Foster ch12 4th Edition+ (Statistic+attributes)

Chapter 12
Statistically-Based
Quality Improvement
for Attributes
Copyright
2010 Pearson Education, Inc. Publishing as Prentice Hall.
12- 1
Strategic Quality Planning

Statistically-Based Quality Improvement for Attributes
Chapter 12
Generic
process for developing attribute
charts
Understanding attribute charts
Reliability models
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Generic process for developing attribute charts
1.
2.
3.
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Identify Critical Operations ( Soldering

process)
Identify critical product characteristics (
Solder Bridging)
Determine whether the product
characteristics is a variable or an attribute
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Generic process for developing attribute charts
4.
5.
6.
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Select the appropriate process chart

( p or np chart)
Establish control limits
Update the limits when changes have
been made to the process
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Understanding Attribute Charts
Attribute Charts deal with binomial and

Poisson processes, not measurements
Think in terms of defects and defectives
rather than diameters and widths
We cannot measure
scratching because it
is attribute
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A defect is an irregularity or problem

with a larger unit.
The larger unit may contain many
defects
A piece of glass (Defectives unit)
may contain several bubbles or
scratches (Defects)
Defects are countable
Example: Scratches, missing remote
control, picture blur, color tone.
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A defective is a unit that, as a whole, is

not acceptable or does not meet
performance requirements
Defectives (unit) are monitored p and np

charts
Defects are monitored using c and u
charts
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Defects and Defectives
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A p chart is a process chart that is used the

proportion of items in a sample defective
Effective to determine when there has been a
shift in the proportion defectives for a
particular product or service
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p chart applications include:
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Late deliveries
Incomplete orders
Calls not getting dial tones
Accounting transaction errors
Parts that do not mate properly
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P-chart
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P-charts
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The np chart is a graph of the

number of defectives in a subgroup
The np chart requires the sample
size of each subgroup be the same
The uses for the np chart are
essentially the same as the p chart
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np chart
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np chart
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The c chart is a graph of the number of

defects per unit.
The units must be of the same sample
space .. Size, height, length, volume
The c chart is used to detect nonrandom
events in the life of a production process
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The u chart is a graph of the average

number of defects per unit.
The units can be of different Sizes,
height, length, volume
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C & U Chart
Number of defects
Number of average defects
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Reliability Models
Bathtub shaped function for life time
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The vertical axis is the failure rate

The horizontal axis is time
Shows products are
more likely to fail either
early or late in their
lifetimes
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Life History Curve

1. Initial Use:
It is characterized by marginal and short-life

parts that cause a rapid decrease in the failure
rate.
Work-miss failure and variation by operators.
It may be part of the testing activity prior to
shipment for some products
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Life History Curve

2. Useful life phase:
Failures occur in a random manner due to the constant

failure rate. Reliability of parts (use time).
3. Replacement phase:
Is depicted by a sharp raise in failure rates.

Mainly consumable parts.
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Reliability Models
Series reliability
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Components are in a series if the performance

of the entire system depends on all the
components functioning properly
The Components need not be physically wired
sequentially
All parts must function for the system to function
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Reliability Models
Parallel reliability
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High reliability systems often require

extremely require high component reliability
When it is impossible an alternative is to use a
backup system
Another word for backup is redundant or
parallel
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Series System
For a series systems, the reliability is the
product of the individual components.
RS = R1 R2 ... Rn
As components are added to the series, the
system reliability decreases.

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Series System
1
0.98
0.99
0.90
0.97
RS = 0.98 X 0.99 X 0.90 X 0.97=0.847
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Parallel System
1
2
n
Rs = 1 - (1 - R1) (1 - R2)... (1 - Rn)
When a component does not function, the product
continues to function, using another component,

until all parallel components do not function.
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Parallel System
0.90
1
2
0.80
Rs = 1 - (1 0.90) (1 0.80)
= 1- (0.1)(0.2)
= 1- 0.02
= 0.98
1
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Series-Parallel System
C
RA
RB
RC
RD
D
C
RC
Convert
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to equivalent series system

RA
RB
RD
C
RC = 1 (1-RC)(1-RC)
Series-Parallel System
C
RA
RB
0.90
0.90
RC
0.90
RD
D
RC
0.80
Rs = Ra X Rb X Rc X Rd
= 0.90 X 0.90 X 0.98 X 0.90
= 0.71
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0.90
Design
The
most important aspect of reliability is

the design.
It
should be as simple as possible.
The
fewer the number of components,

the greater the reliability.
Another
way of achieving reliability is to

have a backup or redundant
component (parallel component).
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Summary
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The objective of using process charts is

to continually improve your processes
As we make changes and improvements
there will be fewer defects and defectives
12- 31

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Chapter 12

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

process for developing attribute

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

Identify Critical Operations ( Soldering

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

Select the appropriate process chart

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

Attribute Charts deal with binomial and

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

A defect is an irregularity or problem

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

A defective is a unit that, as a whole, is

Defectives (unit) are monitored p and np

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Defects and Defectives

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

A p chart is a process chart that is used the

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

p chart applications include:

2010 Pearson Education, Inc. Publishing as Prentice Hall.

2010 Pearson Education, Inc. Publishing as Prentice Hall.

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

The np chart is a graph of the

2010 Pearson Education, Inc. Publishing as Prentice Hall.

2010 Pearson Education, Inc. Publishing as Prentice Hall.

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

The c chart is a graph of the number of

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

The u chart is a graph of the average

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Number of average defects

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

Bathtub shaped function for life time

The vertical axis is the failure rate

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Life History Curve

It is characterized by marginal and short-life

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Life History Curve

Failures occur in a random manner due to the constant

Is depicted by a sharp raise in failure rates.

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

Components are in a series if the performance

2010 Pearson Education, Inc. Publishing as Prentice Hall.

Strategic Quality Planning

High reliability systems often require

2010 Pearson Education, Inc. Publishing as Prentice Hall.

product of the individual components.

system reliability decreases.