Syntel CQA Forum Control Charts CQA Doc No 18

Control Charts

Control charts are powerful and simple tools that can help you determine
whether a process is in control or out-of-control.
♦ An in-control process exhibits only random variation within the control
limits.
♦ An out-of-control process demonstrates unusual variation that may be due
to the presence of special causes.
In other words, control charts can help you determine whether or not the
process average (center) and process variability (spread) are operating at
constant levels. Control charts help you focus problem-solving efforts by
distinguishing between common and special cause variation.

A control chart consists of:

Plotted points, which represent individual observations, moving
ranges, or moving averages and are typically summary statistics for the quality
characteristic of interest. The data points are plotted in time order.
Center line, which is the expected value of the individual observations,
moving ranges, or moving averages.
Control limits, which are set at a distance of 3 s above and below the
center line and provide a visual display for the expected amount of variation
for the individual observation.
Control limits predict how the process should behave. The control limits
are based on the actual behavior of the process, not the desired behavior —
they are not specification limits. A process can be in control and yet not be
capable of meeting requirements.
Control charts evaluate the pattern of variation for stability through the
use of tests for special causes. If you detect special cause variation, you should
seek out the factors that contribute to this variation so that you can implement
corrective measures.

UCL : Upper Control Limit, LCL: Lower Control Limit. They are derived using
process variation data for a extended period.
UTL: Upper Tolerance limit, LTL: Lower Tolerance Limit. They are accepted
limits of customer.

Types of Control Chart

Individual chart (X)

An Individuals (I) chart allows you to monitor a quality characteristic

when your data are individual measurements. Each plotted point represents a
single sample measurement. Use an I chart to determine whether the process
center is in control.
An in-control process exhibits only random variation within the 3-s control
limits.
An out-of-control process exhibits unusual variation, which may be due to the
presence of special causes.
The process variation should be in control before assessing the process
center using an I chart. If the process variation is out-of-control, then the
control limits for the I chart will be inaccurate and may not adequately
determine the control of your process. Use a moving range (MR) chart or the
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Syntel CQA Forum Control Charts CQA Doc No 18
combined I-MR chart to assess whether or not the process variation is in
control.

Formulas for calculating control limits :

UCL : X bar + 2.66 mr bar

LCL : X bar - 2.66 mr bar

Moving Range (MR) Chart

The Moving Range (MR) Chart is used to monitor and detect changes in
process variation when your data are individual measurements. Each plotted
point, or moving range, is simply the absolute value of between two
consecutive measurements. The MR chart helps you to determine whether
there has been a sudden change in your process.

Formulas for calculating control limits :

UCL : 3.27 * mr bar

LCL : 0

Example :
Sample Value Moving Range
1 3
2 4 1
3 7 3
4 4 3
5 6 2
Sum 24 9
Mean 4.8(Xbar) 2.25(mr bar)

Formulas for calculating control limits :

Individual chart:
UCL = X bar + 2.66 mr bar = 4.8 + 2.66 * 2.25 = 10.795
LCL = X bar - 2.66 mr bar = 4.8 - 2.66 * 2.25 = -1.185

Moving range chart:

UCL = 3.27 * mr bar = 3.27*2.25 = 7.3575
LCL = 0
sample I MR

UCL=10.78
10
Individual Value

5 Mean=4.8

0
LCL=-1.184

Subgroup 1 2 3 4 5
C2 3 4 7 4 6

8
7 UCL=7.351
6
Moving Range

5
4
3
2 R=2.25
1
0 LCL=0

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