Control charts

2WS02 Industrial Statistics

A. Di Bucchianico
Goals of this lecture
Further discussion of control charts:
variable charts
She!hart charts
rational sub"rou#in"
runs rules
#erfor$ance
C%S%& charts
'W&A charts
attribute charts (c) # and n# charts*
s#ecial charts (tool !ear charts) short+run charts*
Statisticall, versus technicall, in control
Statistically in
control
stable over ti$e -
#redictable
Technically in control
!ithin s#eci.cations
Statisticall, in control vs technicall, in control
statisticall, controlled #rocess:
inhibits onl, natural rando$ /uctuations (co$$on causes*
is stable
is #redictable
$a, ,ield #roducts out of s#eci.cation
technicall, controlled #rocess:
#resentl, ,ields #roducts !ithin s#eci.cation
need not be stable nor #redictable
She!hart control chart
"ra#hical dis#la, of #roduct characteristic !hich is i$#ortant for
#roduct 0ualit,
X-barChartforyield
Subgroup
X-bar
0 4 8 12 16 20
13,6
13,8
14
14,2
14,4
Upper
Control
Liit
Centre Line
Lo!er
Control
Liit
Control charts
Basic #rinci#les
ta1e sa$#les and co$#ute statistic
if statistic falls above %C2 or belo! 2C2) then out+of+control si"nal:
X-barChartforyield
Subgroup
X-bar
0 4 8 12 16 20
13,6
13,8
14
14,2
14,4
ho! to "hoo#e "ontrol liit#$
&eanin" of control li$its
li$its at 3 4 standard deviation of #lotted statistic
basic e4a$#le:
9973 . 0 ) 3 3 (
) 3 3 (
) 3 3 (
) (
Z P
X P
X P
UCL X LCL P
X X
X X
UCL
LCL
'4a$#le
dia$eters of #iston rin"s
#rocess $ean: 56 $$
#rocess standard deviation: 0.07 $$
$easure$ents via repeated sa$#les of 8 rin"s ,ields:
mm LCL
mm UCL
mm
n
x
9865 . 73 ) 0045 . 0 ( 3 74
0135 . 74 ) 0045 . 0 ( 3 74
0045 . 0
5
01 . 0
= =
= + =
= = =

Individual versus $ean

Centreline
1 10
%3,&%
%4,03
group ean#
indi'idual
ob#er'ation#
9an"e chart
need to $onitor both $ean and variance
traditionall, use ran"e to $onitor variance
chart $a, also be based on S or S
2
for nor$al distribution:
' 9 : d
2
' S (;artle,<s constant*
tables e4ist
#referred #ractice:
.rst chec1 ran"e chart for violations of control li$its
then chec1 $ean chart
Desi"n control chart
sa$#le si=e
lar"er sa$#le si=e leads to faster detection
settin" control li$its
ti$e bet!een sa$#les
sa$#le fre0uentl, fe! ite$s or
sa$#le infre0uentl, $an, ite$s>
choice of $easure$ent
9ational sub"rou#s
ho! $ust sa$#les be chosen>
choose sa$#le si=e fre0uenc, such that if a s#ecial cause
occurs
bet!een+sub"rou# variation is $a4i$al
!ithin+sub"rou# variation is $ini$al.
bet!een sub"rou#
variation
!ithin sub"rou#
variation
Strate", 7
leads to accurate esti$ate of
$a4i$ises bet!een+sub"rou# variation
$ini$ises !ithin+sub"rou# variation
pro"e## ean
Strate", 2
detects contrar, to strate", 7 also te$#orar, chan"es of #rocess
$ean
pro"e## ean
?hase I (Initial stud,*: in control (7*
?hase I (Initial stud,*: in control (2*
?hase I (Initial Stud,*: not in+control
@rial versus control
if #rocess needs to be started and no relevant historic data is
available) then esti$ate A and or R fro$ data (trial or initial study*
if #oints fall outside the control li$its) then #ossibl, revise control
li$its after ins#ection. 2oo1 for #atternsB
if relevant historical data on A and or R are available) then use
these data (control to standard*
Control chart #atterns (7*
C,clic #attern)
three arro!s !ith diCerent !ei"ht
Control chart of hei"ht
Dbservation
;
e
i
"
h
t
C@9 : 0.00
%C2 : 70.00
2C2 : +70.00
0 3 6 & 12 1( 18
-10
-6
-2
2
6
10
Control chart #atterns (2*
@rend)
course of #in
Control chart of hei"ht
Dbservation
;
e
i
"
h
t
C@9 : 0.00
%C2 : 70.00
2C2 : +70.00
0 4 8 12 16 20
-10
-6
-2
2
6
10
Control chart #atterns (3*
Shifted $ean)
AdEusted hei"ht Dartec
Control chart of hei"ht
Dbservation
;
e
i
"
h
t
C@9 : 0.00
%C2 : 70.00
2C2 : +70.00
0 4 8 12 16 20
-10
-6
-2
2
6
10
Control chart #atterns (6*
A #attern can "ive e4#lanation of the cause
C,clic diCerent arro!s) diCerent !ei"ht
@rend course of #in
Shifted $ean adEusted hei"ht Dartec
Assu$#tion: a cause can be veri.ed b, a #attern
@he feather of one arro! is da$a"ed outliers belo!
?hase II: Control to standard (7*
?hase II: Control to standard (2*
9uns and =one rules
if observations fall !ithin control li$its) then #rocess $a, still be
statisticall, out+of+control:
#atterns (runs) c,clic behaviour* $a, indicate s#ecial causes
observations do not .ll u# s#ace bet!een control li$its
e4tra rules to s#eed u# detection of s#ecial causes
Western 'lectric ;andboo1 rules:
7 #oint outside 3+li$its
2 out of 3 consecutive #oints outside 2 +li$its
6 out of 8 consecutive #oints outside 7 +li$its
F consecutive #oints on one side of centre line
too $an, rules leads to too hi"h false alar$ rate
Warnin" li$its
crossin" 3 +li$its ,ields alar$
so$eti$es !arnin" li$its b, addin" 2 +li$itsG no alar$ but
collectin" e4tra infor$ation b,:
adEust$ent ti$e bet!een ta1in" sa$#les and-or
adEust$ent sa$#le si=e
!arnin" li$its increase detection #erfor$ance of control chart
Detection: $eter stic1 #roduction
$ean 7000 $$) standard deviation 0.2 $$
$ean shifts fro$ 7000 $$ to 0.3 $$>
ho! lon" does it ta1e before control chart si"nals>
?erfor$ance of control charts
e4#ressed in ter$s of ti$e to alar$ (run len"th*
t!o t,#es:
in+control run len"th
out+of+control run len"th
X-barChartforyield
Subgroup
X-bar
0 4 8 12 16 20
13,6
13,8
14
14,2
14,4
Statistical control and control charts
statistical control: observations
are nor$all, distributed !ith $ean and variance
2
are inde#endent
out of (statistical* control:
chan"e in #robabilit, distribution
observation !ithin control li$its:
#rocess is considered to be in control
observation be,ond control li$its:
#rocess is considered to be out+of+control
In+control run len"th
#rocess is in statistical control
s$all #robabilit, that #rocess !ill "o be,ond 3 li$its (in s#ite of
bein" in control* +H false alar$B
run len"th is .rst ti$e that #rocess "oes be,ond 3 li$its
co$#are !ith t,#e I error
Dut+of+control run len"th
#rocess is not in statistical control
increased #robabilit, that #rocess !ill "o be,ond 3 li$its (in s#ite
of bein" in control* +H true alar$B
run len"th is .rst ti$e that #rocess "oes be,ond 3 si"$a li$its
until control charts si"nals) !e $a1e t,#e II errors
&etrics for run len"ths
run len"ths are rando$ variables
A92 : Avera"e 9un 2en"th
S92 : Standard Deviation of 9un 2en"th
9un len"ths for She!hart Ibar+ chart
in+control: # : 0.0025
%C2
2C2
0.JJ530.JJ530.JJ530.0025
)
ti$e to alar$ follo!s "eo$etric distribution:

$ean 7-# : 350.6

standard deviation: ((7+#**-# : 3KJ.J

Geo$etric distribution
*'ent prob+
0+002%
,eoetri" -i#tribution
p
r
o
b
a
b
i
l
i
t
y
0 0+1 0+2 0+3 0+4 0+( 0+6 0+% 0+8 0+& 1
.X 1000/
0
0+(
1
1+(
2
2+(
3
.X 0+001/
Lu$erical values
She!hart chart for $ean (n=1*
sin"le shift of $ean:
?(MIMH3* A92 S92
0 0.0025 350.6 3KJ.J
7 0.022 63.J 63.6
2 0.78 K.3 8.3
3 0.8 2 7.6
Scale in Stat"ra#hics
Are our calculations !ron">>>
01L Cur'e for X-bar
2ro"e## ean
0
'
e
r
a
g
e

r
u
n

l
e
n
g
t
h
-2 -1+( -1 -0+( 0 0+( 1 1+( 2
0
(0
100
1(0
200
2(0
300
3(0
400
Sa$#le si=e and run len"ths
increase of sa$#le si=e N corres#ondin" control li$its:
sa$e in+control run len"th
decrease of out+of+control run len"th
Lu$erical values
She!hart chart for $ean (n=5*
sin"le chan"e of standard deviation ( +H c*
c
?(MIbarMH3
A92 S92
7 0.0025 350.6 3KJ.J
7.7 0.00K6 78K.K 78K.7
7.2 0.072 F0.8 F0.0
7.3 0.027 65.K 65.0
7.6 0.032 37.7 30.K
7.8 0.06K 22.0 27.6
9uns rules and run len"ths

in+control run len"th: decreases (!h,>*

out+of+control run len"th: decreases (!h,>*

?erfor$ance She!hart chart
in+control run len"th DO
out+of+control run len"th
DO for shifts H 2 standard deviation "rou# avera"e
Bad for shifts P 2 standard deviation "rou# avera"e
e4tra run tests
decrease in+control len"th
decrease out+of+control len"th
C%S%& Chart
#lot cu$ulative su$s of observation

chan"e #oint
C%S%& tabular for$
assu$e
data nor$all, distributed !ith 1no!n
individual observations
H C C C C
C X K C
C K X C
i i
i i i
i i i
+ +

+
, max if alarm ; 0
, 0 max
, 0 max
0 0
1 0
1 0
Choice K and H
K is reference value (allo!ance) slac1 value*
C
+
$easures cu$ulative upward deviations of A
0
NK
C
-
$easures cu$ulative downward deviations of A
0
+K
for fast detection of chan"e #rocess $ean A
7
:
K= MA
0+
A
7
M

H=5 is "ood choice

C%S%& Q+$as1 for$
%C2
2C2
C2
chan"e #oint
Dra!bac1s Q+$as1
onl, for t!o+sided sche$es
headstart cannot be i$#le$ented
ran"e of ar$s Q+$as1 unclear
inter#retation #ara$eters (an"le) ...* not !ell deter$ined
9ational sub"rou#s and C%S%&
e4tension to sa$#les:
re#lace b, /n
contrar, to She!hart chart ) C%S%& !or1s best !ith individuals
Co$bination

C%S%& charts a##ro#riate for s$all shifts (P7.8*

C%S%& charts are inferior to She!hart charts for lar"e
shifts(H7.8*
use both charts si$ultaneousl, !ith R3.8 control li$its
for She!hart chart
;eadstart (Fast Initial 9es#onse*
increase detection #o!er b, restart #rocess
es#. useful !hen #rocess $ean at restart is not e0ual at tar"et
value
set C
N
0
and C
+
0
to non+=ero value (often H-2 *
if #rocess e0uals tar"et value A
0
is) then C%S%&s 0uic1l, return
to 0
if #rocess $ean does not e0ual tar"et value A
0
) then faster alar$
C%S%& for variabilit,

de.ne Y
i
= (X
i
-
!
*/ (standardise*
de.ne "
i
= (MY
i
M-0.F22*-0.36J
C%S%&s for variabilit, are:
H S S S S
S V K S
S K V S
i i
i i i
i i i
> = =
+ =
+ =
+ +

+
, max if alarm ; 0
/ , 0 max
/ , 0 max
0 0
1
1

'4#onentiall, Wei"hted &ovin" Avera"e chart

"ood alternative for She!hart charts in case of s$all

shifts of $ean

#erfor$s al$ost as "ood as C%S%&

$ostl, used for individual observations (li1e C%S%&*

is rather insensitive to non+nor$alit,

*340 Chart for Col51
6b#er'ation
*
3
4
0
C71 8 10+00
UCL 8 11+00
LCL 8 &+00
0 3 6 & 12 1(
&
&+4
&+8
10+2
10+6
11
11+4
Wh, control charts for attribute data
to vie! #rocess-#roduct across several characteristics
for characteristics that are lo"icall, de.ned on a classi.cation
scale of $easure
L.B. %se variable charts !henever #ossibleB
Control charts for attributes
@hree !idel, used control charts for attributes:
#+chart: fraction non+confor$in" ite$s
c+chart: nu$ber of non+confor$in" ite$s
u+chart: nu$ber of non+confor$in" ite$s #er unit
For attributes one chart onl, suSces (!h,>*.
Attributes are characteristics !hich have a
countable nu$ber of #ossible outco$es.
#+chart
( )
x n
x
p p
x
n
x D P

= = 1 9 :
n x ,+++, 1 , 0 =
Lu$ber of nonconfor$in" #roducts is bino$iall,
distributed
n
D
p =
;
sample fraction of nonconforming:
n
p p
p
/ 1 .
;
2
;

=
mean:
p =
variance
#+chart
m
p
m n
D
p
m
i
i
m
i
i
==
==
11
;
avera"e of sa$#le fractions:
( )
( )
n
p p
p LCL
p CL
n
p p
p UCL

=
=

+ =
1
3
1
3
Fraction Lonconfor$in" Control Chart:
Assu$#tions for # chart
ite$ is defect or not defect (confor$in" or non+confor$in"*
each e4#eri$ent consists of n re#eated trials-units
#robabilit, p of non+confor$ance is constant
trials are inde#endent of each other
Counts the nu$ber of non+confor$ities in sa$#le.
'ach non+confor$in" ite$ contains at least one non+
confor$it, (cf. # chart*.
'ach sa$#le $ust have co$#arable o##ortunities for non+
confor$ities
Based on ?oisson distribution:
?rob(T nonconf. : #* :
c+chart
! k
c e
k c
c+chart
?oisson distribution: $ean:c and variance:c
c c LCL
c CL
c c UCL
3
3
=
=
+ =
Control 2i$its for Lonconfor$ities:
is avera"e nu$ber of nonconfor$ities in sa$#le c
u+chart
$onitors nu$ber of non+confor$ities per unit.
n
c
u =

n is nu$ber of ins#ected units #er

sa$#le

c is total nu$ber of non+

confor$ities
n
u
u LCL
u CL
n
u
u UCL
3
3
=
=
+ =
Control Chart for
Avera"e Lu$ber of
Lon+confor$ities ?er
%nit:
&ovin" 9an"e Chart
use !hen sa$#le si=e is 7
indication of s#read: $ovin" ran"e
Situations:
auto$ated ins#ection of all units
lo! #roduction rate
e4#ensive $easure$ents
re#eated $easure$ents diCer onl, because of laborator, error
&ovin" 9an"e Chart
calculation of $ovin" ran"e:
d
2
) D
3
and D
6
are constants de#endin" nu$ber of observations
1
=
i i i
x x MR
2
2
3
3
d
MR
x LCL
x CL
d
MR
x UCL
=
=
+ =
MR D LCL
MR CL
MR D UCL
3
4
=
=
=
individual
$easure$en
ts
$ovin"
ran"e
'4a$#le:
Qiscosit, of Aircraft ?ri$er ?aint
Batch Qiscosit, &9
J 33.6J 0.22
70 33.20 0.2J
77 33.K2 0.62
72 33.00 0.K2
73 33.86 0.86
76 33.72 0.62
78 33.F2 0.52
Batch Qiscosit, &9
7 33.58
2 33.08 0.50
3 36.00 0.J8
6 33.F7 0.7J
8 33.6K 0.38
K 36.02 0.8K
5 33.KF 0.36
F 33.25 0.67
(2 + 33 = x 48 + 0 = MR
Qiscosit, of Aircraft ?ri$er ?aint
since a $ovin" ran"e is calculated of n:2 observations) d
2
:7.72F)
D
3
:0 and D
6
:3.2K5
24 + 32
128 + 1
48 + 0
3 (2 + 33
(2 + 33
80 + 34
128 + 1
48 + 0
3 (2 + 33
= + =
=
= + =
LCL
CL
UCL
CC for individuals CC for $ovin" ran"e
0 48 + 0 0
48 + 0
(% + 1 48 + 0 26% + 3
= =
=
= =
LCL
CL
UCL
Qiscosit, of Aircraft ?ri$er ?aint
X
0 3 6 & 12 1(
32
32+(
33
33+(
34
34+(
3(
C7180+48
UCL81+(%
LCL80+00
0 3 6 & 12 1(
0
0+4
0+8
1+2
1+6
I
&9
@ool !ear chart
1no!n trend is re$oved (re"ression*
trend is allo!ed until $a4i$u$
slanted control li$its
2S2
%S2
2C2
%C2
reset
?itfalls
bad $easure$ent s,ste$
bad sub"rou#in"
autocorrelation
!ron" 0ualit, characteristic
#attern anal,sis on individuals-$ovin" ran"e
too $an, run tests
too lo! detection #o!er (A92*
control chart is not a##ro#riate tool (s$all ##$s) incidents) ...*
confuse standard deviation of $ean !ith individual