品數共 1000 個，採 _____ 檢驗方式，

抽出 100 個產品，檢查出不合格品數共計 2 個。

CHAPTER 07 20

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 p Chart example:

09:00 n = 10, Nonconforming Units = 3

09:30 n = 10, Nonconforming Units = 2

10:00 n = 10, Nonconforming Units = 4

10:30 n = 10, Nonconforming Units = 2 → Construct the p chart

… …
50%-
300
不 250 UCL
40%-
良 200
30%-
150
率 100
20%-
(p) 50 LCL
10%-0

CHAPTER 07 21

Example
 Assuming that a batch of cardboard
cartons are in stock, 50 samples are
taken every half an hour, and after
recording the number of unqualified
products, the defective rate is
calculated as follows:

• 假設一批硬紙盒庫存品，每半小時抽
取 50 個樣本數，記錄其不合格品數
後，並計算不良率如下表：

CHAPTER 07 22

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Example

CHAPTER 07 23

Example

• 從圖中可知，目前製程不在管制
內，因第 15 個樣本點超出上管
制界限 (此時間點發生什麼事？)
• 加以調查並找尋可歸屬原因。

CHAPTER 07 24

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Phase I and Phase II (p231)

 Phase I (階段一):
• Construct the control chart according to the sample data.
• If the process is stable, fix the control limits, and enter to the phase II.
(當製程為穩定狀態，則 ___________，進入階段二監控未來的生產)

 Phase II (階段二):
• Input the new sample data with Phase I control chart.
• Monitor the process and draw the conclusion.

10/23/2023 CHAPTER 06 25

Phase I and Phase II (p292)

 The quality characteristic is plotted against the trial limits, if any points
plot out of control, assignable causes should be investigated, and points
removed.
• Assume the reason for assignable cause is found, and the process is adjusted.
(假設已找尋到可歸屬原因，並且調整完製程或機台)
• With removal of the points, the limits are then recalculated.
(此 _______________，並 _____________________________)

CHAPTER 07 26

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Example
 新修正的管制界限與管制圖為何？

CHAPTER 07 27

Example
 新修正的管制界限與管制圖為何？

CHAPTER 07 28

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Exercise 7.2
 A process that produces titanium forgings (鈦 Day Nonconforming Units
製鍛造零件) for automobile turbocharger 1 3
wheels (汽車渦輪增壓輪胎) is to be 2 2
3 4
controlled through use of a fraction
4 2
nonconforming chart. Initially, one sample of
5 5
size 150 is taken each day for ten days, and the 6 2
results shown in following table are observed. 7 1
8 2
a) Establish a control chart to monitor future
9 0
production. 10 5

CHAPTER 07 29

Exercise 7.2
Day Nonconforming Units 𝑝̂
1 3
2 2
3 4
4 2
5 5
6 2
7 1
8 2
9 0
10 5

CHAPTER 07 30

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Exercise 7.2
• 結論：從圖中可知，沒有樣本點
落在管制界限外，且樣本點呈隨
機分佈，表示目前製程是在管制
狀態。

CHAPTER 07 31

Sample Size of p Control Chart (p299)

 If the in-control value of the fraction nonconforming is small, another

useful criterion is to choose n large enough so that the control chart will
have a positive lower control limit.

• Example, if p = 0.05 and three-sigma limits are used, the sample size

CHAPTER 07 32

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Exercise 7.2
b) What is the smallest sample size that could be used for this process and still
give a positive lower control limit on the chart?

CHAPTER 07 33

Variable Sample Size (p301)

 In some applications of the control chart for the fraction nonconforming,

the sample is a 100% inspection of the process output over some period
of time. Time n Fail Time n Fail
09:00 1000 4 09:00 1300 3
• Since different numbers of units 10:00 1000 4 10:00 1200 4
could be produced in each period, 11:00 1000 6 11:00 1000 6
12:00 1000 5 12:00 950 5
the control chart would then have
13:00 1000 5 13:00 1000 5
a variable sample size. 14:00 1000 5 14:00 1200 2
15:00 1000 4 15:00 1200 5
• p chart (UCL, CL, LCL)?
16:00 1000 6 16:00 1100 6
17:00 1000 4 17:00 1400 4

CHAPTER 07 34

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Three Approaches for Control Charts

with Variable Sample Size
 1. Variable Width Control Limits

 2. Control Limits Based on Average Sample Size

 3. Standardized Control Chart

CHAPTER 07 35

Variable Width
Control Limits
• If the ith sample is of
size ni, then the control
limits are

CHAPTER 07 36

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Variable Width Control Limits (p303)

CHAPTER 07 37

Control Limits based on an Average

Sample Size (p303)

CHAPTER 07 38

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The Standardized Control Chart (p304)

CHAPTER 07 39

The Standardized Control Chart

UCL = 3
CL = 0
LCL = -3

However, it maybe more

difficult for operating
personnel to understand and
interpret, because references
to the actual process fraction
defective has been “lost”

CHAPTER 07 40

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The Standardized
Control Chart

CHAPTER 07 41

Summary
 1. Variable Width Control Limits
• 優點：可 ________ 各組樣本的上下管制界限
• 缺點：計算 ______

 2. Control Limits Based on Average Sample Size

• 優點：計算 ______
• 缺點：各組樣本數變化量不可超過 20%

 3. Standardized Control Chart

CHAPTER 07 42

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The np Control Chart (p300)

 It is also possible to base a control chart on the number nonconforming

rather than the fraction nonconforming.
 Called a number of nonconforming (np) control chart.
 Let n = sample size, p = proportion of nonconforming. The control
limits are:

(if a standard, p, is not

given, use 𝑝̅ → 𝑝)

CHAPTER 07 43

Exercise 7.9 (改)

 A process is monitored by a p control chart with three sigma. The
UCL = 0.161, CL = 0.08, LCL = 0.
• Please construct the np control chart if the sample size remains the same.

CHAPTER 07 44

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7.3 Control Charts for

Nonconformities (Defects)

Control Charts for Nonconformities (Defects)

 It is often useful to work directly with the number of defects or
nonconformities (_________) rather than the fraction nonconforming.
 Examples:
• The number of defective welds in 100 m of oil pipeline
(輸油管道中不良焊縫的數量)
• Control charts for particles in the semiconductor manufacturing process
(半導體晶圓缺陷點變異管制圖)

Ref.: https://images.app.goo.gl/fcuB46akCNfcMyC8A

CHAPTER 07 46

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• 半導體晶圓缺陷點變異管制圖：
#1 #2 #3
09:00 Defect / per unit = 2

09:30 Defect / per unit = 4 …

10:00 Defect / per unit = 3

10:30 Defect / per unit = 2  特點：(1)

… … (2)
5300
-
缺 250
4- UCL
200
點 3150
-
數 100
2-
(c) 50 LCL
1 -0

CHAPTER 07 47

(p309)

Control Charts for Nonconformities (Defects)

 It is possible to develop control chart for either the total number of
nonconformities in a unit or the average number of nonconformities per unit.

• 每單位中的缺點總數或____________________制定的管制圖

 These control charts usually assume that the occurrence of nonconformities

in sample of constant size is modeled by Poisson distribution.
• Let c be the parameter for a ____________ distribution.

CHAPTER 07 48

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Poisson Distribution (p309)

 卜瓦松分配 (Poisson Distribution)：

• 定義：描述單位時間 (或範圍) 內隨機事件發生的次數的機率分布。
• 分配機率函數：

• 參數解釋：
 P(X = x) = 在一段期間內發生 x 次失誤之機率  舉例：
 λ = 在一段期間內平均發生失誤之缺點數 (亦即 𝑐̅)  長期觀察某機
 x = 發生失誤次數 (亦即 c) 台平均每年損
 e = 2.7183 壞三次

CHAPTER 07 49

(p309)

Poisson Distribution
 舉例：
• 長期觀察某機台年平均損壞三次，因此 ______ 。
• 在製程製作產品條件未改變的情形下，預期該機台失效次數 (X) 會服從
Poisson distribution，即為 X ~ Poisson (______)
• 請問該機台一年內最多失效 1 次的機率為？

參考來源：https://m.facebook.com/1291476424213306/posts/3670332089661049/

CHAPTER 07 50

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(p309)

Control Charts for Nonconformities (Defects)

 The probability of obtaining x nonconformities on a single inspection
unit, when the average number of nonconformities (平均缺點數量) is
a constant, c, is found using:

• Then the mean and variance of the Poisson distribution are equal to the
value c.

CHAPTER 07 51

Control Charts for Nonconformities (Defects)

 1. Standard value is  2. Standard value is not given (p309, 310)
given (with known c) (with unknown c)

CHAPTER 07 52

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Example 7.3 Nonconformities in Printed

Circuit Boards (p310)

 The number of nonconformities observed in 26 successive samples of

100 printed circuit boards (_________________).

 Note that, for reasons of

convenience, the inspection unit is
defined as 100 boards.
 Set up a c hart for these data.

Ref.: https://images.app.goo.gl/uHTmA1p61Mc3594V7

CHAPTER 07 53

Example 7.3 Nonconformities in Printed

Circuit Boards
Inspection unit: …
X1,1 X1,2 X1,100 Defects: 10
100 PCB

X2,1 X2,2 … X2,100 Defects: 12

X26,1 X26,2 … X26,100 Defects: 11

CHAPTER 07 54

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Example 7.3 Nonconformities in Printed

Circuit Boards
If no standard is given,
then c may be estimated as

CHAPTER 07 55

• 結論：從圖中可知，樣本點 6 及樣本點 20
落在管制界限外，因此可得出目前製程是
處於不穩定狀態 (或失控狀態) ，需找出異
常原因並調整製程。
(p310)

 調查樣本點 6：
• 新來的檢驗人員對檢驗流程不熟悉，故
未認出可能存在的幾種不合格點類型。
 調查樣本點 20：
• 問題來自於波峰焊接機台溫度控制，經
處理後已調整完畢。

CHAPTER 07 56

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 Exclude these two samples and revise the trial control limits. The estimate of c is

 The revise the trial control limits:

CHAPTER 07 57

No lack of control is indicated; however, the

number of nonconformities per board is still
unacceptably high. Further action is
necessary to improve the process.

CHAPTER 07 58

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Exercise 7.35 Sample Nonconforming of

Number Nonconformities
 The data represent the number of 1 1
nonconformities (defects) per 1000 2 1
meters in telephone cable (電話纜線). 3 3
From analysis of these data, 4 7
a) Would you conclude that the process 5 8
6 10
is in statistical control?
7 5
b) What control procedure would you 8 13
recommend for future production? 9 0
(新修正的管制圖為何？) 10 9
11 24

CHAPTER 07 59

Exercise 7.35
Sample Nonconforming of
Number Nonconformities
1 1
2 1
3 3
4 7
5 8
6 10
7 5
8 13
9 0
10 9
11 24

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• 結論：從圖中可知，目前製程不在管

Exercise 7.35 制內，因第 11 個樣本點超出上管制界

限，應加以調查並找尋可歸屬原因。
• 假設可歸屬原因被找到，並做製程調
整後，可將此點刪除，並重新計算管
制上下界限。

CHAPTER 07 61

Exercise 7.35

CHAPTER 07 62

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• 結論：從圖中可知，目前製程不在管

Exercise 7.35 制內，因第 8 個樣本點超出上管制界

限，應加以調查並找尋可歸屬原因。
• 假設可歸屬原因被找到，並做製程調
整後，可將此點刪除，並重新計算管
制上下界限。

CHAPTER 07 63

Exercise 7.35

• 結論：修正完後之管制界限如左圖，
目前已無異常樣本點，可進到 Phase II
進行未來資料點的製程監控。

CHAPTER 07 64

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Choice of Sample Size: The u Chart (p314)

 Example 7.3 illustrates a control chart for nonconformities with the

sample size exactly equal to one inspection unit. The inspection unit is
chosen for operational or data-collection simplicity.
 However, there is no reason why the sample size must be restricted to
one inspection unit.

• c 管制圖是假定______________的情況下，但缺點數常隨著產品之
長度、面積或體積而改變，故需定義一個__________(inspection unit)。

CHAPTER 07 65

Procedures with Variable Sample Size

 Control charts for nonconformities are occasionally formed using 100%
inspection of the product. When this method of sampling is used, the
number of inspection units in a sample will usually not be constant.
• For example, the inspection of rolls of cloth or paper often leads to a
situation in which the size of the sample varies, because not all rolls are
exactly the same length or width.

• 檢查布匹常會導致樣品尺寸有變化，因並
非所有布匹長度或寬度完全相同。

CHAPTER 07 66

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Choice of Sample Size: The u Chart

 Example:

X2 …
X1
X3

30 m x 30 m
50 m x 50 m
60 m x 60 m

Defects: 10 Defects: 8 Defects: 20

CHAPTER 07 67

The u Chart (p315)

 If we find c total nonconformities in a sample of n inspection units,

then the average number of nonconformities per inspection unit (每個檢
查單元的平均缺點數量) is u = c /n.

X1
09:00 100x50, Defect = 4

X2 09:30 50x50, Defect = 2

10:00 100x100, Defect = 8

X3
… … … …

CHAPTER 07 68

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The u Chart (p315)

 Control limits for the average number of nonconformities is

 Note that 𝑢 is the ratio of

the total number of
observed nonconformities
to the total number of
inspection units.

• 缺點總數與所有檢查
單位之比例。

CHAPTER 07 69

The u Chart (p315)

 If n is variable,

CHAPTER 07 70

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Example 7.5 Constructing a u chart

 In a textile finishing plant, dyed cloth is inspected for the occurrence of
defects per 50 square meters (每 50 平方公尺檢查染布是否有缺陷).

 Data on ten rolls of cloth are shown in

table. Use the data to set up a control chart
for nonconformities per unit.

CHAPTER 07 71

Example 7.5 Constructing a u chart (法一)

平方公尺數 缺陷個數 檢查單位數

CHAPTER 07 72

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Example 7.5 Constructing a u chart (法一)

平方公尺數 缺陷個數 檢查單位數 u:每個檢查單元的不合格平均數量

CHAPTER 07 73

Example 7.5 Constructing a u chart (法一)

CHAPTER 07 74

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Example 7.5 Constructing a u chart (法二)

平方公尺數 缺陷個數 檢查單位數

CHAPTER 07 75

Example 7.5 Constructing a u chart (法二)

• 從圖中可知，沒有樣本點落在
管制界限外，且樣本點呈隨機
分佈，表示目前製程是在管制
狀態。

CHAPTER 07 76

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Exercise
 A carpet manufacturer (地毯製造商) Number m2 c n
monitors product quality with u 1 30 4
control charts. Assumer that 5m2 is an 2 30 6
3 50 5
inspection unit. 4 50 4
a) What are the center line and control 5 40 2
limits for a control chart for average 6 50 6
nonconformities per unit (法二) 7 30 1
8 25 3
used to monitor future production?
9 30 5
10 40 3

CHAPTER 07 77

Exercise
Number m2 c n
1 30 4 6
2 30 6 6
3 50 5 10
4 50 4 10
5 40 2 8
6 50 6 10
7 30 1 6
8 25 3 5
9 30 5 6
10 40 3 8

CHAPTER 07 78

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• 結論：從圖中可知，沒有樣本點落在
管制界限外，且樣本點呈隨機分佈，
Exercise 表示目前製程是在管制狀態。

Number m2 c n u
1 30 4 6
2 30 6 6
3 50 5 10
4 50 4 10
5 40 2 8
6 50 6 10
7 30 1 6
8 25 3 5
9 30 5 6
10 40 3 8

CHAPTER 07 79

7.4 Choice Between Attributes and

Variables Control Charts

40
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Choice Between Attributes and Variables

Control Charts (p326)

 In other cases, the choice will not be obvious, and the analyst must take
several factors into account in choosing between attributes and variables
control charts.
 Summary:

CHAPTER 07 81

計量值管制圖 計數值管制圖
1. Variables data can be more informative 1. Attributes data is easy to collect, and several
since specific information about the process characteristics may be collected per unit.
mean and variance is obtained directly. 2. Expensive and time-consuming measurements
2. Variables control charts provide an may sometimes be avoided by attributes
indication of impending trouble (即將發生 inspection.
優點
之錯誤) (corrective action may be taken
before any defectives are produced).
3. Variables control charts usually require a
much a smaller sample size than does the
corresponding attributes control chart.
1. If the several quality characteristics are
treated as variables, then each one must be
measured, and either a separate Xbar-R chart
must be maintained on each or some 1. Attributes control charts will not react unless
multivariate control technique that considers the process has already changed (more
缺點
all the characteristics must simultaneously be nonconforming items may be produced).
employed.
2. Variables type inspection is usually more
expensive and time-consuming on a per unit
basis than attributes inspection.

CHAPTER 07 82

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Choice Between Attributes and Variables

Control Charts (p326)

 The most important advantage of the xbar and R control charts is that
they often provide an indication of impending (即將發生的) trouble
and allow operating personnel to take corrective action before any
defectives are actually produced.
• Xbar 和 R 管制圖的最大優點是，它們通常會提供即將發生缺點的徵
兆，讓操作人員在產出任何不良品之前，就採取矯正措施。

CHAPTER 07 83

Choice Between Attributes and Variables

Control Charts (p327)

 Thus,
• xbar and R charts are leading indicators of trouble,
• whereas p charts (or c and u charts) will not react unless the process has
already changed so that more nonconforming units are being produced.

CHAPTER 07 84

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Appendix
 Select samples with n = 6 from 4 equipment and [LSL, USL]=[10, 30]
EQP Data by Attributes Yield Data by Variables (𝒙, S)
EQP 1 [1,1,1,0,0,0] 50%
EQP 2 [0,1,1,1,0,0] 50%
EQP 3 [1,1,1,1,1,1] 100%
EQP 4 [1,1,1,1,1,1] 100%
註：1 為合格品；0 為不合格品
1. Which EQP performs the best?
2. Construct the probability distribution plots (Minitab) for 1&2 and 3&4.

CHAPTER 07 85

Review – Control Chart

 Types of Control Chart 計數值
計量值
資料性質？

不合格品數？
缺點數？
樣本大小？

是 否
是 否

𝒙-R 𝒙-S 𝑰 – MR 𝒑 np c u
chart chart chart chart chart chart chart

CHAPTER 07 86

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品質計劃與管制 (Quality Planning and Control)

Q&A

 #7.2 (7E.4 → 7E.2)

Exercises  #7.3
 #7.5
(Chapter 07)
 #7.19
 #7.26 (a) (b)
 #7.35
 #7.36
 #7.39 (a) (b)

CHAPTER 07 88

44