Quality Control and Assurance

Statistical Process Control-

Variable Control Chart
Prepared by Aditya T. Pratama
2023
Reference :
Introduction to Statistical Quality Control, Douglas Montgomery
Managing for Quality and Performance Excellence, James Evans & William Lindsay
Fundamentals of Quality Control and Improvement, Amita
Quality Control and Assurance

Introduction
• Concept of variation is the difference in an object
to be studied.
• An example of variation:
• the difference in Indonesian people's height between
155 cm and 175 cm
• the output from making cylinders is 30.2 mm, 30.3 mm,
30.4 mm
• the taste of fried chicken in a restaurant varies,
sometimes the meat is hard, sometimes the meat is soft.
Quality Control and Assurance

Type of Variation
Production Process

Measurement

Variation

Stable: Unstable:
• output variations are relatively
• output variations are not the same over time
stable over time (can be
predicted) (unpredictable)
• only common causes are in the • there is an X factor (special cause) that
process causes variations to become unstable

Process is capable Process is not capable Process is capable but the

Variation < Specification Variation > Specification position of variation shifts
• Variation < Specification
• Variation position shifts
Quality Control and Assurance
Quality Control and Assurance

Introduction
• Control charts are used to analyze the results of a
process that has been running in quality control.
• If there is no data that goes outside the control
limits and the results of the data plot graph contain
no deviations, then it can be said to be under
control.
• The control chart aims to detect special causes or
data that is outside the control limits so that
corrective action can be taken against these causes.
Quality Control and Assurance

Type of Variable Control Chart

• X bar R Control Chart
• X bar S Control Chart
• X bar MR Control Chart
Quality Control and Assurance

X bar R Control Chart

• The X Bar R control chart is used to monitor
processes that are measured based on variable
data.
• Control charts are specifically for seeing changes in
data based on their concentration (average) while R
charts are specifically for monitoring changes in
terms of spread.
Quality Control and Assurance

X bar R Control Chart

The sequence for creating X bar and R control charts is as follows:
• Determine the sample or subgroup size (n)
• Collect data from at least 60-100 individual data points
• Calculate the mean value of each subgroup.
• Calculate the mean of all xbars to be used as the center line (CL) limit.
• Calculate the range by subtracting the highest data and the smallest
data from the subgroup.
• Calculate the mean and range calculation results.
• Calculating control limit X
• Calculating control limits R
• Plot and analyze the data using Excel or Minitab
• Calculating the process capability index (Cp & Cpk)
 Quality Control and Assurance

X bar R Control Chart

The control limit X:

The control limits R:

 Quality Control and Assurance

X bar R Control Chart

The Process Capability (Cp): The Process Capability (Cpk):

Cpk Criteria:
• If Cpk = Cp, the process is
Cp Criteria: exactly in the center.
• If Cp > 1.33, the process • If Cpk = 1, the process produces
capability is excellent. a product that meets
specifications.
• If 1.00 ≤ Cp ≤ 1.33 , the process • If Cpk < 1, the process produces
capability is fair. a product that does not
• If Cp < 1.00, the process conform to specifications.
capability is not capable. • Ideal CPK conditions are:
Cp > 1.33 and Cp = Cpk.
 Quality Control and Assurance

X bar R Control Chart

Analogy:
Quality Control and Assurance

X bar, S Control Chart

• The X bar S Control Charts are used for samples
number that more than 10.
• In principle, making this control chart is almost the
same as the X bar R control chart.
Quality Control and Assurance

X bar, S Control Chart

The sequence for creating X bar S Control Chart:
• Determine the sample/subgroup size (n > 10)
• Collect the number of subgroups (k), at least 20-25 subgroups
• Calculate the average value of each subgroup, namely X.
• Calculate the average value of all X, which is the center line of the
X control chart.
• Calculate the standard deviation of each subgroup (s).
• Calculate the average value of all s, namely S which is the center
line of the control chart S.
• Calculate the control limits from the control chart X
• Calculate the control limits from the control chart S
• Plot and analyze the X and S control chart
Quality Control and Assurance

X bar, S Control Chart

• X bar control limit:

• S bar control limit:

Quality Control and Assurance

X bar, MR Control Chart

• In some cases, the sample size used for statistical
process control is only one (n = 1).
• The only one sample size is usually due to the
characteristics of the population being very
homogeneous, for example in chemical fluids, and
mineral content in water, etc., so that taking just
one sample unit is expected to describe the
characteristics of the other units within certain
limits.
Quality Control and Assurance

X bar, MR Control Chart

The sequence to develop X bar MR Control Chart:
• Collect the individual data (n=1) for 30 or more sample sets.
• Calculate the Moving Range values (MR). The MR value is
the absolute value of the difference between the current
measurement value and the previous measurement value,
or the highest value minus the lowest value from two
consecutive measurements. (note: MR values must be
greater than or equal to zero)
• Determine the center line for the X and MR control charts
• Estimate the UCL and LCL for the X and MR control chart
• Plot ana analyze the X bar MR control chart.
 Quality Control and Assurance

X bar, MR Control Chart

• Centre line X: CL= X bar • Process Capability
• Centre line MR: CL= MR bar

• Control limit X bar control chart:

• Control limit MR control chart:

Quality Control and Assurance

Variable Control Chart - Summary

Control Chart Control Limit Upper Control Lower Control
(CL) Limit (UCL) Limit (LCL)

X and R

XX and
and SS

𝑀𝑅 𝑀𝑅
𝑑2 𝑑2
X and MR
Quality Control and Assurance

Exercise X bar R Control Chart

Measurement (n=5)
Sample x1 x2 x3 x4 x5
1 2.38 2.45 2.4 2.35 2.42
2 2.39 2.4 2.43 2.34 2.4
3 2.4 2.37 2.36 2.36 2.35
4 2.39 2.35 2.37 2.39 2.38
5 2.38 2.42 2.39 2.35 2.41
6 2.41 2.38 2.37 2.42 2.42
7 2.36 2.38 2.35 2.38 2.37
8 2.39 2.39 2.36 2.41 2.36
9 2.35 2.38 2.37 2.37 2.39
10 2.43 2.39 2.36 2.42 2.37
11 2.39 2.36 2.42 2.39 2.36
12 2.38 2.35 2.35 2.35 2.39
13 2.42 2.37 2.4 2.43 2.41
14 2.36 2.38 2.38 2.36 2.36
15 2.45 2.43 2.41 2.45 2.45
16 2.36 2.42 2.42 2.43 2.37
17 2.38 2.43 2.37 2.39 2.38
18 2.4 2.35 2.39 2.35 2.35
19 2.39 2.45 2.44 2.38 2.38
20 2.35 2.41 2.45 2.47 2.47
 Quality Control and Assurance

Exercise X bar R Control Chart

Xbar control chart: R control chart:

• Management need to take corrective action if there

is outlier data from R control chart
• First, we will remove the subgroup of observations
that are outside the control limits from the R
control chart, then re-create the R control charts in
which is under control.
• Then, if there is no data that is out of control, the
next step is to calculate process capability.
 Quality Control and Assurance

Exercise X bar R Control Chart

Process Capability
0.0605

• The Cpk value of 0.4615 taken from the CPL value indicates
that the process tends to approach the lower specification
limit. The Cp value of 0.6410 turns out to be less than 1, this
indicates that the process capability to meet the specified
specifications is low.
• Next, calculate the nonconformance level (in ppm)
 Quality Control and Assurance

Exercise X bar R Control Chart

Nonconformance level X < LSL = 2.35

• if z = -1.38; then Pz = 0.0838, if converted into ppm the value becomes 0.0838 x
1,000,000= 83800 ppm.
Nonconformance level X > USL = 2.45

• if z = 2.46; Pz = 0.0069, if converted into ppm the value becomes 0.0069 x

1,000,000=6900 ppm.
• Based on the calculation results, the total nonconformance level is P (X < LSL =
2.35 mm) + P (X > USL = 2.45 mm) = 83800 ppm + 6900 ppm = 90700 ppm.
• This means that in one million products produced there are 90,700 products
that do not meet the desired specifications.
Quality Control and Assurance

Exercise X bar R Control Chart

• If all the data is between the UCL and LCL then the data is said to be in
control.
• These limits (UCL X, LCL X, X, UCL R, LCL R, R) will be used as control
limits for the next period, so that we can find out whether the process
continues to be under continuous control, a control chart Xbar and R for
the next period is created using the limits for the next period.
Quality Control and Assurance

Exercise X bar R Control Chart

(minitab)
Xbar-R Chart of x1, ..., x5
2.450
1
1
2.425 UCL=2.4239
Sample Mean

2.400 __
X=2.3899
2.375

LCL=2.3559
2.350
1 3 5 7 9 11 13 15 17 19
Sample

UCL=0.1248
0.12

0.09
Sample Range

_
0.06 R=0.059

0.03

0.00 LCL=0
1 3 5 7 9 11 13 15 17 19
Sample
Quality Control and Assurance

Exercise X bar R Control Chart

(minitab)
Quality Control and Assurance

Exercise X bar S Control Chart

Measurement (n=12)
Sample x1 x2 x3 x4 x5 x6 x7 x8 x9 x10 x11 x12
1 11.91 11.85 12.04 12.02 11.98 11.99 12 11.98 11.89 11.9 12.01 11.8
2 12.29 12 11.85 11.85 11.98 11.88 12.02 11.9 11.95 12.15 12.01 11.78
3 11.93 11.96 12.07 11.86 12.03 11.97 12.07 11.78 11.87 11.95 11.79 12.06
4 12.09 12.11 12.07 11.82 12 12.02 12.04 12.09 12.01 11.99 11.92 11.99
5 11.93 12.12 12.06 11.97 12.17 12.05 11.87 11.86 11.79 11.96 12.07 12.04
6 11.77 11.93 11.83 11.93 12.01 11.89 12.02 11.91 11.88 11.98 12.07 11.88
7 11.91 12.03 12.07 11.85 11.99 11.97 12.04 11.97 11.92 11.96 12.04 12.08
8 11.84 11.79 12.07 11.95 12.05 11.94 11.81 11.88 11.87 11.8 11.8 11.81
9 12.28 11.98 12.13 11.72 12.16 12.05 12.07 11.98 11.87 12.01 11.93 12.08
10 12.05 11.9 12.08 11.83 11.92 11.96 11.84 11.92 11.91 12.06 11.98 11.8
11 12.19 12.05 11.97 11.8 11.88 11.98 11.78 12 12.02 11.87 11.88 11.83
12 12.22 12.11 11.93 11.82 11.97 12.01 12.04 11.92 11.96 12.08 12.03 12.06
13 11.88 11.96 11.95 12.34 12.11 12.05 12.01 11.96 11.82 11.86 12.1 11.83
14 11.95 11.84 12.01 11.87 11.87 11.91 12.06 11.96 11.94 11.9 11.78 11.79
15 12.24 11.77 11.96 12.12 11.88 11.99 12.09 11.84 11.98 11.96 11.86 12.1
16 11.87 12.07 11.88 12.23 12.16 12.04 11.89 11.97 12.07 12.03 11.82 11.84
17 12.17 12.12 12 11.93 11.87 12.02 11.96 11.8 12.03 11.89 11.98 11.92
18 11.88 12 12.06 11.88 11.9 11.94 11.97 11.96 11.92 12.02 12 11.81
19 11.93 11.92 12.01 12.01 12.03 11.98 12.07 12.01 11.97 12.03 11.86 11.96
20 11.98 12.02 11.95 12.01 11.97 11.99 12.09 12.03 11.78 11.82 12.09 12.01
 Quality Control and Assurance

Exercise X bar S Control Chart

Xbar S Control Chart
Xbar Control Chart:

S Control Chart:
Quality Control and Assurance

Exercise X bar MR Control Chart

Day Thickness Day Thickness
1 14.56 16 14.27
Pizzy Inc is a workshop that operates 2 13.88 17 14.23
in the field of car painting. Sampling
3 13.98 18 14.6
has been carried out to measure the
thickness of the paint layer. 4 14.5 19 14.25
5 14.22 20 14.12
Measurements were taken once a day
6 14.36 21 14.13
for 1 month (30 days). Based on paint
thickness measurement data, the 7 14.46 22 14.47
workshop management wants to use 8 14.32 23 14.73
X bar MR control charts to control the 9 14.27 24 14.02
ongoing process. 10 14.2 25 14.11
11 14.35 26 14.48
12 13.84 27 14.36
13 13.42 28 14.7
14 14.72 29 14.36
15 14.75 30 14.66
 Quality Control and Assurance

Exercise X bar MR Control Chart

Xbar Control Chart:

MR Control Chart:
Quality Control and Assurance

….Thank you