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eee tatistical Quality Control
Quality Control Charts using Excelearning Objectives
« After this class the students should be
able to:
e Distinguish between controlled and uncontrolled
variation
e Distinguish between variables and attributes
e Determine control limits for several types of control
charts
e Use graphics to create statistical control charts with
Excel
e Interpret control charts
e Create a Pareto chartTime management
« The expected time to deliver this
module is 50 minutes. 30 minutes are
reserved for team practices and
exercises and 20 minutes for lecture.Statistical Quality Control
(SCQ)
Process
e Any activity or set of activities that takes inputs
and create a product. The process for an industrial
plant takes raw materials and creates a finished
product is an example.
Statistical Quality Control (SQC) or
statistical process control (SPC)
e The analysis of processes for improving quality.Origins
° 1924 - Walter A. Shewhart
« W. Edwards Deming,Controlled Variation
here is Variation that you can never eliminate it totally.
There are bound to be many small, unobservable,
chance effects that influence the outcome. this kind of
variation is said to be "in control," not because the
process operator is able to control the factors absolutely,
but rather because the variation is the result of normal
disturbances, called common causes, within the
process.
This type of variation can be predicted. In other words,
given the limitations of the process, each of these
common causes is controlled to the greatest extent
possible.Uncontrolled Variation
» Variation that arise sporadically and for reasons
outside the normally functioning process, induced by a
special cause.
» Special causes include differences between machines,
different skill or concentration levels of workers,
changes in atmospheric conditions, and variation in the
quality of inputs.
» Unlike controlled variation, uncontrolled variation can
be reduced by eliminating its special cause.a icine of Variation
« Controlled
e is native to the process, resulting from
normal factors called "common causes”
« Uncontrolled
e is the result of "special causes" and need
not be inherent in the processControl Charts
~~ As long as the points remain between the lower and upper
control limits, we assume that the observed variation is
controlled variation and that the process is in control
Upper Control
Limit (UCL)
Center Line
Process
Values Lower Cintrol
Limit (LCC)aconto! Chart
» Other suspicious patterns could appear in control
charts. Unfortunately, we cannot discuss them all
here.
» Control chart makes it very easy for you to identify
visually points and processes that are out of control
without using complicated statistical tests.
» This makes the control chart an ideal tool for the
shop floor, where quick and easy methods are
needed.aconto! Chart
» Other suspicious patterns could appear in control
charts. Unfortunately, we cannot discuss them all
here.
» Control chart makes it very easy for you to identify
visually points and processes that are out of control
without using complicated statistical tests.
» This makes the control chart an ideal tool for the
shop floor, where quick and easy methods are
needed.aconto! Chart
» Other suspicious patterns could appear in control
charts. Unfortunately, we cannot discuss them all
here.
» Control chart makes it very easy for you to identify
visually points and processes that are out of control
without using complicated statistical tests.
» This makes the control chart an ideal tool for the
shop floor, where quick and easy methods are
needed.aconto! Chart
» Other suspicious patterns could appear in control
charts. Unfortunately, we cannot discuss them all
here.
» Control chart makes it very easy for you to identify
visually points and processes that are out of control
without using complicated statistical tests.
» This makes the control chart an ideal tool for the
shop floor, where quick and easy methods are
needed.Chart and Hypothesis testing
» The idea underlying control charts is closely related to
confidence intervals and hypothesis testing. The
associated null hypothesis is that the process is in
control; you reject this null hypothesis if any point lies
outside the control limits or if any clear pattern appears
in the distribution of the process values.
» Another insight from this analogy is that the possibility
of making errors exists, just as errors can occur in
standard hypothesis testing. Occasionally a point that
lies outside the control limits does not have any special
cause but occurs because of normal process variation.» Categories of control charts:
e those that monitor variables and
e those that monitor attributes.
» Variable charts display continuous measures, such as weight,
diameter, thickness, purity, and temperature. Its statistical analysis
focuses on the mean values of such measures.
» Attribute charts differ from variable charts in that they describe a
feature of the process rather than a continuous variable such as a
weight or volume. Attributes can be either discrete quantities, such as
the number of defects in a sample, or proportions, such as the
percentage of defects per lot.In order to compare process levels at various points in time, we usually
group individual observations together into subgroups.
The purpose of the subgroup is to create a set of observations in which
the process is relatively stable with controlled variation.
For example, if we were measuring the results of a manufacturing
process, we might create a subgroup consisting of values from the
same machine closely spaced in time.
A control chart might then answer the question "Do the averages
between the subgroups vary more than expected, given the variation
within the subgroups?"The X sChart
» Each point in the x-chart displays the subgroup average
against the subgroup number: subgroup 2 occurring after
subgroup 1 and before subgroup 3.
» Asan example, consider a clothing store in which the
owner monitors the length of time customers wait to be
served. He decides to calculate the average wait-time in
half-hour increments. The first half-hour (for instance,
customers who were served between 9 a.m. and 9:30
a.m.) forms the first subgroup, and the owner records
the average wait-time during this interval. The second
subgroup covers the time from 9:30 a.m. to 10:00 a.m.,
and so forth.The X sChart
» It is based on the standard normal distribution.
» The standard normal distribution underlies the
mean chart, because the Central Limit Theorem
states that the subgroup averages
approximately follow the normal distribution
even when the underlying observations are not
normally distributed.allt, The X Chart
» The applicability of the normal distribution allows the
control limits to be calculated very easily when the
standard deviation of the process is known. 99.74% of
the observations in a normal distribution fall within 3
standard deviations of the mean (u). In SPC, this means
that points that fall more than 3 standard deviations from
the mean occur only 0.26% of the time. Because this
probability is so small, points outside the control limits
are assumed to be the result of uncontrolled special
causes.a Control Limits when s is known
LCL @ pee @ @Standard deviation
vn
n @number of number of
observations in the subgroup
LCL @# we A @mean
vanCalculating Control Limits
LCL ex ee # @Standard deviation
al
n @number of number of
observations in the subgroup
LCL @X X @mean of all of the subgroup averages
ofaThe X sChart Example
[ Semester | Score 1_| Score 2 |
1 97 89
2 74 100)
3 85 100)
4 100 ot
5 83) 92
6 72 79 85 100) 78
7 80, 83) 93] 88) 96|
Ej 80 100) 100) 79) 84
9 87 70) 84 96 83
10 75 77 84 75 85
4 55) 95 89 700} 700}
12 75 73 100 72 78
13 75) 700| 89 66 700}
14 69 88 100} 84 84
15 100) 84 95) 80 92]
16 ot 700) 99) 7 73
17) 92 90) 93 87 90)
18 82 80 80) 79) 76
19) 54 89| 97 84 7A
20 83 66 69) 100) 82]The X sChart Example
To create a control chart of the teacher's scores:
1
Click StatPlus > QC Charts > XBar Chart.
Click the Subgroups in rows across columns option button.
Click the Data Values button and select the range names Score -1
through Score 5. Click OK.
Click the Sigma Known checkbox and type 5 in the accompanying
text box.
Click the Output button and send the control chart to a new chartaf Scores Control Chart
Fee ee ee ee ney
eenalysis
° One corollary to the preceding analysis
should be stated: Because even a single
professor experiences wide fluctuations
in student evaluations over time,
apparent differences among various
faculty members can also be deceptive.
You should use all such statistics with
caution.nalysis
° One corollary to the preceding analysis
should be stated: Because even a single
professor experiences wide fluctuations
in student evaluations over time,
apparent differences among various
faculty members can also be deceptive.
You should use all such statistics with
caution.nalysis
° One corollary to the preceding analysis
should be stated: Because even a single
professor experiences wide fluctuations
in student evaluations over time,
apparent differences among various
faculty members can also be deceptive.
You should use all such statistics with
caution.Control Limits when s is unknown
» The control limits are
LCL @X RA,R
UCL @X RA,R
» Rrepresents the average of the subgroup ranges, and
X is the average of the subgroup averages. A;is a
correction factor that is used in quality-control charts.
There are many correction factors for different types
of control charts.Control Limits when s is unknown
» The control limits are
LCL @X RA,R
UCL @X RA,R
» Rrepresents the average of the subgroup ranges, and
X is the average of the subgroup averages. A;is a
correction factor that is used in quality-control charts.
There are many correction factors for different types
of control charts.QC Correction Factors
Ad dy dD, Dy D; Dy
1.88 1.128 0 3.686 0 3.268
1.023 1.693 0 4.358 0 2.574
0.729 2.059 0 4.698 0 2.282
0.577 2.326 0 4.918 0 2.114
0.483 2.534 0 5.078 0 2.004
0.419 2.704 0.204 5.204 0.076 1.924
0.373 2.847 0.388 5.306 0.136 1.864
0.337 2.970 0.547 5.393 0.184 1.816
10 0.308 3.078, 0.687 5.469 0.223 sere
11 0.285 3.173, 0.811 5.535, 0.256 1.744
12 0.266 3.258, 0.922 5.594 0.284 pletlize
13 0.249 3.336 1.025 5.647, 0.308 1.692
weonrauronts
» Source: Adapted from "1950 ASTM Manual on Quality Control of Materials,"
‘American Society for Testing and Materials, in J. M. Juran, ed., Quality Control
Handbook (New York: McGraw-Hill, 1974), Appendix II, p. 39.na The X sChart: A Coating Process
» Using the data from a manufacturing firm that
sprays one of its metal products with a special
coating to prevent corrosion, create an X-chart
and analysis the results.
» The company has just begun to implement SPC.
consequently, “? is unknown. (20 minutes)eference
« Data Analysis with Excel. Berk & Carey,
Duxbury, 2000, chapter 12, p. 475-488