QualityManagementSystem Module 4

STATISTICAL QUALITY CONTROL

Engr. Re y A n n E . B a n d e , M M , M S M a n E
Statistical quality control (SQC) is the term used to describe the
set of statistical tools used by quality professionals
SQC encompasses three broad categories of;
Descriptive statistics
e.g. the mean, standard deviation, and range
Statistical process control (SPC)
Involves inspecting the output from a process
Quality characteristics are measured and charted
Helpful in identifying in-process variations
Acceptance sampling used to randomly inspect a batch of goods to determine
acceptance/rejection
Does not help to catch in-process problems
Variation exists in all processes.
Variation can be categorized as either;
Common or Random causes of variation, or
Random causes that we cannot identify
Unavoidable
e.g. slight differences in process variables like diameter, weight, service
time, temperature

Assignable causes of variation

Causes can be identified and eliminated
e.g. poor employee training, worn tool, machine needing repair
Descriptive Statistics include n

x
The Mean- measure of central
tendency i
The Range- difference between
largest/smallest observations in a set
x= i =1

of data
n

 (x )
Standard Deviation measures the n
2
amount of data dispersion around
i −X
mean
Distribution of Data shape σ= i =1
Normal or bell shaped or n −1
Skewed
Normal distributions Skewed distribution
STATISTICAL
PROCESS CHART
CONSTRUCTION
What is a control chart?
• The control chart is a graph used to study how a process changes over time. Data are plotted in
time order.
• A control chart always has a central line for the average, an upper line for the upper control limit
and a lower line for the lower control limit.
• Lines are determined from historical data.
Anatomy of a Control Chart
• X and Y Axis or the time series data
• The average line
• The control limits
• Lower Control Limit – LCL
• Upper Control Limit – UCL
• Signals:
• Outliers – data points that are above
the UCL or below the LCL
• Trends – 6 or more points that are
either entirely ascending or entirely
descending
• Shifts – 9 or more points either
entirely above or entirely below the
average line
When to use a control chart?
 Basic Principles

General model for a control chart

UCL = μ + kσ
CL = μ
LCL = μ – kσ

(Proposed by Walter A. Shewhart in1920’s)

 Types of the control charts

Variables control charts - variable data are

measured on a continuous scale.

Attributes control charts - attribute data are

counted and cannot have fractions or decimals.
(Proposed by Walter A. Shewhart in1920’s)
X̄ and R (or X̄ and S) Control Charts – Variable
Data (Continuous)
X̄ Chart: Monitors the average of a sample of data points.

R Chart (Range Chart): Monitors the range (the difference between the
highest and lowest values) within each sample.

S Chart (Standard Deviation Chart): Similar to the R chart, but instead of

range, it monitors the standard deviation within each sample.
Key Differences:
•X̄ Chart: Focuses on shifts in the mean of the
process.
•R/S Chart: Focuses on changes in the variation
within the process.
•Use X̄ and R when you have small samples
(typically 2–10 observations per sample).
•Use X̄ and S when you have larger samples (more
than 10 observations).
Let’s have a review!!!
Where:
X is the individual value (data)
n is the sample size (subgroup size)
X bar is the average reading in a sample
R is the Range, in other words, the difference between the largest and smallest value in each sample.
R-bar is the average of all the ranges.
UCL is the Upper control limit
LCL is the Lower control limit
 Observations
SAMPLE
Example: In the manufacturing 1 2 3 4
1 44 26 24 34
industry, plate thickness is one of 2 50 48 51 43
the important CTQ factors. During 3 32 28 26 22
4 52 55 56 44
the Measure phase, the project 5 16 16 21 26
team performed the process 6 36 36 35 31
7 21 22 18 21
capability study and identified 8 29 21 23 22
that the process was not capable 9 26 46 44 14
10 24 22 22 44
(less than 2 sigmas). In the 11 18 24 24 49
Analyze phase, they collected 20 12 24 20 26 23
13 19 21 27 28
sets of plate thickness samples 14 8 11 12 12
with a subgroup size of 4. 15 24 18 27 24
16 56 52 56 50
17 32 22 18 25
18 8 12 11 17
19 51 54 52 49
20 30 35 35 22
A quality control inspector at Time 1 Time 2 Time 3
Observation 1 15.8 16.1 16.0
the Cocoa Fizz soft drink
company has taken three Observation 2 16.0 16.0 15.9

samples with four Observation 3 15.8 15.8 15.9

observations each of the Observation 4 15.9 15.9 15.8

volume of bottles filled. If the Sample
standard deviation of the means (X-bar)
Sample
bottling operation is 0.2 ranges (R)
ounces, use the below data to
x 1 + x 2 + ...x n σ
develop control charts with x= , σx =
k n
limits of 3 standard deviations where (k ) is the # of sample means and (n)
for the 16 oz. bottling is the # of observations w/in each sample
operation. UCL x = x + zσ x

LCL x = x − zσ x
 x 1 + x 2 + ...x n σ
x= , σx =
Solution and Control Chart (x-bar) k n
where (k ) is the # of sample means and (n)
is the # of observations w/in each sample
UCL x = x + zσ x
• Center line (x-double bar):
LCL x = x − zσ x

15.875 + 15.975 + 15.9

𝑥ሜlj = = 15.92
3
• Control limits for±3σ limits:

0.2
𝑈𝐶𝐿𝑥̄lj = 15.92 + 3 ∗ = 16.225
4
0.2
𝐿𝐶𝐿𝑥̄lj = 15.92 − 3 ∗ = 15.62
4
STATISTICAL PROCESS CONTROL & CHARTS
Control Chart for Range (R)
Factors for three sigma control limits
• Center Line and Control Limit Factor for x-Chart Factors for R-Chart
formulas: Sample Size
(n) A2 D3 D4
2 1.88 0.00 3.27
0.2 + 0.3 + 0.2 3 1.02 0.00 2.57
𝑹ሜ = = 0.233 4 0.73 0.00 2.28
3 5 0.58 0.00 2.11
6 0.48 0.00 2.00
7 0.42 0.08 1.92
𝑈𝐶𝐿𝑥̄lj = 2.28 ∗ 0.233 = 0.53 8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
𝐿𝐶𝐿𝑥̄lj = 0 ∗ 0.233 = 0 12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
SEATWORK
A quality control inspector at the Crunchy Potato Chip Company has taken 10 samples
with 4 observations each of the volume of bags filled. The data and the computed
means are shown in the following table. If the standard deviation of the bagging
operation is 0.2 ounces, use the information in the table to develop control limits of 3
standard deviations for the bottling operation. Calculate the x̄ bar and draw the
chart. Is the process in control?
END OF PRESENTATIONS