V Statistical Quality Control
V Statistical Quality Control
Statistical Quality Control (SQC) is the procedure or method for the control
of quality by the application of the theory of probability to the results of inspection of
samples of the population. It is a method for determining the extent to which the
quality goals are being met without checking every item produced and for indicating
whether or not variation in the quality which are exceeding the anticipated
expectations.
Causes of Variation:
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Variation in the quality of manufactured product in the repetitive process in industry
is inherent and inevitable. These variation are broadly classified as being due to two
causes
1. Chance causes
2. Assignable causes
Chance causes: These are small variations which are natural and inherent in the
manufacturing process. The variation occurring due to these causes is beyond the
human control and cannot be prevented or eliminated under any circumstances. The
minor causes which do not affect the quality of the products to an extent are called as
Chance Causes (or) Random causes. For example Rain, floods, power cuts, etc..
Assignable causes: The second type of variation which is present in any production
process is due to non-random causes. The assignable causes may occur in at any stage
of the process, right from the arrival of the raw materials to the final delivery of the
product. Some of the important factors of assignable causes are defective raw
materials, fault in machines, unskilled manpower, worn out tools, new operation, etc.
Statistical quality control is one of the tools for scientific management and has
following main advantages over 100 percent inspection:
Greater efficiency: It requires lesser time and boredom as compared to the 100
percent inspection and hence the efficiency increases.
Easy to apply: It is easy to apply even by man who does not have extensive
specialized training.
Accurate prediction: Specifications can easily be predicted for the future, which is
not possible even with 100 percent inspection.
Process control: This is concerned with the control of the quality of the goods while
they are in the process of production. In process control, we could detect the defects
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and faults of the process and could correct the errors. If the process is under control,
it means that assignable causes are absent.
Product control: This is concerned with the acceptance or otherwise of the lot. In
this, the finished goods are tested as acceptable or non-acceptable products. We test
and decide whether the goods are acceptable and fit for dispatch on the basis of the
inspection of the random sample.
Control chart: Control chart is graphical device mainly used for the study and
control of the manufacturing process. It is simple to construct and easy to interpret.
Attributes are the quality characteristic of a product that are not amenable for
measurement, but are identified by their presence or absence.
Control chart for mean is constructed and used for taking decision regarding the
quality of the items. The sample mean alone may not reflect the quality variations of
the items, but the range of the sampled values is known to be simple measure of the
quality variation. Hence the control chart for the sample range is also constructed
and used for taking decisions regarding the quality of the items.
1. The sample means in each of the N samples each of size n will be given. Let
X 1 , X 2 ,..., X N be the means of the N samples and R1 , R2 ,..., RN be the range of the
N samples. By range of sample R can be obtained by R = Maximum sample
value – Minimum sample value.
X X 2 ... X N R R2 ... RN
2. Compute X 1 and R 1 .
N N
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3. The values of A2, D3 and D4 for the given sample size n are taken from the table
of control chart constants.
4. Compute central limit X , upper control limit X A2 R , lower control limit
X A2 R which represent respectively the central line, the UCL and LCL of
X chart. Also, compute central limit R , upper control limit D4 R , lower
control limit D3 R which represent respectively the central line, the UCL and
LCL of R chart.
5. Draw the x-axis and y-axis, which represent as the sample number and sample
mean respectively. Draw the central line, UCL line and LCL line using the
respective values. Also, we plot the points and join adjacent points by line
segments. The graph thus obtained is the X chat. Similarly draw it for R-
chart with central line, UCL line and LCL line using the respective values.
6. If the plotted points fall within the LCL and UCL lines, the process is under
control. Otherwise, the process is out of control.
Problem 1: The following data gives the average life in hours and range of
12 samples each of 5 lamps. Construct X - chart and R – chart, comment on
state of control.
Sample No 1 2 3 4 5 6 7 8 9 10 11 12
X 120 127 152 157 160 134 137 123 140 144 120 127
R 30 44 60 34 38 35 45 62 39 50 35 41
Solution:
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UCL X A 2 R
136.75 ( 0.577 )( 42.75) 161.42
LCL X A 2 R
136.75 ( 0.577 )( 42.75) 112.08
Since all the sample points lie within the LCL and UCL lines, the process is under
control.
CL = R = 42.75
LCL = D3 R = 0
UCL = D4 R = (2.115) (42.75) = 90.41
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Since all the sample points lie within the LCL and UCL lines, the process is under
control.
Problem 2: The following table gives the sample means and ranges for 10
samples, each of size 6, in the production of certain component. Construct
the control charts for mean and range and comment on the nature of
control.
Sample 1 2 3 4 5 6 7 8 9 10
Mean X 37.3 49.8 51.5 59.2 54.7 34.7 51.4 61.4 70.7 75.3
Range 9.5 12.8 10.0 9.1 7.8 5.8 14.5 2.8 3.7 8.0
R
Solution:
9.5 12.8 10.0 9.1 7.8 5.8 14.5 2.8 3.7 8.0 84.0
R 8.4
10 10
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From the given table, we see that means corresponding to sample numbers 4,8,9,10
is greater than the upper control limit. Hence the process is out of control.
R 8.4
LCL D3 R 0
UCL D4 R 16.834
Since all the sample points lie within the LCL and UCL lines, the process is under
control.
Sample No 1 2 3 4 5 6 7 8 9 10
Observed 49 50 50 48 47 52 49 55 53 54
Measurements 55 51 53 53 49 55 49 55 50 54
X 54 53 48 51 50 47 49 50 54 52
49 46 52 50 44 56 53 53 47 54
53 50 47 53 45 50 45 57 51 56
Solution:
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Sample No 1 2 3 4 5 6 7 8 9 10
Observed 49 50 50 48 47 52 49 55 53 54
Measurements 55 51 53 53 49 55 49 55 50 54
X 54 53 48 51 50 47 49 50 54 52
49 46 52 50 44 56 53 53 47 54
53 50 47 53 45 50 45 57 51 56
Total 260 250 250 255 235 260 245 270 255 270
X 52 50 50 51 47 52 49 54 51 54
R 6 7 6 5 6 9 8 7 7 4
52 50 50 51 47 52 49 54 51 54 510
X 51
10 10
6 7 6 5 6 9 8 7 7 4 65
R 6.5
10 10
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Since the point (5, 47) lies outside the LCL, the process is out of control.
R 6.5
LCL D3 R 0
UCL D4 R 13.748
Since all the sample points lie within the LCL and UCL lines, the process is under
control.
Problem 4: Construct a control chart for mean and the range for the
following data based on fuses, samples of 5 being taken every hour (each set
of 5 has been arranged in ascending order of magnitude). Comment on
whether the production seems to be under control, assuming that these are
the first data.
42 42 19 36 42 51 60 18 15 69 64 61
65 45 24 54 51 74 60 20 30 109 90 78
75 68 80 69 57 75 72 27 39 113 93 94
78 72 81 77 59 78 95 42 62 118 109 109
87 90 81 84 78 132 138 60 84 153 112 136
Solution:
42 42 19 36 42 51 60 18 15 69 64 61
observat
Sample
65 45 24 54 51 74 60 20 30 109 90 78
ions
75 68 80 69 57 75 72 27 39 113 93 94
78 72 81 77 59 78 95 42 62 118 109 109
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87 90 81 84 78 132 138 60 84 153 112 136
Total 347 317 285 320 287 410 425 167 230 562 468 478
Sample
mean 69.4 63.4 57 64 57.4 82 85 33.4 46 112.4 93.6 95.6
X
Sample
Range 45 48 62 48 36 81 78 42 69 84 48 75
(R)
1 1 859.2
X Xi 69.4 63.4 57 64 57.4 82 85 33.4 46 112.4 93.6 95.6 71.6
N 12 12
1 1 716
R R i 45 48 62 48 36 81 78 42 69 84 48 75 59.67
N 10 12
From the table of control chart for sample size n=5, we have
A2 0.578, D3 0 & D4 2.11
10
120
sample mean
100
80
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12
Sample Number
Conclusion: Since 8th and 10th sample mean fall outside the control limits the
statistical process is out of control according to X chart
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12
Sample Number
Conclusion : Since all the sample means fall within the control limits the
statistical process is under control according to R chart
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on an invoice. Attribute charts are used to study the stability of processes over time,
provided that a count of nonconformities can be made. Attribute charts are used when
measurements may not be possible or when measurements are not made because of
time or cost issue.
To control the quality of certain products whose attributes are available, the following
control charts are used,
Of the above, p-chart is used when all the samples drawn from the produced items
are of the same size or of different size; np-chart is used only when all the samples
are of the same size n; c-chart is used only when each sample consists of only one
items.
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2. Compute central limit np , upper control limit np 3 np 1 p , lower control
Problem 1: The data given below are the number of defectives in 10 samples
of 100 items each. Construct a p-chart and an np-chart and comment on the
results.
Sample 1 2 3 4 5 6 7 8 9 10
No. of 6 16 7 3 8 12 7 11 11 4
defectives
Solution:
CL p 0.085
LCL p 3
p 1 p 0.00133
n
UCL p 3
p 1 p 0.16867
n
6 16 7 3 8 12 7 11
0.06, 0.16, 0.07, 0.03, 0.08, 0.12, 0.07, 0.11,
100 100 100 100 100 100 100 100
11 4
0.11, 0.04.
100 100
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Since all the sample points lie within the LCL and UCL lines, the process is under
control.
LCL n p 3 n p 1 p 0.133
UCL n p 3 n p 1 p 16.867
Since all the sample points lie within the LCL and UCL lines, the process is under
control.
Problem 2: Construct a control chart for fraction defectives (P- chart) for
the following data
Sample Number 1 2 3 4 5 6 7 8 9 10
Sample Size 90 65 85 70 80 80 70 95 90 75
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No. of defectives 9 7 3 2 9 5 3 9 6 7
Solution:
Here we note that the size of the sample varies from sample to sample.
90 65 85 70 80 80 70 95 90 75 800
n 80
10 10
CL p 0.075
LCL p 3
p 1 p 0.013
n
UCL p 3
p 1 p 0.163
n
9 7 3 2 9 5 3 9
0.100, 0.108, 0.035, 0.029, 0.113, 0.063, 0.043, 0.095,
90 65 85 70 80 80 70 95
6 7
0.067, 0.093.
90 75
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Since all the sample points lie within the LCL and UCL lines, the process is under
control.
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The average sample size(n) per day= 1400/14 days = 1000
Total no of pieces inspected per day
Percentage of defective per day
Total no of defective found per day
50 60
2 50 = 0.05 9 60 = 0.06
1000 1000
150 140
3 150 = 0.15 10 140 = 0.14
1000 1000
200 50
4 200 = 0.20 11 50 = 0.05
1000 1000
150 70
5 150 = 0.15 12 70 = 0.07
1000 1000
50 40
6 50 = 0.05 13 40 = 0.04
1000 1000
80 40
7 80 = 0.8 14 140 = 0.14
1000 1000
0.1(1 0.1)
ULC 0.1 3 0.4
1000
0.1(1 0.1)
LCL 0.1 3 0
1000
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Conclusion: Since all the sample points lie within the LCL and UCL lines, the
process is under control.
Sample no 1 2 3 4 5 6 7 8 9 10
No. of defectives 24 38 62 34 26 36 38 52 33 44
Solution:
CL np 38.7
UCL np 3 np(1 p) 53.31
LCL np 3 np(1 p) 24.07
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The process is out of control since the value of the sample number 3 is outside of the
upper control limit.
Sample No. 1 2 3 4 5 6 7 8 9 10
Proportion
0.10 0.04 0.08 0.15 0.08 0 0.01 0.05 0.05 0.08
Defective
Sample No. 11 12 13 14 1 16 17 18 19 20
Proportion
0.10 0 0.06 0.05 0.03 0.20 0.05 0.07 0.01 0.08
Defective
Estimate the proportion defective of the process. Does the process appear
to be under control with respect to the proportion of defective bolts?
Solution:
We know that the proportion defective of the process can be estimated by average
proportion defective of the samples.
1 k 1
We calculate p from equation follows p
n i1
di
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1.29 0.065
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Here the manufacturer visually inspected each selected bolt and classified it as
defective or non-defective. So we use the control chart for attributes. Since the
proportion defective for each sample is given, we can use the p-chart. Here the
process proportion defective is not known.
So we use equations to obtain the center line and control limits for the p-
chart as follows
CL=
p 0.065
LCL p 3
p 1 p 0.065 3 0.065 x0.35
0.65 3 0.025 0.010
n 100
UCL p 3
p 1 p 0.065 3 0.065 x0.35
0.65 3 0.025 0.140
n 100
We now construct the p-chart. We draw the centre line as a solid line and control
limits as dotted lines on the graph and plot the points by taking the sample number
on the X-axis and the proportion defective (p) on the Y-axis.
Conclusion: Since few the sample points lie beyond the LCL and UCL lines, the
process is beyond the control.
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Procedure to draw the c-chart:
When it is required to control the number of defects per unit, c-chart is used. ‘c’
represents the number of defects in a unit.
c1 c2 ... cN
1. Compute c , where ci is the number of defects in the ith unit.
N
2. Compute central limit c , upper control limit c 3 c , lower control limit
c 3 c which represent respectively the central line, the UCL line and the
LCL line.
3. Draw the x-axis and y-axis which represent as the sample number and number
of defectives respectively. Also draw the central line, UCL and LCL lines using
the respective values. The graph thus obtained is the c-chart.
4. If the plotted points fall within the LCL and UCL lines, the process is under
control. Otherwise, the process is out of control.
Problem 1: 15 tape recorders were examined for quality control test. The
number of defects in each tape recorder is recorded below. Draw the
appropriate control chart and comment on the state of control.
Unit No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
No of defects 2 4 3 1 1 2 5 3 6 7 3 1 4 2 1
Solution:
The number of defects per sample containing only one item is given,
2 4 3 1 1 2 5 3 6 7 3 1 4 2 1 45
c 3
10 15
CL c 3
UCL c 3 c 3 3 3 8.196
LCL c 3 c 3 3 3 2.196
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Since all the sample points lie within the LCL and UCL lines, the process is under
control.
Problem 2: A plant produces paper for newsprint and rolls of papers are
inspected for defects. The results of inspection of 20 rolls of papers are given
below: draw the c-chart and comment on the sate of control.
Roll No 1 2 3 4 5 6 7 8 9 10
No of defects 19 10 8 12 15 22 7 13 18 13
Roll No 11 12 13 14 15 16 17 18 19 20
No of defects 16 14 8 7 6 4 5 6 8 9
Solution:
The number of defects per sample containing only one item is given,
19 10 8 ... 6 8 9 220
c 11
20 20
CL c 11
UCL c 3 c 11 3 11 20.950
LCL c 3 c 11 3 11 1.050
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The process is out of control since the value of the sample number 6 is outside of the
upper control limit.
Specification limits:
The control chart may show that the process is in control at particular level. But it
may also be interest to know whether the process can meet the specification limits
set for the item. A decision of the point may be made by comparing what are called
the natural tolerance limits of the process with the specification limits.
For example, when the target length of bolt is 2.5cm, the specification limits may be
assumed as 2.4cm and 26.cm, viz., 2.5 0.1 cm.
Tolerance limits:
Tolerances are provided to the parts because variations in the material properties
introduce errors and production machines themselves have inherent inaccuracies.
Another reason to introduce tolerance is that it is not possible to make perfect settings
by operator so some tolerances are provided. Tolerance limits of a quality
characteristic are defined as those values between which nearly all the manufactures
items will lie. If the measurable quality characteristic X is assumed to be normally
distributed with mean 3 since only 0.27% of all the items produced can be
expected to fall outside these limits.
If the estimated tolerances lie well within the specification limits, this will
signify that the process is too good. Then to a revision of the specification limits may
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be called for, or else it may mean that some relaxation of the conditions of production
may be allowed, leading perhaps to lower costs.
The ideal situation will be attained when the tolerance limits are
approximately coincide with the specification limits.
Exercise Problems:
1. The following data gives readings of 10 samples of size 6 each in the production
of a certain product. Draw control chart for mean and range with its control limits.
Sample 1 2 3 4 5 6 7 8 9 10
Mean 383 508 505 582 557 337 514 614 707 753
2. The following data show the values of sample mean ( X ) and its range (R) for the
samples of size five each. Calculate the values for control limits for mean, range
chart and determine whether the process is in control.
Sample number 1 2 3 4 5 6 7 8 9 10
Mean 11.2 11.8 10.8 11.6 11.0 9.6 10.4 9.6 10.6 10.0
Range 7 4 8 5 7 4 8 4 7 9
3. A quality control inspector has taken ten samples of size four packets each from
a potato chips company. The contents of the sample are given below, Calculate the
control limits for mean and range chart.
Observations
Sample #
1 2 3 4
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8 12.4 12.3 12.6 12.5
4. From the following data, calculate the control limits for the mean and range
chart.
Sample No. 1 2 3 4 5 6 7 8 9 10
50 51 50 48 46 55 45 50 47 56
55 50 53 53 50 51 48 56 53 53
Sample Observations 52 53 48 50 44 56 53 54 49 55
49 50 52 51 48 47 48 53 52 54
54 46 47 53 47 51 51 57 54 52
5. The following data represent the no. of non-conforming per 1000 meters in
Telephone cable. Would you conclude that the process is in control? What control
Procedure would you recommended for future?
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