Quality Basics

6th Edition

Chapter 10
Control Charts for Attributes

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
1
Quality by Donna C. S. Summers (z-lib.org)
 Length Time Activity

50 8:00 8:50 Chapter 10

Agenda –Basic
Statistics for Process 15 8:50 9:05 Break
Control 15 9:05 9:45 Chapter 10 Cont.-Minitab Training for Beginners

40 9: 45 10:45 Class Activity: Construct Control Chart

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 Learning Objectives
1. To learn how to construct fraction nonconforming (p) charts for both constant and variable
sample sizes
2. To learn how to construct number nonconforming (np) charts
3. To learn how to construct percent nonconforming charts
4. To learn how to construct charts for counts of nonconformities (c charts)
5. To learn how to construct charts for nonconformities per unit (u charts) for both constant and
variable sample sizes
6. To understand how to interpret p, np, c, and u charts
7. Minitab Training for Beginners

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 Evaluation TimeTable

Quiz 1 October 15, 2021

Assignment 1 November 5, 2021

EvaluationQuiz 2 November 19, 2021

Assignment 2 December 3, 2021
Timetable Assignment
–Basic3 December 10, 2021
Statistics for
Process Control
Final Presentation December 17, 2021

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Attributes Charts
• Attributes are characteristics associated with a product or service.
These characteristics either do or do not exist, and they can be
counted.
• Attribute charts are used when measurements may not be possible
or when measurements are not made because of time or cost issues.
• Attribute charts have some disadvantages. They do not give any
indication about why the nonconformity occurred, nor do the charts
provide much detail.

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Control Charts for Attributes

• What is the best way for a company to study the number of

complaints or returns? How does a firm assess the
nonconforming product being produced?
• Attribute charts can assist in monitoring processes providing
goods or services. These charts can be used whenever counts or
percentages of nonconformities can be obtained.
• Attribute charts enable users to track performance, monitor
process stability, and discover where improvements can be
made.

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Types of Charts
• When nonconformities are investigated, two conditions may
occur. The product or service may have a single non-conformity
or several that prevent it from being used. These conditions are
called “nonconforming.”
• In other situations, the nonconforming aspect may reduce the
desirability of the product but not prevent its use; consider, for
example, a dented washing machine that still functions as
expected. These are called “nonconformities.”

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Chapter 10: Control Charts for Attributes
Two types of nonconformities:
1. Nonconforming. The product or service has one or more
nonconformities that prevent it from being used.
Use a p, np, or % chart to track performance.
2. Nonconformity. The nonconforming aspect may reduce the
desirability of the product, but it can still be used.
Use a c or u chart to track performance.

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Chapter 10: Control Charts for Attributes

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The Fraction nonconforming (p)
chart

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p chart
• The Fraction nonconforming (p) chart is:

• Based on the binomial distribution

• Used to study the proportion of nonconforming products or
services being provided
• Also known as a fraction defective or p chart

https://www.youtube.com/watch?v=u8T18qvP3Jo
(Attribute Control p np c & u charts explained with an example in
Minitab 5:45 min)

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 Rules :Binomial Probability Distribution

The binomial probability distribution can be used if two conditions are

met:
1. There is a nearly infinite number of items or a steady stream of items
being produced.
2. The outcome is seen as either a success or a failure. Or in terms of a
product, it is either conforming or nonconforming.

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Fraction Nonconforming (p) Charts: Constant
Sample Size
To create a p chart:
1. Gather the data.
2. Calculate p, the fraction nonconforming.
3. Plot the fraction nonconforming (p) on the control chart.
4. Calculate the centerline and control limits.
5. Draw the centerline and control limits on the chart.
6. Interpret the chart.

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p chart –p & pBAR
The fraction nonconforming (p), plotted on the p
chart, is calculated using n, the number of
inspected items, and np, the number of
nonconforming items found:

The centerline of the control chart is the

average of the subgroup fraction
nonconforming.

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p chart-Upper and Lower Control Limit

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 p chart

Point 8 in Figure 10.1 is above the upper control limit and should be investigated to determine if an assignable
cause exists.

Great interest is the significant decrease in the fraction nonconforming after point 13.
This reflects the installation of a new machine.
https://www.spcforexcel.com/knowledge/control-chart-basics/control-chart-rules-interpretation/ (Control Chart
Rules and Interpretation_ 8 min reading)
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What is the primary purpose of a P-chart in
statistical process control?
a) To monitor the average value of a process
b) To monitor the proportion of defective items in a process
c) To monitor the range of variation in a process
d) To monitor the total number of defects in a process

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Which of the following is a key component of
a P-chart?
a) X-bar
b) R-chart
c) Control limits
d) Standard deviation

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Fraction Nonconforming (p) Charts: Variable
Sample Size

When the amount sampled varies, fraction nonconforming charts

can be easily adapted to varying sample sizes.
Constructing a p chart in which the sample size varies requires
that the control limits be calculated for each different sample size,
changing the value for n in the control limit calculations each time
a different sample size is taken.

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there are two points out of control at the end of the chart (points 21 and 22) but no unusual patterns.

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Percent Nonconforming Chart
Constructing a percent nonconforming chart is the same as constructing a
fraction nonconforming chart. The values are changed to a percentage by
multiplying by a factor of 100.

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Question – p chart
The House of Bolts is one of the largest producers of
industrial (Class III) bolts. The bolts are sampled daily
with a sample size of 500. The bolts are inspected for
thread engagement and overall design. A nonconforming
bolt would display an irregular bolt size or poor
thread engagement. The control chart shows the fraction
of nonconforming bolts per sample size. Create
a p chart with the following data. Assume assignable
causes and revise the chart.
https://www.youtube.com/watch?v=ulXF660npAA&t=2s
(p-Chart in Excel | Control Chart | LCL & UCL)

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Answer p chart

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Number
Nonconforming (np)
Chart

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Number Nonconforming (np) Chart

A number nonconforming (np) chart tracks the number of

nonconforming products or services produced by a process.
A number nonconforming chart eliminates the calculation of p, the
fraction nonconforming.
Those studying the process keep track of the number of
nonconforming units (np) by comparing the inspected product
with the specifications.

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Number Nonconforming (np) Chart
A number
•
nonconforming (np) chart tracks the number of
nonconforming products or services produced by a process. It is a
whole number chart. m=the total number of subgroups

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Answers

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Chapter 10: Control Charts for Attributes
• The chart is under control. The
points flow smoothly back and
forth across the centerline.
• The majority of the points near
the centerline.
• There are no trends, runs,
cycles, or sudden shifts in level
apparent in the data.
• All of the points fall between
the upper and lower control
limits.

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What is the main benefit of using an NP-
chart in quality control?
a) It provides insights into process centering.
b) It identifies common causes of variation.
c) It helps in tracking the number of defects in a sample.
d) It measures the overall variability in a process.

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In an NP-chart, what does a stable process
typically look like?
a) Data points fall randomly within the control limits
b) Data points consistently cluster near the UCL
c) Data points trend upward over time
d) Data points are concentrated near the LCL

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Question np chart
To reduce the costs associated with an accident and its
consequences, returning the employee to work, even in
a limited capacity is critical. The safety engineer wants
management to understand the importance of managing
the days it takes to return employees to work. To
show their past performance, he wants to create an
easy-to-understand chart for his manager. Calculate the
centerline and control limits for an np chart. Graph
and interpret the chart. What level of days to return
to work can be expected in the future?

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Answer np chart

https://www.youtube.com/watch?v=TtQwvXJm2sE ( Attribute Control np chart MS Excel)

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Charts for counts of nonconformities
• Charts for counts of nonconformities monitor the number of nonconformities
found in a sample. Nonconformities represent problems that exist with the
product or service.
• Nonconformities may or may not render the product or service unusable.
Two types of charts recording nonconformities may be used:
a count of nonconformities (c) chart or
a count of nonconformities per unit (u) chart.
• As the names suggest, one chart is for total nonconformities in the sample,
and the other chart is for nonconformities per unit.

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Number of
Nonconformities (c)
Chart

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Number of Nonconformities (c) Chart
The number of nonconformities chart, or c chart, is used to track the count of
nonconformities observed in a single unit or product or single service
experience, n = 1.

m=the total number of samples

Count-of-nonconformities charts (c) can combine the counts of a variety of

nonconformities, such as the number of mishandled, dented, missing, or
unidentified suitcases to reach a particular airport carousel.
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Number of Nonconformities (c) Chart

Point 6 is out of control and should be investigated to determine the cause

of so many nonconformities. There are no other patterns present on the
chart. Except for point 6, the chart is performing in a very steady manner.
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Number of
Nonconformities per
Unit (u) Chart

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Number of Nonconformities per Unit (u) Chart
A number of nonconformities per unit, or u chart, is a chart that
studies the number of nonconformities in a unit (n > 1).

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• The number of nonconformities per unit (u), used on the u chart, is
calculated using
• n, the number of inspected items, and
• c, the count of nonconformities found

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c=the number of nonconformities u= the number of nonconformities per unit
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Chapter Number of Nonconformities per Unit
(u) Chart

Except for point 16, the chart appears to be under statistical control. Point
16 should be investigated to determine the cause of such a large number
of nonconformities per unit.
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Group 1 -2
Given the following information about mistakes made on tax forms, make and
interpret a fraction nonconforming chart.

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Group 3-4
Nearly everyone who visits a doctor’s office is covered
by some form of insurance. For a doctor, the processing
of forms in order to receive payment from an insurance
company is a necessary part of doing business.
If a form is filled out incorrectly, the form cannot be
processed and is considered nonconforming (defective).
Within each office, an individual is responsible
for inspecting and correcting the forms before filing
them with the appropriate insurance company. A local
doctor’s office is interested in determining whether
errors on insurance forms are a major problem. Every
week they take a sample of 20 forms to use in creating
a p chart. Use the following information to create a p
chart. How are they doing?

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Group 5-6
For 15 years, a county has been keeping track of traffic
fatalities. From the total number of fatal traffic accidents
each year, a random sample is taken and the driver is
tested for blood alcohol level. For the sake of creating
control charts, a blood alcohol level higher than 80 mg
is considered nonconforming. Given the following information,
create a p chart with a sample size that varies.
Consider the following information when interpreting
the chart. In 1991, the county began a three-pronged
attack against drunk driving. Mandatory seat
belt legislation was enacted, advertisements on radio
and TV were used to increase public awareness of the
dangers of drinking and driving, and harsher sentences
were enacted for drunk driving. Based on your knowledge
of chart interpretations, were these programs successful?
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Group 7-8
The Davis Plastic Company produces plastic baseball
bats for a major sporting goods company. These bats
are inspected daily but are not inspected at a constant
number each day. The control chart shows how many
bats were inspected and how many nonconformities
were found per unit. Nonconformities include wrong
taper on bat, incomplete handle, bad knurl on grip,
or deformed bat ends. Create a u chart with the following
data. Assume assignable causes and revise the
chart.

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Group 9-10
To reduce the costs associated with an accident and its
consequences, returning the employee to work, even in
a limited capacity is critical. The safety engineer wants
management to understand the importance of managing
the days it takes to return employees to work. To
show their past performance, he wants to create an
easy-to-understand chart for his bosses. Calculate the
centerline and control limits for an np chart. Graph
and interpret the chart. What level of days to return
to work can be expected in the future?

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MINITAB TRAINING
FOR BEGINNERS

A SSIG N M E N T F O R N E XT SE SSIO N :
• D E V E LO P P A N D U C H ART
• D E V E LO P X BA R -R C H ART

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Develop Attributes Chart in Minitab

https://www.youtube.com/watch?v=u8T18qvP3Jo

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Assignment for next session: develop X bar –
R chart in Minitab
• Camshaft length data
• A quality engineer at an automotive parts plant monitors the lengths
of camshafts. Three machines manufacture camshafts for three shifts
each day. The engineer measures five camshafts from each machine
during each shift.
• You can use this data to demonstrate Xbar-R Chart and other analyses
that compare multiple time series variables.
• You can create three control charts with this data to monitor each
machine. You should download the data given following link
• https://support.minitab.com/en-us/datasets/control-charts-data-sets/camshaft-length-
data/
• https://www.youtube.com/watch?v=nojM9zJ9RaI

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Assignment for next session: develop U
chart in Minitab
• Transcription errors data
• A manager for a transcription company wants to assess the
quality of the transcription service. The manager randomly
selects 25 sets of pages from consecutive orders and counts
the number of typographical errors (defects). Each set has a
different number of pages.
• You can use this data to demonstrate U Chart.
• https://support.minitab.com/en-us/datasets/control-charts-
data-sets/transcription-errors-data/

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Assignment for next session: develop
descriptive statistics in Minitab
• Shipping center data (Minitab project)
• A company that sells books online has three regional shipping
centers. Each shipping center uses a different computer system to
enter and process orders. The company wants to identify the most
efficient computer system and to use that computer system at each
shipping center. You can use this data to
demonstrate Histogram, Scatterplot, Display Descriptive Statistics, You
should download the data given following link
• https://support.minitab.com/en-us/datasets/getting-started-
guide-data-sets/shipping-center-data-minitab-project/

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 ONLINE
RESOURCES
• Full manual
Minitab http://bcs.whfreeman.com/webpub/statistics/
ips6e/Manuals/Student_Minitab_Manual/IPS
6e.Mt.St.pdf
•
https://www.causeweb.org/cause/archive/rep
ository/Minitab/Minitab.pdf

• https://slideplayer.com/slide/5995243/

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Thank you!

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