INE-432 QUALITY CONTROL

CHAPTER 4

Control Chart for Variables

Academic Year – 2nd Semester 2025 (462)

Statistical Process Control (SPC)
The Seven major Tools of SPC
Control Chart
Process Control
Variable
 Control Charts for x̄ and R

Average: Where, n: sample size

Grand average: Where,m= number of samples

Range= Xmaximum- Xminimum

The average range

 𝑥1 𝑥2 𝑥3 𝑥4 𝑥5

Example 6.1:
A hard-bake process (see Section 5.3.1) is
used in conjunction with photolithography in
semiconductor manufacturing. We wish to
establish statistical control of the flow width
of the resist in this process using 𝑋ത and R
charts. Twenty-five samples, each of size five
wafers, have been taken when we think the
process is in control. The interval of time
between samples or subgroups is one hour.
The flow width measurement data (in
microns) from these samples are shown in
Table 6.1.
 R-Chart

This is NOT out of control since

For samples of n = 5, we find from
it is 0.6823
Appendix Table VI that D3 = 0 and D4 = 2.114.

R chart indicates that process variability is in control

 ഥ Chart
𝑿

A2 = 0.577 from Appendix Table VI for samples of size n = 5

The process is in control

 Estimating Process Capability
The 𝑋ത and R charts provide information about the performance or
process capability of the process.

Is an estimator of 𝜎

𝐔𝐒𝐋−𝐋𝐒𝐋
Process capability ratio (PCR) = Cp =
𝟔𝛔

The largest allowable value for a quality characteristic is called the upper specification limit (USL),
and the smallest allowable value for a quality characteristic is called the lower specification limit (LSL).

Example: Based on the previous example, if the specification limits on the flow width are
1.50 ± 0.50 microns, what is the process capability ratio?

𝐔𝐒𝐋−𝐋𝐒𝐋 𝟐−𝟏
Cp = = =1.192
𝟔𝛔 𝟔(𝟎.𝟏𝟑𝟗𝟖)
 ഥ and R Charts.
Changing Sample Size on the 𝑿
In some situations, it may be of interest to know the effect of
changing the sample size on the x-bar and R charts. Needed
information:
For the 𝑥̅ chart the new control limits are
 n=3

From the table based

on n=3
The new control limits. Note that the effect of reducing the
Therefore, the new control limits on the 𝑥̅ chart are: sample size is to increase the width of the limits on the 𝑥̅
𝜎
chart (because 𝑛 is smaller when n = 5 than when n = 3)

NEW
Based
on n=3
For the R chart, the new parameters are:

The center line and the upper control limit on the R chart are
lower (because the expected range from a sample of n = 3
is smaller than the expected range from a sample of n = 5).
 ഥ and S
𝐂𝐨𝐧𝐭𝐫𝐨𝐥 𝐜𝐡𝐚𝐫𝐭 𝐟𝐨𝐫 𝑿
sample variance
➔ sample standard deviation is
The parameters of the s chart:

Then the 𝑥̅ chart parameters become

 74.030 + 74.002 + 74.019 + 73.992 + 74.74.008
=
5
Example: Construct and interpret 𝑥̅ and s charts using the piston
ring inside diameter measurements in Table 6.3.

The grand average and the average standard deviation are

And

➔ the parameters for the 𝑥̅ chart are:

There is no indication that the process is
out of control
The parameters for the s chart are:
There is no indication that the process is
out of control

Estimation of Standard Deviation (σ)

 ഥ and Moving Range Charts
𝑿

ഥ and MR charts?
When to use 𝑿
Moving Range Control Chart
 Moving Range Control Chart
The moving range is defined as

The parameters for the MR chart are:

9
CL=𝑀𝑅 = ∑ 𝑚 𝑀𝑅> Where m is number of samples
(𝑚 <9) >? 9

LCL=D3 MR

UCL=D4 MR

For the control chart for individual measurements, the parameters are
Example:
The mortgage loan processing unit of a bank monitors the costs of
processing loan applications. The quantity tracked is the average weekly
processing costs, obtained by dividing total weekly costs by the number
of loans processed during the week. The processing costs for the most
recent 20 weeks are shown in the next Table. Set up individual and
moving range control charts for these data.
 n=2

= 288 − 310 =22

= 297 − 288 =9
m=20

𝑚
1
𝑀𝑅 = D 𝑀𝑅>
(𝑚 − 1)
>? 9

22 + 9 + 1 + 9 + 4 + 9 + 3 + 11 + 2 + 12 + 5 + 2 + 2 + 2 + 15 + 19 + 2 + 13 + 5 + 3
= 7.79
19
 MR- Control Chart

LCL=D3 MR

Center Line( CL) = MR

UCL=D4 MR

n=2
There is no indication that the process is
➔ out of control

CL = MR = 7.79

LCL=D3 MR = 0 7.79 = 0 D3 and D4 are from the table based on n=2

UCL=D4 MR = (3.267) (7.79)=25.45
 Individual Measurements Control Chart
The parameters for individual measurements control chart are:

➔
There is no indication that the process is
out of control

d2 is from the table based on n=2

 Charts Based on Standard Values
In case of: The standard deviation 𝜎 𝐢𝐬 𝐠𝐢𝐯𝐞𝐧:

➔ The parameters of the 𝑥̅ chart are:

AND
The parameters of the R chart are:
Example: Find the center line and control limits for 𝑥̅ and R control charts:
If n=10, u=80 , and 𝜎=10

Answer

For R control chart

For 𝑥̅ control chart

Center line (CL) = u = 80 CL= d2 𝜎= (3.078)(10)= 30.78

UCL= u+A 𝜎= 80+0.949(10)=89.49 UCL= D2 𝜎=(5.469)(10)= 54.69

LCL= u-A 𝜎= 80-0.949(10)=70.51 LCL= D1 𝜎=(0.687)(10)= 6.87

A, d2, D1, and D2 are from the table based on n= 10

 Charts Based on Standard Values
In case of: The standard deviation 𝜎 𝐢𝐬 𝐠𝐢𝐯𝐞𝐧:

➔ The parameters of the s chart are:

Example: Find the center line and control limits for s control charts:
If n=10, u=80 , and 𝜎=10

➔ UCL= (1.669)(10)= 16.69

CL=(0.9727(10)=9.727

LCL= (0.276)(10)= 2.76

■ AP P EN D IX V I
Factors for Constructing Variables Control Charts

Chart for Averages Chart for Standard Deviations Chart for Ranges
Factors for Factors for Factors for
Observations
Control Limits Center Line Factors for Control Limits Center Line Factors for Control Limits
in
Sample, n A A2 A3 c4 1/c4 B3 B4 B5 B6 d2 1/d2 d3 D1 D2 D3 D4
2 2.121 1.880 2.659 0.7979 1.2533 0 3.267 0 2.606 1.128 0.8865 0.853 0 3.686 0 3.267
3 1.732 1.023 1.954 0.8862 1.1284 0 2.568 0 2.276 1.693 0.5907 0.888 0 4.358 0 2.574
4 1.500 0.729 1.628 0.9213 1.0854 0 2.266 0 2.088 2.059 0.4857 0.880 0 4.698 0 2.282
5 1.342 0.577 1.427 0.9400 1.0638 0 2.089 0 1.964 2.326 0.4299 0.864 0 4.918 0 2.114
6 1.225 0.483 1.287 0.9515 1.0510 0.030 1.970 0.029 1.874 2.534 0.3946 0.848 0 5.078 0 2.004
7 1.134 0.419 1.182 0.9594 1.0423 0.118 1.882 0.113 1.806 2.704 0.3698 0.833 0.204 5.204 0.076 1.924
8 1.061 0.373 1.099 0.9650 1.0363 0.185 1.815 0.179 1.751 2.847 0.3512 0.820 0.388 5.306 0.136 1.864
9 1.000 0.337 1.032 0.9693 1.0317 0.239 1.761 0.232 1.707 2.970 0.3367 0.808 0.547 5.393 0.184 1.816
10 0.949 0.308 0.975 0.9727 1.0281 0.284 1.716 0.276 1.669 3.078 0.3249 0.797 0.687 5.469 0.223 1.777
11 0.905 0.285 0.927 0.9754 1.0252 0.321 1.679 0.313 1.637 3.173 0.3152 0.787 0.811 5.535 0.256 1.744
12 0.866 0.266 0.886 0.9776 1.0229 0.354 1.646 0.346 1.610 3.258 0.3069 0.778 0.922 5.594 0.283 1.717
13 0.832 0.249 0.850 0.9794 1.0210 0.382 1.618 0.374 1.585 3.336 0.2998 0.770 1.025 5.647 0.307 1.693
14 0.802 0.235 0.817 0.9810 1.0194 0.406 1.594 0.399 1.563 3.407 0.2935 0.763 1.118 5.696 0.328 1.672
15 0.775 0.223 0.789 0.9823 1.0180 0.428 1.572 0.421 1.544 3.472 0.2880 0.756 1.203 5.741 0.347 1.653
16 0.750 0.212 0.763 0.9835 1.0168 0.448 1.552 0.440 1.526 3.532 0.2831 0.750 1.282 5.782 0.363 1.637
17 0.728 0.203 0.739 0.9845 1.0157 0.466 1.534 0.458 1.511 3.588 0.2787 0.744 1.356 5.820 0.378 1.622
18 0.707 0.194 0.718 0.9854 1.0148 0.482 1.518 0.475 1.496 3.640 0.2747 0.739 1.424 5.856 0.391 1.608
19 0.688 0.187 0.698 0.9862 1.0140 0.497 1.503 0.490 1.483 3.689 0.2711 0.734 1.487 5.891 0.403 1.597
20 0.671 0.180 0.680 0.9869 1.0133 0.510 1.490 0.504 1.470 3.735 0.2677 0.729 1.549 5.921 0.415 1.585
21 0.655 0.173 0.663 0.9876 1.0126 0.523 1.477 0.516 1.459 3.778 0.2647 0.724 1.605 5.951 0.425 1.575
22 0.640 0.167 0.647 0.9882 1.0119 0.534 1.466 0.528 1.448 3.819 0.2618 0.720 1.659 5.979 0.434 1.566
23 0.626 0.162 0.633 0.9887 1.0114 0.545 1.455 0.539 1.438 3.858 0.2592 0.716 1.710 6.006 0.443 1.557
24 0.612 0.157 0.619 0.9892 1.0109 0.555 1.445 0.549 1.429 3.895 0.2567 0.712 1.759 6.031 0.451 1.548
25 0.600 0.153 0.606 0.9896 1.0105 0.565 1.435 0.559 1.420 3.931 0.2544 0.708 1.806 6.056 0.459 1.541

c4  (
For n > 25. A= 3 A3 = 3 4 n − 1)
n c4 n 4n − 3
3 3
B3 = 1 − B4 = 1 +
c4 2(n − 1) c4 2(n − 1)
3 3
B5 = c 4 − B6 = c 4 +
2(n − 1) 2(n − 1)