Control Charts

Control Chart: The control chart is a graph used to study how a process changes
over time. Data are plotted in time order. A control chart always has a central
line for the average, an upper line for the upper control limit and a lower line for
the lower control limit. These lines are determined from historical data. By
comparing current data to these lines, you can draw conclusions about whether
the process variation is consistent (in control) or is unpredictable (out of
control, affected by special causes of variation).
Control Chart Basic Procedure
➢Choose the appropriate control chart for your data.
➢Determine the appropriate time period for collecting and plotting data.
➢Collect data, construct your chart and analyze the data.
➢Look for “out-of-control signals” on the control chart. When one is identified,
mark it on the chart and investigate the cause. Document how you investigated,
what you learned, the cause and how it was corrected.
Sampling: For traditional inspection, to take the number of products in a random
is called sampling.

Universe How many objects in a sample is

called sample size !

SAMPLES
Sample size 4

➢100% inspection is not possible in large

production sector.
➢For destructive testing.
➢For time saving.

Standard
deviation/
3-Sigma
Normal Distribution
 Normal Distribution
A normal distribution is an arrangement of a data set in which
most values cluster in the middle of the range and the rest taper
off symmetrically toward either extreme.
A continuous Example: Height is one simple example
of something that follows a normal
distribution of distribution pattern: Most people are of
a random average height, the numbers of people
variable with its that are taller and shorter than average
mean, median, are fairly equal and a very small (and
and mode equal still roughly equivalent) number of
people are either extremely tall or
extremely short.

- +
It is often called a "Bell Curve“ because it looks like a
bell.
Normal distributions are often written as

where mu is the mean and sigma is the standard deviation.

For example the normal distribution N(5, 100) has a mean 5
and a standard deviation of 100.

Properties of a normal distribution

➢The mean, mode and median are all equal.
➢The curve is symmetric at the center (i.e. around the mean, μ).
➢ Exactly half of the values are to the left of center and exactly
half the values are to the right.
➢The total area under the curve is 1.

➢The mean (average) is found by adding all of the numbers together and dividing by the
number of items in the set: 10 + 10 + 20 + 40 + 70 / 5 = 30.
➢The median is found by ordering the set from lowest to highest and finding the exact
middle. The median is just the middle number: 20.
The empirical rule tells you what percentage of your data falls within a
certain number of standard deviations from the mean:

• 68% of the data falls within one standard deviation of the mean.
• 95% of the data falls within two standard deviations of the mean.
• 99.7% of the data falls within three standard deviations of the mean.

31.74% occurrences or data fall outside the NDC

About 5% fall outside NDC

About less than 1% fall outside NDC

3-sigma limit
provides more
satisfactory
information about
the Quality !!!!
Why are we learning Normal distribution to study Control Chart
??????
 Standard Normal Distribution
A special type of normal distribution is the standard normal distribution
or Z-distribution.
The standard normal distribution has a mean of 0 and a standard
deviation of 1, Z(0,1).

The Z-distribution is a normal distribution with mean zero and standard

deviation 1; its graph is shown here. Almost all (about 99.7%) of its values
lie between –3 or -4 and +3 or +4 according to the Empirical Rule. Values
on the Z-distribution are called z-values, z-scores, or standard scores.
 Example 1
Suppose that in a particular geographic region, the mean and standard deviation of
scores on a reading test are 100 points, and 12 points, respectively. Our interest is in the
scores of 55 students in a particular school who received a mean score of 96. We can ask
whether this mean score is significantly lower than the regional mean—that is, are the
students in this school comparable to a simple random sample of 55 students from the
region as a whole, or are their scores surprisingly low?

Solution: Standard error during sampling, Z-score of the reading test,

(Standard score)

Standard score is the signed number of standard deviations by which the value of an
observation or data point is above the mean value of what is being observed or
measured.

From Z-chart, value of probability (p) at -2.47= 0.0068=0.68%

Hence, the 55 students are comparable to a simple random
sample from the population of all test-takers.
 Example 2
The bottom 30.15% of students failed an end of semester exam. The mean for the
test was 120 and standard deviation was 17. what was the passing score of the
exam.?

We know, Z = (M-µ)/σ
Where,
µ= 120
σ = 17
M = passing score= ?
Failed = 30.15 % students

-Z Z=0 +Z

Hence, Area under the bell

curve is 1. Hence,
M = Z*σ + µ 100%
Area under the SDC or Probability = 30.15%
 Z= -0.52
M = Z*σ + µ = 111.16
Ans.
 Types of Control Charts

Control charts: The control chart is a graph used to study how a process changes over
time. Data are plotted in time order. A control chart always has a central line for the
average, an upper line for the upper control limit and a lower line for the lower control
limit. These lines are determined from historical data.

What is Central Limit Theorem?

The central limit theorem (CLT) is a statistical theory that states that given a sufficiently
large sample size from a population with a finite level of variance, the mean of all
samples from the same population will be approximately equal to the mean of the
population.
Types of Control Charts
 Determination of Control Charts Limits

Universe or population is the collection of

all items from where samples are taken !

Population or
Universe Size
N= 1000.
(Say)

A group of items in
a lot to be measured
is called sample.

No. of samples m= 08 and

sample size n= 04.
 Prime notation is used to designate a parameter of universe.

Notation Universe Sample

Mean X̅̅̅̅ or X’ X̅̅

Standard σ' σ
Deviation
σ
Range R’ R

Sample -- n
Size
No. of --- m
Samples
Statistical theory was discussed in class and
control limit was shown in board !!!!

Please check class note for other formulas !!!!

 Relative Precision
Relative precision is defined as a ratio of the precision of a given
measurement and the value of the measurement itself. Thus, if d is a
measured distance, and sd is the standard deviation of the measurement,
then the relative precision is sd/d. It is expressed as percentage or a
fractional ratio such as 1/ 500 or by parts per million (ppm).

Relative Precision Index (RPI)= sd/d ≈

(U-L)/d
Product Specification, 2.5 ± .03 m

2.5 ± .03 m
Radical Process Improvement (RPI):
U-L/ R̅
U= 2.53 m
L= 2.47 m
 Product Specification, 2.5 ± .03 m

U= 2.53 m
L= 2.47 m

2.5 ± .03 m
Tolerance of
Specification
(ST) = U-L

Universe with Tolerance (UT)= 6 σ’ 2.54 (say)

U=2.53

Condition 1:
If UT > (U-L), the precision of the
(UT)= 6 σ’
2.50
product is acceptable as compared
with the precision required. Hence,
L=2.47
relatively comparable precision. 2.46 (say)

Acceptable!!
 Condition 2:
If UT < (U-L), the precision of the product is relatively low. However,
rework on the job is necessary !!! In addition, production cost is
high !!!
Accepted !!! Product Specification, 2.5 ± .03 m
U=2.53

2.52 (say)
(UT)= 6 σ’

2.50

2.5 ± .03 m
2.48 (say)
L=2.47

Rejection
Condition 3:
If ST== UT, it is said to
be optimum RPI.
 Sample Problems of X̅, R, and σ Charts

Problem # 1 Control charts for X̅ and R are maintained on the outside diameter of a shaft.
The subgroup size is 04. After 20 subgroups ∑ X̅ = 43.75 and ∑R = 0.286. The specification
of the product is 2.15±0.02 unit. Products falling above and below the specification limit
are rejected. The process is statistical controlled and normally distributed. Find the control
limits for X̅ and R charts, Process capability, RPI of the process and % rejection. How to
reduce the % of rejection if any?

Problem # 2 Small boxes of snacks are labeled “Net weight 10 ounces”. Each hour,
random sample sizes of 04 boxes are weighted to check the process control. Five hours of
observations yielded the following;

Time Weights
Box 1 Box 2 Box 3 Box 4
9.00 am 9.8 10.4 9.9 10.3
10.00 am 10.1 10.2 9.9 9.8
11.00 am 9.9 10.5 10.3 10.4
Noon 9.7 9.8 10.3 10.2
1.00 pm 9.7 10.1 9.9 9.9

Using these data, construct limits for X̅̅ and R charts. Is the process in controlled? What
other steps should the QC department follow at this point of production?
 Sample Problems of X̅, R, and σ Charts
Problem # 3 The dimension of a certain manufactured part is specified as 2.05±.020. If the
dimension falls below lower specification limit, the part must be rejected,, if above upper
specification limit, rework is needed. Control charts for X̅ and R are maintained on the
dimensions. The subgroup size is 04. After 20 subgroups, ∑ X̅ = 41.340 and ∑R = 0.320. If the
process is in statistically controlled and normally distributed, what can you conclude
regarding its ability to meet specification? If not, determine the percentage of rework and
that of scraped. Can you make any suggestion for improvement? Find also control limits for
X̅̅ and R –charts.

Problem # 4 Control chart for X̅̅ and σ are maintained on the resistance in ohms of a certain
rheostat coil based on subgroup size of 05. After 30 subgroups ∑ X̅ = 58.395 and ∑σ = 1356.

i) Determine the centerlines and 3-sigma control limits for the process.
ii) Establish the value σ’ assuming that the process is operating in satisfied control.
iii) Assuming that the distribution generated by the process is approximately normal, what
proportion of the rheostat coils meets specification 2000±150 ohm?
 Sample Problems of X̅, R, and σ Charts
Problem #5 A manufacturer of bolts maintains X̅ and R for certain bolts. The bolt is made
at a diameter of 0.25 inch and required specification is 0.25 ± 0.005 inch. After 25
subgroups of four items in each subgroup, it was found that ∑ X̅ = 6.250 and ∑R = 0.1287.
Compute 3-sigma limits for X̅ and R. Find σ’, assuming the process is in control. What % of
manufactured bolts will not meet required specification under assumption that process
generates a normal distribution? What is RPI?

Homework: From R.C. Guptas’ Book--- Problem 3.14,

3.52, 3.53, and 3.54

Thank you all !!!

Practice more, its easy ☺