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Control Charts

The document discusses statistical process control and control charts. It defines statistical control as a state where only common cause variation is present. It also defines special cause variation as being due to specific assignable causes and investigates when a process is out of control. The document outlines the four states a process can be in and describes the benefits of using control charts, including detecting issues early and limiting unnecessary inspection. It also discusses the key elements of control charts and provides examples of X-bar and R charts, X-bar and S charts, I-MR charts, P charts, and U charts.

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89 views28 pages

Control Charts

The document discusses statistical process control and control charts. It defines statistical control as a state where only common cause variation is present. It also defines special cause variation as being due to specific assignable causes and investigates when a process is out of control. The document outlines the four states a process can be in and describes the benefits of using control charts, including detecting issues early and limiting unnecessary inspection. It also discusses the key elements of control charts and provides examples of X-bar and R charts, X-bar and S charts, I-MR charts, P charts, and U charts.

Uploaded by

Ryan ms
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Statistical Process Control

What is Statistical Control?

 Statistical control or process “stability” is a state in


which only common cause variation is evident.

 Common cause variation is the normal expected


variation in a process that is:
 Due to the process itself
 Produced by interactions of variables within that
process
 Present in all processes, Unavoidable
 Predictable
 Inherent in a process, Normal and expected within
process
What is Out of Control?

 A process that is out of statistical control or “unstable”


demonstrates evidence of special cause variation.

 Special Cause Variation is...


 Due to a specific cause
 Caused by special circumstances not inherent in the
process.
 Generally easier to detect than common causes.
 Not predictable, Not always present
 Meaningful factors of process,
 Cause can be avoided and should be investigated
Definition

Graphs or charts that plot out


process data or management data
(outputs) in a time-ordered
sequence.
The 4 Process States

Each process falls into one of four states:


1. Ideal
It is in statistical control and produces 100 percent conformance to
specifications or goals.
2. Threshold
The process is in statistical control but occasionally exhibits non-
conformance at times.
3. Brink of chaos
It is not in statistical control but is not producing defects.
This is usually a precursor to the last state;
4. Out of control
It is producing unpredictable non-conformance.
Benefits of Process Control Charts

Each process falls into one of four states:

 Provide a simple, common language for talking about


process performance and behavior,
 Allow operators to detect and correct issues before they
cause deeper problems,
 Limit the need for inspection,
 Determine process capability based on past performance
and trends,
 Predict future performance if the system is stable and in
control
 Assess the impact of process changes
Elements of Control Charts

 A center line

 An upper control limit

 A lower control limit, and

 Process values plotted on the chart.


Types of Control Charts
Types of Control Charts
Data

Continuous Attribute
1. Control Chart for Continuous Data

Continuous
Data

n=1 n>1

I-MR Kecil Besar


Chart n<9 n>=9

Xbar-R Xbar-S
Chart Chart
Example:
A company uses plastic pellets to manufacture outer cases for
computer monitors. They want to evaluate whether the color of the
cases is consistent over time

Data Collection:
Quality inspectors randomly select 5 cases every 4 hours over an 8-
day period. The color of each case is assessed using the L value
(color reading)

Dataset:
Color.MPJ
Example: Tasks

Tasks

1. Develop Xbar and R Chart


2. Specifying parameters
3. Split Worksheet
4. Displaying Xbar and R chart for each vendor
5. Combine Control Charts on the Same Display
Example: Xbar-S
Problem
Parts that are manufactured in injection-molding process are
shrinking excessively. The average shrinkage of 5% is unacceptable,
and the process has too much variability.

A quality-improvement team uses a designed experiment to


investigate factors that my affect shrinkage in the injection-molding
process. Based on the results of the experiment, the reduce the mold
temperature.

After lowering the temperature, the team decides to further reduce


shrinkage by modifying the injection-molding tool.
Data Collection
The team collects shrinkage data in subgroups of size 10 every 8
hours. They label the initial data (Baseline/Benchmark), the data after
first process change (Reduce Temperature), and the data after the
second process change (Molding Tool Modification).

Dataset: Improve.MPJ
Example: Task

Tasks

1. Develop Xbar and S Chart


2. Xbar and S Chart with historical grouping
Example: I-MR
Problem
Food science students want to evaluate the consistency of the fill
weights for Peanut Butter ice cream. The ice cream is packed in half-
gallon containers. The target weight is 1150 grams. The specification
limits are 1100 and 1200 grams

Earlier evidence indicates this process was stable with a mean of


1150 grams and the standard deviation of 8.6 grams.

Data Collection

Students record the Fill Weight of each container over the course of
one business day.

Dataset: IceCreamFillWeight.MPJ
Example: I-MR
Task
1. Develop I-MR chart by specifying correct parameter
2. Identify the amount of process shift
Control Charts for Attribute Data
2. Control Chart for Attribute Data

Attribute
Data

Defective Defects

Binary Count
Outcome Data

P, Laney P’, NP U, Laney U’, C


2. Control Chart for Attribute Data

The term attribute data is used in the quality control


literature to describe two situations:
1. Each item produced is either defective or nondefective
(conforms to specifications or does not).

2. A single item may have one or more defects, and the


number of defects is determined.

In the former case, a control chart is based on the


Binomial distribution; in the latter case, the Poisson
distribution is the basis for a chart.
Example
Inspection Results
Day n X
1 100 20
2 100 5
3 100 30
4 100 35
5 100 24
Example

Day n X p=X/n
1 100 20 0.20
2 100 5 0.05
3 100 30 0.30
4 100 35 0.35
5 100 24 0.24
Sum 1.14
p-bar 0.23
Example

p-Chart for Bulbs

0.4

0.3 LCL
UCL
0.2
p

p-bar
0.1 p

0
1 2 3 4 5
Day
Example 1: Defective Data
Problem
A manufacture of piston rings tracks the number of
nonconforming rings that are produced each day. The
quality team wants to reduce the proportion of defective
rings because the high rate of defectives reduce overall
quality
Data Collection and Task
Data Collection:
Each day, the team inspects every piston ring that is
produced and records the total number of nonconforming
rings. Each piston is categorized into good/bad

Dataset:
Piston.MPJ

Tasks:
Diagnose P or Laney P’,
Create P Chart
Creating a P chart with an average subgroup size
Example: Defect Data
Problem
A furniture manufacturer is concerned about customer
complains related to surface blemishes, including color,
scratches, dents, grain, and finish, on wooden and tables.
Data Collection and Task
Data Collection:
A quality team inspects each table for nonconformities
indicated above. For about 3weeks, the team records the
number of surface blemishes and the number of pieces
inspected.

Dataset:
Furniture.MPJ

Diagnose U or Laney U’,


Create UChart

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