GUIDELINES FOR CONSTRUCTING CONTROL CHART (PART - 1) ‘Control Chart is a graphical device to aid in process control. It consist of a graph with a central line denoting the target value or standard and two limit lines on either side of the central line called ‘Upper Control Limit’ and ‘Lower Control Limit’. Quality measured periodically is plotted on the chart and status of control assessed. A) Collect samples at fixed interval and record the measurements slalelslele B) Total the value for each subgroup. Calculate | D) Determine the range for each subgroup the average for each subgroup Range is equal to largest value minus smallest value. We call each measurement as ’ and the average of | Range for the first subgroup is 6, for second 12 and the sibgrothy as) 5X so on First subgroup Second subgroup | First subgroup is = 498, 502, 502, 496, 500 498 502 | Range (R) = 502-496 = 6 pa 492 | Second subgroup is = 502, 492, 504, 496, 500 502 504 a fog | Range (R) = 504-492 = 12 sc 500 Te) Calculate the average range 291 2494 | Ranges are _ 6,12, 10, 18, 10, 2, 12, 10, 10, uel 6 6, 16,6, 8, 8,6, 2, 6, Band 14. ‘Average = Total/Number of values Total = 176 ie. X= a Jen average = R* Age =a F) Calculate the control limit for X = 498.8 and so on. Read A, from standard factor table to determine 3 6 limits." For subgroup size 5, A, = 0.57 C) Calculate the overall average. This is called X ] Size of Sub Averages Xs = 499.6, 498.8, 498.8, 500 498.4, Group(n) | A, | D, | DB | dt | 3a | anc uniaeniariowty | 2 [vam] - [sar] saz] eae | aioe | | 3 EH | ie tess| 1772 | _—_ 499.6, 499.6, 500.4 and 502.8. | 3 | zna| sore] canr | Total of Xs = 1003.6 | 6 6 Number of Xs = 20 or (os | 218. 2326| 1.290 0483 asa) 184 ng 30GUIDELINES FOR CONSTRUCTING CONTROL CHART (PART - 2) G) Calculate the control limits for K as HH) Similarly Calculate the UCL, & LCL, using ote the factor D, and D, uc, -X+A,R = 500.18 + (0.577 x 8.8) For ‘D’ value use the standard table given above. = 500.18 + 5.08 = 505.26 | cl, =0,R ta, = K- AR = 500.18 - 5.08 = 495.10 2.115 x 8.8 = 186 Lc, = 0, R=0x88=0 1) DETERMINE THE SCALE FOR THE GRAPH AND PLOT THE GRAPH ‘Variable Cont Chan RY PaaNo- aN aaa Fore tion nie Jorene Ye wa [cinerea Bas Ross pa 91298 Tine [eos Pase[ es ow [ois om [ows fw [erfeo foe] nafs rena) aml fel ae aa a ane | | a el X-R CHART 50526 ' uct; | 500,18 3 las 510 La, ‘Time - Hours aTi GUIDELINES FOR CONSTRUCTING CONTROL CHART (PART - 3) While X-R and X Control Charts are used for continuous value (measurement) we have other control charts for discrete variables (Attribute PERCENTAGE DEFECTIVE CHART - P CHART Place: Arcee Jute Mills Part: Gunny Bags Inspected by: DK Srivastava Wo, of] ot =e] S| a = No, | Date defec: | defec- Helssle 4 Jf spected| ‘tives | “tive wo.) #=]5 [> Ge |- +F pape poo a 2° |3 a gl i 2 | we | ao | om | sa 3 | 3] 3 Se& 5 | ose | ie | te | Tate Saal Fe |S aes 7] ass [a7 [a9hiaeo oan froerfizc0 | 3 ail eeess| aera ere lictoe | 380 | 32 pocseltzs [0207 poe fs. | 400 Pam iy Be ie ches 5 | foe | 46 [ete|tao o.ata poss feo | 3.0 23 a: | dre | 26 pacts|iaea[ozas poe ieso | 410 - ws = = z 5. | 225 | 22 [9.78]15.00 |0.200 Jo.06t }16.40 | 4.20 . - - = = 6. | 176 | 18 fo.23]13.27 |0.226 J0.069 }17.20 | 3.40 s |e | tm | we | toa S| tae | to [o:79|ta49 [oan oer |iroo | 3.0 we. | wa | os | wo | mss a | bon | 25 pacaafiaas fos frost | 390 m | aa fom | oo | nae 5. | Ste | 4a foas|taa7 [o.aze ows |i720 | 3.40 | wa [ome | oe | sat to. | '95 | 10 fo.sa| 2:75 [0:08 foovelis70 | 090 eli |e |e | oe 1: | 83 | 13 f¥3a)0:72 o'asofo.oes feo | Ba |eae ican paces 12: | doe | 19 [oan ]i83t o's oeafe ro | 330, Hebel tea oe a 15: | 25 | °S ]323]'s.08 Joa bssabr oo | 0.00 — ita. | 160 | 14 [8.75 ]12-65 [0.237 90.072 17.50 | 3.10 ™ = = = To 15. | 185 | 19 0.27]13.60 |0.221 o.067 |17.00 | 3.60 bid Lid = = bee x6. | 203 | 21 ft0.34]14.25 0.211 fo.064}16.70 | 3.90 we [me fos | ow | 20 5 | fae | 45 fraalts:6o.a0 fos 7.00 | 3.60 [ave [ous fos pan a | 42s | 4 fr-zofi se [0.26 fo fa. | 2.20 mw. | ae | ws | 9 | nz HS: | 135 | 43 facts fttee fos faore eo | 2:50 x: | ae | ae | 2 | we 26: | 185 | 43 foczr|taso [o.az acer ir.00 | 3:60 a | we | io | te | om at: | 240 | 22 fcae|ia. [0.207003 fe-0 | 400 ra Cae AEC lark [tee bx | ier | 48 porelize [one por |r | 3.20 era Fee a Bs | 468 | 48 fcsi fave [ozs por fi7 0 | 350 se atte ie za | 185 | 14 fucaefizos [oar pom isso | 2:10 = wn . m }25_ | 145 | 16 }1.03]12.04 }o.249 Jo.076 17.90 | 2.70 Tabane fae ae] ae te 0 P-CHART FOR % DEFECTIVE JUTE BAGS JUTE BAGS — Pn ce 3EGUIDELINES FOR CONSTRUCTING CONTROL CHART (PART - 4) 7 La NUMBER DEFECTIVE CONTROL CHART ~ NP CHART + [eees g S2\laale SIS] 3 [ee] Pisce: Arcee Jute atts Part: Gunny Bags 218 see 5315 [32/82] 2 la) coor seeme rae cane te z [de] 8]? i [=(t {$8 | 30} 3 | ifs ]' |e Uch, = apsaafnp BD feel S| 9] | * 71 (373 fe foe} 50/2 a fafa] e]a ft le Let. ea fap BD 7 fiore| 50} '3 | > | 3 i 5 fit] 30] ; 3 . Ss: haa] 30 | 3 2 i 7 = folds] 30/2] | 2 irae) 30] 7 i . i2fisiel 30] 3 fa cea fifi] 30] 3 | 2 | 2] 3 ay: . aera] 30s i 2} {i ‘sltere| 30] & 1/2 ald? wlio) 3) 9] | 1/3 eae Whore] 30] 4 i 142 where] 301 3 | a i ; — — wheal ol efi] [4 3 E (20.[23/8] 50] 6 1}2 142 -_ nents NUMBER DEFECTS CONTROL CHART - c CHART Time | petects | Time | Detects Org: Balaji Carpet Ltd. Process: Final Ingpection Basis: Visual Inspector: Sanjay 08.00 4 13.00 1 08.30 3 | 1330] 4 09.00 2 14.00} 3 UCLe=C +3 V c Lcle=C-3 + 09.30 0 | 1430] 2 10.00 1 | 1500} 0 10.30 5 15.30 oO " vere 11.00 6 16.00 3 4 11.30 4 | 1630} 2 : 12.00 © | i700] 5 : : 1230 3 | 1730] 4 52. “C Control chart 20 — = [Time[lispcunt- [Noa Defecs) NUMBER DEFECTS CONTROL CHART - U-CHART 108.00 1.00 3 Balaji Carpet Ltd. Process: Final Inspection oso | 1:00 4 ; ae 20 | 1.00 4 Basis: Visual Inspector: Sanjay 30 | 1.00 4 : Sa fo30 | 1:00 4 vclu= 0+ 34fin Ho.30 | 1:00 3 ne) ig | i vows 83m H2.00 | 150, 2 on H2.30 | 450, 0 13:00 | 50 5 : oc 13.30 | 30 é i mits 4.00 | 4:80 7 . aso | 180 4 Hs.00 | 180, 3 : Hs.30 | 180 2 6.00 | 4:80 3 TE 6.30 | 80 4 Teri lz00 | 1:80 i a 33GUIDELINES FOR CONSTRUCTING CONTROL CHART (PART - 5) VARIOUS OUT OF CONTROL PROCESS CONDITIONS, POINTS OUTSIDE CONTROL LIMITS Upper [Seven upwards points] _ [Drastic downward trend | contol << | I entra Lower Oe ae ee aw ee tim ‘TREND WHEN’ POINTS FORM CONTINUOUS UPWARD/ DOWNWARD TREND Seven-point ongth of run ie abnormal 40 out of 11 consecutive Upper contrat Unit Cntrat tine SS Cit RUN WHEN POINTS OCCUR CONTINUOUSLY ON ONE SIDE OR MORE APPROACH TO CONTROL LIMIT: WHEN 2 OUT OF 3 POINTS OCCUR OUTSIDE 2 SIGMA LINE APPROACH TO CENTRAL LINE: WHEN MOST OF THE POINTS ARE WITHIN 1.5 SIGMA LINE —— 34 PERIODICITY: WHEN CURVE SHOWS REPEATEDLY UP AND DOWNWARD TREND