CONTROL CHARTS

VARIABLE CONTROL CHARTS

1. The fill volume of soft-drink beverage bottles is an important quality characteristic.
The volume is measured (approximately) by placing a gauge over the crown and
comparing the height of the liquid in the neck of the bottle against a coded scale. On
this scale, a reading of zero corresponds to the correct fill height. Fifteen samples of
size n = 10 have been analyzed, and the fill heights are shown in Table 6E.5. (a) Set
up X bar and s control charts on this process. Does the process exhibit statistical
control? If necessary, construct revised control limits. (b) Set up an R chart, and
compare with the s chart in part (a). (c) Set up an s2 chart and compare with the s
chart in part (a).
TA B L E 6 E . 5. Fill Height Data
Sample
Number x1 x2 x3 x4 x5 x6 x7 x8 x9 x10
1 2.5 0.5 2.0 −1.0 1.0 −1.0 0.5 1.5 0.5 −1.5
2 0.0 0.0 0.5 1.0 1.5 1.0 −1.0 1.0 1.5 −1.0
3 1.5 1.0 1.0 −1.0 0.0 −1.5 −1.0 −1.0 1.0 −1.0
4 0.0 0.5 −2.0 0.0 −1.0 1.5 −1.5 0.0 −2.0 −1.5
5 0.0 0.0 0.0 −0.5 0.5 1.0 −0.5 −0.5 0.0 0.0
6 1.0 −0.5 0.0 0.0 0.0 0.5 −1.0 1.0 −2.0 1.0
7 1.0 −1.0 −1.0 −1.0 0.0 1.5 0.0 1.0 0.0 0.0
8 0.0 −1.5 −0.5 1.5 0.0 0.0 0.0 −1.0 0.5 −0.5
9 −2.0 −1.5 1.5 1.5 0.0 0.0 0.5 1.0 0.0 1.0
10 −0.5 3.5 0.0 −1.0 −1.5 −1.5 −1.0 −1.0 1.0 0.5
11 0.0 1.5 0.0 0.0 2.0 −1.5 0.5 −0.5 2.0 −1.0
12 0.0 −2.0 −0.5 0.0 −0.5 2.0 1.5 0.0 0.5 −1.0
13 −1.0 −0.5 −0.5 −1.0 0.0 0.5 0.5 −1.5 −1.0 −1.0
14 0.5 1.0 −1.0 −0.5 −2.0 −1.0 −1.5 0.0 1.5 1.5
15 1.0 0.0 1.5 1.5 1.0 −1.0 0.0 1.0 −2.0 −1.5
2. The net weight (in oz) of a dry bleach product is to be monitored by X bar and R
control charts using a sample size of n 5. Data for 20 preliminary samples are
 shown in Table 6E.6. (a) Set up X bar and R control charts using these data. Does
the process exhibit statistical control? (b) Estimate the process mean and standard
deviation. (c) Does fill weight seem to follow a normal distribution?
TA B L E 6 E . 6
Sample
Number x1 x2 x3 x4 x5
1 15.8 16.3 16.2 16.1 16.6
2 16.3 15.9 15.9 16.2 16.4
3 16.1 16.2 16.5 16.4 16.3
4 16.3 16.2 15.9 16.4 16.2
5 16.1 16.1 16.4 16.5 16.0
6 16.1 15.8 16.7 16.6 16.4
7 16.1 16.3 16.5 16.1 16.5
8 16.2 16.1 16.2 16.1 16.3
9 16.3 16.2 16.4 16.3 16.5
10 16.6 16.3 16.4 16.1 16.5
11 16.2 16.4 15.9 16.3 16.4
12 15.9 16.6 16.7 16.2 16.5
13 16.4 16.1 16.6 16.4 16.1
14 16.5 16.3 16.2 16.3 16.4
15 16.4 16.1 16.3 16.2 16.2
16 16.0 16.2 16.3 16.3 16.2
17 16.4 16.2 16.4 16.3 16.2
18 16.0 16.2 16.4 16.5 16.1
19 16.4 16.0 16.3 16.4 16.4
20 16.4 16.4 16.5 16.0 15.8
3. Parts manufactured by an injection molding process are subjected to a compressive
strength test. Twenty samples of five parts each are collected, and the compressive
strengths (in psi) are shown in Table 6E.11. (a) Establish X bar and R control charts for
compressive strength using these data. Is the process in statistical control? (b) After
establishing the control charts in part (a), 15 new subgroups were collected and the
 compressive strengths are shown in Table 6E.12. Plot the X bar and R values against the
control units from part (a) and draw conclusions.
TA B L E 6 E . 1 1. Strength Data
Sample
Number x1 x2 x3 x4 x5 ¯x R
1 83.0 81.2 78.7 75.7 77.0 79.1 7.3
2 88.6 78.3 78.8 71.0 84.2 80.2 17.6
3 85.7 75.8 84.3 75.2 81.0 80.4 10.4
4 80.8 74.4 82.5 74.1 75.7 77.5 8.4
5 83.4 78.4 82.6 78.2 78.9 80.3 5.2
6 75.3 79.9 87.3 89.7 81.8 82.8 14.5
7 74.5 78.0 80.8 73.4 79.7 77.3 7.4
8 79.2 84.4 81.5 86.0 74.5 81.1 11.4
9 80.5 86.2 76.2 64.1 80.2 81.4 9.9
10 75.7 75.2 71.1 82.1 74.3 75.7 10.9
11 80.0 81.5 78.4 73.8 78.1 78.4 7.7
12 80.6 81.8 79.3 73.8 81.7 79.4 8.0
13 82.7 81.3 79.1 82.0 79.5 80.9 3.6
14 79.2 74.9 78.6 77.7 75.3 77.1 4.3
15 85.5 82.1 82.8 73.4 71.7 79.1 13.8
16 78.8 79.6 80.2 79.1 80.8 79.7 2.0
17 82.1 78.2 75.5 78.2 82.1 79.2 6.6
18 84.5 76.9 83.5 81.2 79.2 81.1 7.6
19 79.0 77.8 81.2 84.4 81.6 80.8 6.6
20 84.5 73.1 78.6 78.7 80.6 79.1 11.4
4. Control charts for X bar and R are maintained for an important quality characteristic.
The sample size is n = 7; X bar and R are computed for each sample. After 35 samples,
we have found that
 (a) Set up X bar and R charts using these data. (b) Assuming that both charts exhibit
control, estimate the process mean and standard deviation. (c) If the quality
characteristic is normally distributed and if the specifications are 220 ± 35, can the
process meet the specifications? Estimate the fraction nonconforming. (d) Assuming
the variance to remain constant, state where the process mean should be located to
minimize the fraction nonconforming. What would be the value of the fraction
nonconforming under these conditions?

ATTRIBUTES CONTROL CHARTS

5. The data in Table 7E.1 give the number of nonconforming bearing and seal
assemblies in samples of size 100. Construct a fraction nonconforming control chart
for these data. If any points plot out of control, assume that assignable causes can be
found and determine the revised control limits.
TA B L E 7 E . 1
Number of Number of
Sample Nonconforming Sample Nonconforming
Number Assemblies Number Assemblies
1 7 11 6
2 4 12 15
3 1 13 0
4 3 14 9
5 6 15 5
6 8 16 1
7 10 17 4
8 5 18 5
9 2 19 7
10 7 20 12

6. A process produces rubber belts in lots of size 2500. Inspection records on the last
20 lots reveal the data in Table 7E.5. (a) Compute trial control limits for a fraction
nonconforming control chart. (b) If you wanted to set up a control chart for
controlling future production, how would you use these data to obtain the center line
and control limits for the chart?

TA B L E 7 E . 5
Number of Number of
Lot Nonconforming Lot Nonconforming
Number Belts Number Belts
1 230 11 456
2 435 12 394
3 221 13 285
4 346 14 331
5 230 15 198
6 327 16 414
7 285 17 131
8 311 18 269
9 342 19 221
10 308 20 407
 7. A paper mill uses a control chart to monitor the imperfection in finished rolls of
paper. Production output is inspected for twenty days, and the resulting data are
shown here. Use these data to set up a control chart for nonconformities per roll of
paper. Does the process appear to be in statistical control? What center line and
control limits would you recommend for controlling current production?
TA B L E 7 E . 1 1. Data on Imperfections in Rolls of Paper

NUMBER NUMBER OF NUMBER OF

DAY OF ROLLS IMPERFECTIONS PER UCL LCL
IMPERFECTIONS
PRODUCED ROLLS PRODUCE
1 18 12 0.67 1.29 0.11
2 18 14 0.78 1.29 0.11
3 24 20 0.83 1.21 0.19
4 22 18 0.82 1.24 0.17
5 22 15 0.68 1.24 0.17
6 22 12 0.55 1.24 0.17
7 20 11 0.55 1.26 0.14
8 20 15 0.75 1.26 0.14
9 20 12 0.60 1.26 0.14
10 20 10 0.50 1.26 0.14
11 18 18 1.00 1.29 0.11
12 18 14 0.78 1.29 0.11
13 18 9 0.50 1.29 0.11
14 20 10 0.50 1.26 0.14
15 20 14 0.70 1.26 0.14
16 20 13 0.65 1.26 0.14
17 24 16 0.67 1.21 0.19
18 24 18 0.75 1.21 0.19
19 22 20 0.91 1.24 0.17
20 21 17 0.81 1.25 0.15
SUMA 411 288
ῡ 0.70

Cálculo de UCL Cálculo de LCL

UCL=Ú +3
√ Ú
n
LCL=Ú−3
√ Ú
n

UCL=0.70+ 3
√ 0.70
20
LCL=0.7007−3
√ 0.70
20

UCL=1. 26 LCL=0.14
 Answer: the process is not in statistical control, it is recommended to control the
samples that are outside the natural variation such as on days 1,2,11,12 and 13.

8. Consider the papermaking process in Exercise 7 Set up a u chart based on an

average sample size to control this process.
411
ń= =20.55 ……( average sample size)
20

Cálculo de UCL Cálculo de LCL

UCL=Ú +3
√ Ú
n LCL=Ú−3
√ Ú
n

UCL=0.70+ 3
√ 0.70
20.55 LCL=0.7007−3
√ 0.70
20.55
UCL=1. 25 LCL=0.15
9. The data in Table 7E.13 represent the number of nonconformities per 1000 meters
in telephone cable. From analysis of these data, would you conclude that the process
is in statistical control? What control procedure would you recommend for future
production?
TA B L E 7 E . 1 3. Telephone Cable Data

SAMPLE NUMBER OF
NUMBER NONCONFORMITIES Ć=
∑ (number of nonconformites)
1 1 22
2 1 189
Ć=
3 3 22
4 7
5 8 Ć=8.59
6 10
7 5
8 13 Cálculo de UCL
9 0
10 19 UCL=Ć +3 √ Ć
11 24 UCL=8.59+ 3 √8.59
12 6
13 9 UCL=1 7.4
14 11
15 15
16 8
Cálculo de LCL
17 3
18 6 LCL=Ć−3 √Ć
19 7
20 4 LCL=8.59−3 √ 8.59
21 9 LCL=−0.20
22 20
 Answer: No, the procces is not in control such as samples 10, 11 and 22 are out
of control. I recomended them to control the process.

10. Kaminski et al. (1992) present data on the number of orders per truck at a
distribution center. Some of this data is shown in Table 7E.20. (a) Set up a c chart
for the number of orders per truck. Is the process in control?
TA B L E 7 E . 2 0 Number of Orders per Truck
No. of No. of
Truck Orders Truck Orders
1 9 9 25
2 10 10 26
3 11 11 27
4 12 12 28
5 13 13 29
6 14 14 30
7 15 15 31
8 16 16 32

11. The following record shows the number of defective items found in a sample of 100
taken twice per day.
Sample Number of Sample Number of
number defectives number defectives
1 4 21 2
2 2 22 1
3 4 23 0
4 3 24 3
5 2 25 2
6 6 26 2
7 3 27 0
 8 1 28 1
9 1 29 3
10 5 30 0
11 4 31 0
12 4 32 2
13 1 33 1
14 2 34 1
15 1 35 4
16 4 36 0
17 1 37 2
18 0 38 3
19 3 39 2
20 4 40 1
Set up a Shewhart np-chart, plot the above data and comment on theresults.
12. Twenty samples of 50 polyurethane foam products are selected. The sample results
are:
Sample No. 1 2 3 4 5 6 7 8 9 10
Number defective 2 3 1 4 0 1 2 2 3 2
Sample No. 11 12 13 14 15 16 17 18 19 20
Number defective 2 2 3 4 5 1 0 0 1 2
Design an appropriate control chart. Plot these values on the chart and interpret the results.
13. Given in the table below are the results from the inspection of filing cabinets for
scratches and small indentations.
Cabinet No. 1 2 3 4 5 6 7 8
Number of defects 1 0 3 6 3 3 4 5
Cabinet No. 9 10 11 12 13 14 15 16
Number of defects 10 8 4 3 7 5 3 1
Cabinet No. 17 18 19 20 21 22 23 24 25
Number of defects 4 1 1 1 0 4 5 5 5
Set up a control chart to monitor the number of defects. What is the average run length to
detection when 6 defects are present? Plot the data on the chart and comment upon the
process.
14. In an effort to improve safety in their plant, a company decided to chart the number
of injuries that required first aid, each month. Approximately the same amount of
hours were worked each month. The table below contains the data collected over a
two-year period.
Year 1 Number of Year 2 Number of
Month injuries (c) Month injuries (c)
January 6 January 10
February 2 February 5
March 4 March 9
April 8 April 4
May 5 May 3
June 4 June 2
July 23 July 2
August 7 August 1
September 3 September 3
October 5 October 4
November 12 November 3
December 7 December 1
Use an appropriate charting method to analyse the data.