Effect of Sampling

14

12

10

0
1 2 3 4 5
Need for Control Charts

Time
Need for Control Charts (contd.)

Time
Stability

Time
Stability and Capability

Time
 Definitions

 Stability : A process is said to be stable if it is

under the influence of common causes.

 Capability : A stable process is said to be capable

if the process variation is less than the customer
requirements.
 Key Elements of and R Chart

 Sampling method
 Subgroup Size
 Subgroup Frequency
 Number of Subgroups
 Data types and Control Charts
Data type Control Chart

Variable X – R (Average & Range)

X – s (Average & Standard deviation)
X – MR (Average & Moving Range)

Attributes ‘np’ (sample size is constant)

Defectives (Binomial Distribution) ‘p’ (sample size varies)

Attributes ‘c’ ( sample size is fixed)

Defects (Poisson Distribution) ‘u’ (sample size is not fixed)
Construction of X bar & R Charts
Calculate the Average and Range of each subgroup
X 1  X 2  ... X n
X
n
R=X highest -X lowest
Calculate control limits for the range chart first.
R1  R2  ..........  Rk
R
k
Upper Control Limit (UCLR) = D4 R
Lower Control Limit (LCLR) = D3 R

Carry out homogenisation

Construction of Control Charts

Compute control limits for the average chart.

X 1  X 2  ..........  X k
X
k
UCL= X  A2 R

LCL= X  A2 R
Carry out homogenisation

Plot the range and the average pair for each subgroup

Draw the limits on the chart.

Control Charts - Table
n D3 D4 A2 d2
2 0 3.268 1.881 1.128
3 0 2.574 1.023 1.693
4 0 2.282 0.729 2.059
5 0 2.114 0.577 2.326
6 0 2.004 0.483 2.534
7 0.076 1.934 0.419 2.704
8 0.136 1.864 0.373 2.847
9 0.184 1.816 0.337 2.970
10 0.223 1.777 0.308 3.078
 Average & Ranges

46.986

46.984

46.982

46.98

46.978

46.976

46.974

46.972

46.97

46.968

46.966
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
 Av erage Chart

46.9800
UCL

46.9780

Mean

46.9760

LCL
46.9740

Range Chart

46.9720
0.01

0.009
UCL
0.008

0.007

0.006

0.005
Mean
0.004

0.003

0.002

0.001
LCL

0
10

12

13

17

18

19
14

15

16
11
1

Sample number
Out of control patterns

UCL

Any point falling beyond

CL
control limits
LCL

UCL

CL
A run of 7 points above
or below mean
LCL
Out of control patterns (contd.)

UCL

7 Points increasing or
CL
decreasing
LCL

UCL

CL
Non- random pattern

LCL
 Pre- Control Chart

NOMINAL Traditional:
LSL PC LINE PC LINE USL 1. Establish pre-control
limits from the nominal and
specification limits, by
dividing the tolerance into 4
equal bands
Red Yellow Green Green Yellow Red
.07 .86 .07
Note: When the Cpk = 1,
approximately 86% of the
values will fall within 1/2 of
1/2
TOLERANCE the tolerance.

TOLERANCE
 Pre-Control Rules
2. Determine Process Capability by taking 5 consecutive parts ( 2 units each). All
must fall within the green zone to decide the process is capable, in control and
“qualified”

3. Sampling Plan: Commence production and take two consecutive parts on a

periodic basis.
Condition Corrective Action
1. Two units in the green zone Continue
2. One unit in the Green and one unit Continue
in the Yellow
Stop & Investiage & requalify.
3. Two units in the Yellow zone
4. One unit in the Red Stop & Investiage & requalify.
 Pre-Control - Advantages

 An economical method to monitor multiple output

variables (Ys) of a product
 Requires only 2 samples at specified frequency
 Simple to understand, training is easy
 Applicable to short production runs as well as long
runs
 No recording, calculating, or plotting of data (Unless
a pre-control chart is used to record results.
 Pre-Control Disadvantages

 It uses the “goal-post” view of quality--a

contradiction of the Taguchi philosophy : “target is
best”
 Process must be stable and capable
 Should not even consider using it for processes with
Cpk’s lower than 1.5,
 Since it is a monitoring technique, it is not very
helpful for diagnosing problems
 Capability (Cp)
lsl usl
Tolerance
Process variation is
more than design
tolerance (6  > T)

6

Process variation is
equal to design
tolerance (6  = T)

Process variation is
less than design
tolerance (6  < T)
(Cpk)

Process variation is less (6  < T)

and process center (average) is at
the center of the design tolerance

Process variation is less (6  < T)

but process center (average) is
shifted towards Upper specification
limit

Process variation is less (6  < T)

but process center (average) is at
Upper specification limit
Process Capability Indices (Cp and
Cpk)

Tolerance USL  LSL

Cp  
6 6

 USL  X X  LSL 
Cpk  Minimum of  , 
 3 3 
Control chart - Defectives
Shift Date Shift Qty. Produced cracked
S No.(i) ni di
1 8/16/95 A 5000 48
2 8/16/95 B 4000 35
3 8/16/95 C 4000 18
4 8/17/95 A 4500 20
5 8/17/95 B 4000 27
6 8/17/95 C 3500 25
7 8/18/95 A 4100 37
8 8/18/95 B 3900 32
9 8/18/95 C 4000 21
10 8/19/95 A 4500 13
11 8/19/95 B 4500 43
12 8/19/95 C 4000 28
13 8/21/95 A 4700 46
14 8/21/95 B 4700 33
15 8/21/95 C 4600 51
16 8/22/95 A 4000 57
17 8/22/95 B 4500 28
18 8/22/95 C 4500 27
19 8/23/95 A 4300 44
20 8/23/95 B 4700 47
21 8/23/95 C 4000 33
22 8/24/95 A 4300 31
23 8/24/95 B 4600 38
24 8/24/95 C 4600 37
total 103500 819
‘p’ chart calculations

Total Quantity rejected d i

p 
Total Quantity inspected ni

p (1  p )
LCL  p  3
n1
0.0079(1  0.0079)
 0.0079  3
5000
 0.00415

p (1  p )
UCL  p  3
n1
0.0079(1  0.0079)
 0.0079  3
5000
 0.0116
 Date Shift ni di pi LCL UCL
8/16/95 A 5000 48 0.00960 0.00415 0.01167
8/16/95 B 4000 35 0.00875 0.00371 0.01212
8/16/95 C 4000 18 0.00450 0.00371 0.01212
8/17/95 A 4500 20 0.00444 0.00395 0.01188
8/17/95 B 4000 27 0.00675 0.00371 0.01212
8/17/95 C 3500 25 0.00714 0.00342 0.01241
8/18/95 A 4100 37 0.00902 0.00376 0.01206
8/18/95 B 3900 32 0.00821 0.00366 0.01217
8/18/95 C 4000 21 0.00525 0.00371 0.01212
8/19/95 A 4500 13 0.00289 0.00395 0.01188
8/19/95 B 4500 43 0.00956 0.00395 0.01188
8/19/95 C 4000 28 0.00700 0.00371 0.01212
8/21/95 A 4700 46 0.00979 0.00404 0.01179
8/21/95 B 4700 33 0.00702 0.00404 0.01179
8/21/95 C 4600 51 0.01109 0.00399 0.01183
8/22/95 A 4000 57 0.01425 0.00371 0.01212
8/22/95 B 4500 28 0.00622 0.00395 0.01188
8/22/95 C 4500 27 0.00600 0.00395 0.01188
8/23/95 A 4300 44 0.01023 0.00386 0.01197
8/23/95 B 4700 47 0.01000 0.00404 0.01179
8/23/95 C 4000 33 0.00825 0.00371 0.01212
8/24/95 A 4300 31 0.00721 0.00386 0.01197
8/24/95 B 4600 38 0.00826 0.00399 0.01183
8/24/95 C 4600 37 0.00804 0.00399 0.01183
 ‘p’ chart
0.01600

0.01400

UCL

0.01200

0.01000

0.00800
p ave.

0.00600

0.00400

LCL

0.00200

0.00000
A B C A B C A B C A B C A B C A B C A B C A B C

8/16/95
8/16/95
8/16/95
8/17/95
8/17/95
8/17/95
8/18/95
8/18/95
8/18/95
8/19/95
8/19/95
8/19/95
8/21/95
8/21/95
8/21/95
8/22/95
8/22/95
8/22/95
8/23/95
8/23/95
8/23/95
8/24/95
8/24/95
8/24/95
 Control chart formulae
Chart Central Line LCL UCL

X-R
R R D3 R D4 R
X X X  A2 R X  A2 R

‘np’ np np  3 np 1  p  np  3 np 1  p 

‘p’ p p 1  p  p 1  p 
p 3 p3
n n

c
‘c’ c 3 c c 3 c
‘u’ u u u
u 3 u 3
ni ni