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Chap06 CC Var

1) The document discusses control charts for monitoring process data with unknown mean (μ) and standard deviation (σ) using x-bar and R charts. Initial trial control limits are determined from a number of samples and any out-of-control points are examined. 2) Periodic review and revision of control limits and center lines is important for effective use of control charts. When the R chart is out of control, points may be eliminated to recalculate limits. 3) Phase II operation uses reliable control limits established in Phase I to monitor future production. Guidelines for control chart design include choosing an appropriate sample size and sampling frequency.

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76 views68 pages

Chap06 CC Var

1) The document discusses control charts for monitoring process data with unknown mean (μ) and standard deviation (σ) using x-bar and R charts. Initial trial control limits are determined from a number of samples and any out-of-control points are examined. 2) Periodic review and revision of control limits and center lines is important for effective use of control charts. When the R chart is out of control, points may be eliminated to recalculate limits. 3) Phase II operation uses reliable control limits established in Phase I to monitor future production. Guidelines for control chart design include choosing an appropriate sample size and sampling frequency.

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ryan pramanda unsam
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Ch 6

VARIABLES CONTROL CHART

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Subgroup Data with Unknown  and 

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Phase I Application of x and R Charts
 Eqns 5-4 and 5-5 are trial control limits
 Determined from m initial samples
 Typically 20-25 subgroups of size n between 3 and 5

 Any out-of-control points should be examined for assignable


causes
 If assignable causes are found, discard points from calculations and
revise the trial control limits
 Continue examination until all points plot in control
 Adopt resulting trial control limits for use
 If no assignable cause is found, there are two options
1. Eliminate point as if an assignable cause were found and revise limits
2. Retain point and consider limits appropriate for control

 If there are many out-of-control points they should be examined


for patterns that may identify underlying process problems

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Revision of Control Limits and Center Lines

 Effective use of control charts requires


periodic review and revision of control
limits and center lines
 Sometimes users replace the center line
on the x chart with a target value
 When R chart is out of control, out-of-
control points are often eliminated to
recompute a revised value of R which is
used to determine new limits and center
line on R chart and new limits on x chart

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Phase II Operation of Charts
 Use of control chart for monitoring future
production, once a set of reliable limits are
established, is called phase II of control chart
usage (Figure 5-4)
 A run chart showing individuals observations in
each sample, called a tolerance chart or tier
diagram (Figure 5-5), may reveal patterns or
unusual observations in the data

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Control vs. Specification Limits
 Control limits are derived
from natural process
variability, or the natural
tolerance limits of a
process

 Specification limits are


determined externally, for
example by customers or
designers

 There is no mathematical
or statistical relationship
between the control limits
and the specification
limits

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Rational Subgroups
 x charts monitor between-sample
variability
 R charts measure within-sample
variability
 Standard deviation estimate of  used to
construct control limits is calculated from
within-sample variability
 It is not correct to estimate  using

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Guidelines for Control Chart Design
 Control chart design requires specification of sample
size, control limit width, and sampling frequency
 Exact solution requires detailed information on statistical
characteristics as well as economic factors
 The problem of choosing sample size and sampling
frequency is one of allocating sampling effort
 For chart, choose as small a sample size is
x
consistent with magnitude of process shift one is
trying to detect. For moderate to large shifts,
relatively small samples are effective. For small
shifts, larger samples are needed.
 For small samples, R chart is relatively insensitive to
changes in process standard deviation. For larger
samples (n > 10 or 12), s or s2 charts are better
choices.
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 An assumption in performance properties is that the
underlying distribution of quality characteristic is normal
 If underlying distribution is not normal, sampling
distributions can be derived and exact probability limits
obtained

 Burr (1967) notes the usual normal theory control limits


are very robust to normality assumption
 Schilling and Nelson (1976) indicate that in most cases,
samples of size 4 or 5 are sufficient to ensure reasonable
robustness
x to normality assumption for chart
 Sampling distribution of R is not symmetric, thus
symmetric 3-sigma limits are an approximation and -risk
is not 0.0027. R chart is xmore sensitive to departures
from normality than chart.
 Assumptions of normality and independence are not a
primary concern in phase I
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Average Run Lengths
 Crowder (1987b) showed that
ARL0 of combined individuals
and moving-range chart with
conventional 3-sigma limits is
generally much less than ARL0
(= 370) of standard Shewhart
control chart

 Ability of individuals chart to


detect small shifts is very poor
 Rather than narrowing the 3-
sigma limits, correct approach
to detecting small shifts is a
cumulative-sum or
exponentially weighted
moving-average control chart
(Chapter 8)

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Normality
 Borrer, Montgomery, and
Runger (1999) found in-
control ARL is
dramatically affected by
nonnormal data
 One approach for
nonnormal data is to
determine control limits
for individuals control
chart based on
percentiles of correct
underlying distribution
 Requires at least 100 and
preferably 200 observations

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