A Practical Guide to Selecting

the Right Control Chart

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com
A Practical Guide to Selecting the Right Control Chart

Introduction

Control charts were invented in the 1920’s by Dr. Walter Shewhart as a visual tool to
determine if a manufacturing process is in statistical control. If the control chart
indicates the manufacturing process is not in control, then corrections or changes
should be made to the process parameters to ensure process and product consistency.
For manufacturers, control charts are typically the first indication that something can be
improved and warrants a root cause analysis or other process improvement investigation.
Today, control charts are a key tool for quality control and figure prominently in lean
manufacturing and Six Sigma efforts.
Variables Data –
With over 300 types of control charts available, selecting the most appropriate one for a Measurements taken on a
given situation can be overwhelming. You may be using only one or two types of charts continuous scale such as
for all your manufacturing process data simply because you haven’t explored further time, weight, length, height,
possibilities or aren’t sure when to use others. Choosing the wrong type of control chart temperature, pressure, etc.
may result in “false positives” because the chart may not be sensitive enough for your These measurements can
process. Or there may be ways to analyze parts and processes you thought weren’t have decimals.
possible, resulting in new insights for possible process improvements.
Attribute Data –
This guide leads quality practitioners through a simple decision tree to select the Measurements taken
right control chart to improve manufacturing processes and product quality. This in discrete units which
guide focuses on variables data, not attribute data, and highlights powerful charting indicates the presence
functionality that users often overlook. You will learn which control chart is best for a or absence of something
given situation. InfinityQS’ ProFicient software offers easy setup and display of a wide such as number of defects,
variety of control charts including the ones highlighted throughout this guide. In injuries, errors, etc. This
addition, ProFicient’s quality hub gathers data from disparate sources, across multiple data cannot have decimals
plants or production lines, using automated or manual sampling to present control and cannot be used to
charts in real time and alerting operators and quality engineers to take samples and calculate other information
initiate process improvements. such as averages.

Table of Contents

Part 1. Control Charts and Basic Considerations . . . . . . . . . . . . . . . . . . . . . . . 3

Part 2. The Three Core Variables Charts: Using Sample Size to Determine Core Chart Type . . . . . . 6

Part 3. Special Processing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sidebar - SPC for Very High Sampling Rates . . . . . . . . . . . . . . . . . . . . . . . . 19

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 2
A Practical Guide to Selecting the Right Control Chart

Part 1. Control Charts and Basic Considerations

What IS and is NOT a Control Chart?

Just to make sure we’re on the same page, let’s first clarify what a control chart is. A
control chart is a real-time, time-ordered, graphical process feedback tool designed to
tell an operator when significant changes have occurred in the manufacturing process.
Control charts tell the operator when to do something and when to do nothing. A control
chart illustrates process behaviors by detecting changes in a process output’s mean
and/or standard deviation about the mean. Every process exhibits some normal
levels of variation, but a control chart is designed to separate this normal
or “common cause” variation from special cause variations. Control charts Note:
indicate visually whether a process is in-control (stable and predictable), It is important to note
or if it is out of control (unstable and unpredictable). Typically when the that just because a process
is stable and in-control doesn’t
control chart indicates the process is out of control, an operator should
mean its output is all within
take action to make adjustments to bring the process back under
specification limits.
control or initiate an investigation into the root cause.

Even though a control chart analysis is NOT the same as a capability analysis
(a process’ ability to meet specifications), one should confirm that the process is
in a state of statistical control before relying on the capability analysis results.

A control chart is also NOT useful for receiving inspection because the samples are not Mean – The average of
ordered in time of original production. Even though samples are taken, say 10 parts out a set of numbers such
of 100 in a box, there is no time ordering of the sampling like there is on a production as sample data which
line, so a control chart is not relevant for this type of data. However, box plots and indicates the “central”
histograms are perfectly suited for non-time-ordered data. value. It is calculated by
taking the sum of the
Control charts should NOT be confused with run charts, which are time-ordered, but samples and then dividing
don’t have control limits. In addition, pre-control charts are not control charts because by the number of samples
these charts compare subgroup plot points with specification limits, not statistical limits. taken.

Specification Limits –
Requirements for
acceptability of a process
output typically set by the
Standard Deviation – customer or engineering.
An estimate of the variation from the mean for a larger population based on a given Typically given as a number,
sample. The formula for estimated standard deviation is: the target value, with upper
and lower limits which
S = estimated standard deviation
define an acceptable range.
Y(x – x)2 S = sum of

s= X = individual sample The specification limit may

n–1 X = sample mean also be given as a not to

n = sample size exceed number or a not
less than number.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 3
A Practical Guide to Selecting the Right Control Chart

Components of a Control Chart

Control charts show time-ordered plotted points around a center line. The center
line is determined by calculating the mean of the plot points, typically about 20 to 25
points. The upper (UCL) and lower control limits (LCL) are typically set at +/- 3 standard
deviations of the plot points. The UCL and LCL show the expected normal (common
cause) plot point variation. Control limits should be updated (recalculated) when the
process improves. However, if you update the control limits when the process degrades,
you are simply letting the process run with more variability. Updating the control limits
only when the process improves promotes less variability and encourages continuous
improvements over time.

Note:
Control limits are based on
observed process data, not on
specification limits. Lines on a chart
representing 75% of the specification
limit are not statistical control limits.
Control limits may not always be
Control charts are often divided into zones as shown. centered on target or within the
The 2 sigma and 1 sigma zones are sometimes used for early detection of an specification limits.

unstable process. Certain patterns within these zones may alert an operator to
monitor more closely. For example, the operator may begin to see patterns such
as more plot points than usual in the 2 sigma zone causing him to increase sampling or
initiate an investigation.

If the process is stable, 99.73% of the plot points should fall within the 3 sigma limits
with half of the points above the centerline and half below; 95% should fall within the 2
sigma limits and 68% within the 1 sigma limits. Based on the normal distribution, control
limits should be representative of 99.73% of a process’“normal” state. In statistical jabber,
Normal Distribution –
this means that when a plot point violates a control limit, there is only a 0.27% chance
Variables data which has
(0.135% above UCL and 0.135% below LCL) that it was NOT a statistically significant
a Gaussian (bell-shaped
event. Therefore, an out-of-control plot point is a rare event when a process is behaving
and symmetrical) curve
in a stable manner. Any points falling outside the control limits should be treated as a
or frequency distribution.
special cause of variation and worthy of investigation.
Control charts are only valid
for data which follows a
normal distribution.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 4
A Practical Guide to Selecting the Right Control Chart

Calculating these limits and zones sounds complicated, but InfinityQS’ ProFicient software automatically computes the
mean, control limits, and standard deviation zones based on the sample data and chart selected. The software displays
the sample data in real time as each new plot point is written to the ProFicient database.

Basic Considerations for Selecting Control Chart Type

In this guide we’ll take a look at three basic factors or questions to consider when determining the most appropriate
control chart for a given situation.

1. What is the sample size?

2. Do I need to group multiple process streams or part features on the same chart?
3. Do I need to combine multiple “like features” that have different target values on the same chart?

Your answers to each of these questions determine the most appropriate type of control chart to use for your situation.
Simply use the decision tree shown here to guide your selection. Parts 2 through 3 in this guide provide more details
for answering these questions, and the benefits and weaknesses of each type of control chart.

Variable Data Control Chart Decision Tree

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 5
A Practical Guide to Selecting the Right Control Chart

Part 2. The Three Core Variables Charts:

Using Sample Size to Determine Core Chart Type

In this section we’ll address question one, “ What is the sample size?”

Question #1 What is the sample size?

IX-MR

Xbar-Range

Xbar-s

Your answer to this question will lead you to a specific type of control chart as shown in
the decision tree, with “n” being the sample size.

Sample Size Equals One: Individual X – Moving Range (IX-MR)

When your sample size is one (n=1), the chart to use is an Individual X – Moving Range
chart (Individual X charts are also called X charts, I charts, IX charts, or individuals
charts).

Examples of when to use a sample size of one include:

• Accounting data
- daily overtime
- number of parts scrapped for a given time period Individual X (IX) – The
actual reading or
• Homogeneous batches (chemicals, liquid foods, etc.) where variation from measurement taken for
consecutive samples would not indicate product variation, but only measurement quality control sampling
error purposes.
• Sampling is expensive and/or time consuming, or destructive testing (automotive
crash-testing) Moving Range – The
absolute difference
• Short production runs (e.g. five pieces in the entire run) between two consecutive
• Process automation sending only one rational data value (PLC sends one value individual values (IX).
every 5 minutes for an oven temperature)

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 6
A Practical Guide to Selecting the Right Control Chart

The IX-MR chart plots IX, the actual reading, and the Moving Range which is the absolute difference between two
consecutive IX plot points. The chart below represents several batches of resin, a homogeneous mixture, and we want
to measure the percent solids of each batch. Highlighted in yellow (the 3rd plot point) in the ProFicient screen shot
below, we see that the individual plot point on the IX chart is 5.0 and the Moving Range is 0.1. Notice that for subgroup
16, the moving range plot point exceeds the upper control limit of 0.9. This is an indication that the variability in resin
% solids exceeds what would be considered “normal.” That is, a special cause of variation is present in our process and
there exists a need for investigation and possible process adjustment.

Resin % Solids
Traditional IX-MR

• 1st Plot Point

• IX=5.2
• MR=0

• 2nd Plot Point

• IX=4.9
• MR=0.3
/4.9-5.2/

• 3rd Plot Point

• IX=5.0
• MR=0.1
/5.0-4.9/

Benefits Weaknesses
• Easy to Understand • Does not independently separate variation in the
• Only 15-25 measurements needed to estimate average from variation in standard deviation
control limits • Not sensitive enough to detect small
• Data can be plotted after each reading taken process changes
• Minimum calculations needed

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 7
A Practical Guide to Selecting the Right Control Chart

Sample Size is Between Two and Nine (inclusively): Xbar – Range (Xbar-R)
When your sample size is between 2 and 9 (2 ≤ n ≤ 9), then use the Xbar – Range chart.
Sample sizes between 2 and 9 (typically 3 or 5) are commonly used when at least a few
parts are made every hour and data are available to be collected at a reasonable cost.

The Xbar chart plots subgroup means, that is, the average of the individual values in
the subgroup. The R chart plots the subgroup Range which is the difference between
the maximum and the minimum individual values within the subgroup. In the example
chart above, the average of subgroup 8, is 2.7526 which is well within the control limits.
The range plot point is the difference between the highest and lowest values in the Range – The difference
subgroup, 0.002, which is also well within the control limits. In fact, all plot points reside between the maximum and
within the control limits indicating a consistent process where only common cause minimum individual values
variation is present. (IX) within a subgroup.
Sample Size is Ten or Higher: Xbar – Standard Deviation (Xbar-s)

Xbar Plot Point

2.7523
2.7537 High
2.7517 Low
8.2577 ÷ 3
= 2.7526

Range Plot Point

2.7537 - 2.7517
= 0.002

Note:
Operators and others
find these charts easy to read
and understand, but for sample
sizes greater than 9, they are not
the most accurate indicators of
process variability.

Benefits Weaknesses
• Separates variation in the averages from variation in • Must use separate chart for
the standard deviation each characteristic on each part (the number of
• Most widely recognized control chart charts can add up quickly!)
• Principles used as the foundation for most advanced • No matter the sample size, only 2 individual values
control charts per subgroup are used to estimate the standard
deviation for the range

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 8
A Practical Guide to Selecting the Right Control Chart

When your sample size is 10 or higher (n ≥ 10), then use the Xbar – Standard Deviation chart. The Xbar-Standard
Deviation chart is often referred to as either an Xbar-s or Xbar-SD chart. Using a sample size of ten or higher is most
common when lots of data are available and the costs for gathering the data is cheap. Examples include data from PLCs
(Programmable Logic Controllers) or other automated data gathering devices. The Xbar-s chart is also commonly used
for injection molding, multi-head filling operations, and continuous high speed production lines where it is possible to
gather many measurements quickly and inexpensively.

The Xbar-s chart plots the mean (the average of the individual values in the subgroup) and the sample standard
deviation of the individual values in the subgroup. In the chart below, subgroup 9 is highlighted. The average of the
subgroup’s 10 plot points is 34.02 and shown on the top Xbar chart, while the standard deviation is 2.755 and plotted
on the lower SD chart.

Benefits Weaknesses
• Very sensitive to small changes in the mean • Large amounts of data need to be gathered.
• In most cases the standard deviation is a more Assuming 20 plot points and n=10, then 200
accurate indicator of process variation than values are needed to calculate
the range control limits
Note:
If you are
currently using the more
popular Xbar-R chart for
InfinityQS’ ProFicient software easily and quickly handles the data and calculations
sample sizes of 10 or more, you
for the Xbar-s chart all in real time. Don’t worry if the sample size changes with will be better off using the Xbar-s
each subgroup, ProFicient can handle that too. chart to more accurately indicate
process changes.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 9
A Practical Guide to Selecting the Right Control Chart

Part 3. Special Processing Options

In this section we’ll take a look at additional questions to ask related to grouping and combining data from processes,
parts, and test characteristics; Group Charts and Target Charts will also be introduced. If we look back at our original
questions, we’ll be addressing questions 2 and 3 here.

Group Charts
Group charts address question 2 in our decision tree, “Do I need to group multiple data streams?” Group charts are
used to display several parameters, characteristics, or process streams on one chart in order to assess the relative
uniformity or consistency among the multiple streams of data. Examples include: measuring shaft diameter in 3 places;
cash register reconciliations among multiple registers; temperature measurements at various locations in an oven;
output from multiple fill heads.

The power of a group chart is two-fold: one, to clearly and distinctly illustrate the extremes or lack of uniformity in a
data set group; and two, to present the data to users so that opportunities for improvement are clearly detected.

Question #2 Do I need to group multiple process streams

or part features on the same chart?

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 10
A Practical Guide to Selecting the Right Control Chart

1.7541 1.7545 1.7539 1.7538 1.7544

High Low

Note:
The group chart is
In the example above, we want to see how uniform five journal bearing
intentionally absent of control limits
diameters are from one crankshaft to the next and to each other. To
because sometimes group charts are
chart these diameters, we could create five separate charts, one for each used for plotting dependent data streams.
diameter, but that’s a lot of charts and would make comparisons difficult. Pooling dependent data values typically
Instead, we label each journal bearing diameter 1 through 5 and then results in incorrect control limits. Besides,
combine all readings on the same Group chart. A Group chart plots only Group charts are more of a diagnostic and
the minimum and maximum values from each group of diameters with the discovery tool than a traditional process
points labeled, identifying the diameter location. Of the 5 bearing diameters control tool.
in the illustration above, bearing 2 has the largest diameter at 1.7545 while
bearing 4 has the smallest at 1.7538. The results from this crankshaft are plotted
as the first MAX and MIN point on the chart. Notice that the chart’s scale has been
modified to only show the last two significant digits from each diameter (1.7545 = 45).

• Group charts are very sensitive and can easily detect differences among data
streams. In our example, bearing 2 is the maximum value three consecutive times.
The chance of this happening randomly is only 0.8% (0.23=0.008). Very quickly we Dependent Data
see this may be worthy of investigation. Streams – Two sets of
process data which depend
• MAX and MIN lines that track each other indicate the data streams are dependent.
on each other, i.e. the
• Converging lines suggest a decrease in within-part variation, i.e. closer lines = more values for one data set are
uniformity. In our example above, the fourth crankshaft is the most uniform. in some way affected by or
related to the other.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 11
A Practical Guide to Selecting the Right Control Chart

• Diverging lines imply increasing within-part variation, i.e. farther spaced lines = less Target Values – The
uniformity. In the example, the first three crankshafts are less uniform than the last historical mean for a quality
three. measurement or the ideal
value for a process output.
• Patterns in plot point labels can also indicate issues with one stream and may
warrant a closer look. If four of the same labels appear when there are five data
Specification Limits
streams grouped, then investigate further. In the example above, bearings 1 and 2
– Requirements for
are always the largest diameters. This may indicate that there is a difference in how
acceptability of a process
the left end of the crankshaft is being manufactured as compared with the right
output typically set by the
side.
customer or engineering.
Typically given as a number,
ProFicient allows the user to group on tests (like in our example), processes, or parts. the target value, with upper
Grouping data, charting each data stream on different charts, or displaying data both and lower limits which
ways at the same time is your choice. ProFicient makes Group charts easy to set up and define an acceptable range.
simple to interpret. The specification limit may
also be given as a not to
exceed number or a not
Target Charts less than number.

Target charts address question 3 in our decision tree, “Do I need to combine
Tolerances – The upper
multiple “like features” that have different target values?” Target charts show
and lower limits of a
multiple characteristics that have different nominal or target values all on one
specification, typically
chart. For example, two parts may have different specification limits, but the same
shown as +/- X, which
total tolerances.
indicates the range for
Target charts are ideal for monitoring the consistency of a production line making
acceptance.

Question #3 Do I need to combine multiple “like features”

that have different target values on the same chart?

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 12
A Practical Guide to Selecting the Right Control Chart

different parts in the same part family. Target charts are used frequently in food and consumer packaged goods
processes. For example, a bakery might use a Target chart for their ovens which bake muffins at 350°F and bread at
375°F. In the Target chart they would be looking at deviation from target for these two temperature set points to assess
how well the oven can maintain the temperatures. Another example would be a paint line where different thicknesses
of paint are applied; 3 mils for one part and 4 mils for another. Target charts are also ideal for assessing tool wear across
multiple runs of different part numbers. By combining, in time order, data across the different part runs, the Target
chart will expose tool wear patterns. Target charts can also be useful for limited production runs because they allow
you to combine enough short run data sets to analyze process capabilities.

The Target chart plots the deviation from the specification limit target and then calculates a single shared set
of control limits using the deviation from target values across multiple parts. In the example below we have
two parts, the blue part and the yellow part. Each has different specification limits, but identical total tolerances
for the same Test (Outside Diameter B). For each part we take 3 samples and calculate the average difference
from the target value. As shown for the blue samples the average difference is 0.0012 and for the yellow samples
the average difference is 0.0003. Charting the difference from target allows us to plot the two parts on the
same chart.

1.5021
1.5020
1.4996
Average 1.5012 - 1.500 = 0.0012

B 1.500 ± 0.005

1.7486
1.7501
1.7504
Average 1.7497 - 1.750 = -0.0003

B 1.750 ± 0.005

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 13
A Practical Guide to Selecting the Right Control Chart

If we first plot the yellow part as shown in the chart below, we use the Xbar-R chart, except that we’re plotting the average
difference from the target value instead of actual values. Highlighted subgroup 20 shows the average difference in the
3 samples is 0.0001. The plotted Range value is 0.0004 which is the calculated difference between the minimum and
maximum values (1.7503 – 1.7499).

If we start making the blue part on the same machine we can simply add the blue part data to our Target Xbar-R chart
as shown below. ProFicient’s “on the fly” processing option allows the user to easily combine data on the same chart
and apply the deviation from target option at any time. The user can switch between Traditional and Target processing
with the same set of data.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 14
A Practical Guide to Selecting the Right Control Chart

Process Control AND Part Control - Using the Same Data

When using conventional-logic SPC software, the user must make the choice between a strategy of either
process control or part control. That’s because data stored for process control requires a different type of data
collection strategy than part control data. But with ProFicient, you don’t have to make that choice. Instead,
both process control and part control strategies can be pursued. You can choose to display all data from a
process across multiple parts or display data specific to a single part. What makes this functionality amazing is
that both options of analysis and display are managed using the same data. Switching between part control
and process control requires only a simple right-mouse click.

Combining Chart Options

We’ve looked at traditional charts, Group charts, and Target charts. These are three distinct processing options suited for
unique manufacturing and analysis needs. However, these options can be combined to provide even more flexibility to
manage those situations where one might need to group data streams where the streams have different specifications.
For example, if we answered yes to question 2 and yes to question 3, and our sample size is 10, then a Group Target
Xbar-s chart may be used as long as the measurements we’re taking use the same units of measure. Combining
Group and Target charts is a good way to get statistically valid information for short runs of multiple process streams
and puts everything onto one chart for better visibility of the process instead of individual parts and individual test
characteristics.

In the example below we’re taking 3 measurements on

one part – Key A, Key B, and Key C. These measurements
are all measured in inches, have the same total tolerance
but different targets. Since the sample size is ten, we’ll have
a total of 30 data values from 10 consecutive parts. Using
Target and Group processing options we can overlay all
three process streams, i.e. A, B, and C, on one chart.

Illustration and Sample Data Source

Stephen A. Wise and Douglas C. Fair.
Innovative Control Charting.
ASQ Quality Press: Milwaukee 1998, p. 231.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 15
A Practical Guide to Selecting the Right Control Chart

Interpreting these charts is once again a matter of looking for patterns. In the chart below
we might investigate why Key A is always higher and has the most variability.

Now that you know about these new types of control charts, you’ll want to use software that was built from the ground-
up to support these charts and many others.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 16
A Practical Guide to Selecting the Right Control Chart

With InfinityQS software, any data in the database can be combined and/or compared on any chart. Place
any combination of parts, processes and tests all on the same chart. We call this “million-way analysis.”
ProFicient unique method of storing and retrieving data from its fully-relational database provides for
limitless queries, real-time combinations of any data and over 300 types of charts. We are not talking about
some third-party analysis tool. All this functionality is written by us right into ProFicient. Don’t worry if you
started your data collection strategy down one path and find out after several subgroups that you need
to make a change - every setting in the data entry configuration can be edited on a go-forward basis.
ProFicient can evolve at the speed of your thoughts.

Multiple Data Normalization Methods

It’s one thing to be able to display any data on any chart,
it’s quite another to combine and compare dissimilar
data entered at different times from different work
stations - all on the same chart. The trick is to normalize
the data so they all can share the same scale. The
normalization techniques used by ProFicient are the
same ones pioneered by the father of short run SPC,
Davis Bothe of International Quality Institute.
If you want to chart all outside diameters created
on a particular machine, regardless of feature size,
no problem. If you want to display on a single box
plot all the key characteristics from a particular part,
regardless of feature type, size or unit
of measure, no problem. ProFicient
supports an amazing number of
normalization techniques and
processing options.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 17
A Practical Guide to Selecting the Right Control Chart

Summary
With over 300 types of control charts available we’ve only covered the tip of the iceberg
in this guide. But we hope you see that the adage “If it ain’t broke, don’t fix it” does
not apply when it comes to choosing a control chart. If you are using a control chart
just because it’s what you’ve always used, or what your predecessor used, there may be
room for improvement. Step outside your comfort zone to try some of the charts we’ve
discussed. Or maybe there’s a way to chart something you thought was not possible via
combinations of chart types.

InfinityQS has seasoned statistical process control experts and application engineers
with manufacturing experience who are available to discuss your situation and help you
determine the best type of control chart. So please give us a call. Below are additional
resources that may be of interest.

Additional Resources:

Quality Metrics Survival Handbook

How to Determine In-Process Sampling Strategies

SPC Tools – Online or download the Pocket Card

- Pp and Ppk Fallout Rates

- Control Chart Constants

- Special Cause Rules

- Empirical Rule

- Capability Study

- Capability Formulas

- Control Chart Selection Tree and Formulas (Pocket Card)

Tech Note: Monitoring Multiple Processes on a Single Control Chart (Group Chart)

Tech Note: Tracking Multiple Frozen Food Ingredients on a Single Chart (Group Target Chart)

Tech Note: Monitoring Within-Piece Variability on a Control Chart (3D Chart)

Innovative Control Charting: Practical SPC Solutions for Today’s Manufacturing Environment,

by Doug Fair and Steve Wise, American Society for Quality, 1997, 292 pp.

InfinityQS SPC Strategies Course

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 18
A Practical Guide to Selecting the Right Control Chart

Sidebar: SPC for Very High Sampling Rates

What is high-speed data collection?

In most manufacturing facilities today there is the capability to gather data at ultra-high-speeds. For example, PLC sensors
can send data every second, or even multiple values per second. Because the data are being collected, the tendency is to
want to plot all the values on SPC charts. The thinking is that with all this data streaming in so fast, plotting it on control
charts will instantly show whether the process is in control and whether changes need to be made. However, too much
data can be problematic, plus plotting every data value is usually not in one’s best interest.

Why plotting all the data can be problematic

When the time interval between each data point is uniform and 100% of the data are captured, the conventional
wisdom is to simply plot each value using an IX-MR chart. On an IX-MR chart, remember that control limits are based on
variability between two consecutive samples. Because the average variation between two consecutive points is small,
the resulting control limits on the IX chart will be absurdly tight compared to patterns that appear in the data over time.
In other words, the tight control limits are focusing on the
trees, but the chart is showing a picture of the forest. When
calculated properly, control limits separate the process noise
(common cause variation) from the signals (special causes
of variation), but in the chart below, the correctly calculated
control limits are not serving any useful purpose other than
to confirm that the variability over time (three days of data in
this case) is far greater that the average variability exhibited
between consecutive sampling periods (one minute in this
case).

How to make the data meaningful

We can make ultra-high-speed data more meaningful by
increasing the amount of time between plot points; in other
words, reducing the sampling rate. We’re not suggesting As shown in the chart nearly every plot point is “out of control.”
throwing data away, but rather plot only a portion of the data.
Let the process “breath” a little between plot points. Consider
the minute-by-minute data on the red chart, if we change the
sampling rate to once per hour (plot every 60th point), using
only 1.67% of the data, this creates more meaningful control
limits. The hour-to-hour variation “relaxes” the control limits
and detects only the prominent signals – the one’s that could
require process adjustments.

Notice the pattern is the same as the chart above, but now we
will get appropriate alarms for special cause variations that
require actions. For example, we can clearly see a process
shift at plot point 50, so we would want to investigate why.

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 19
A Practical Guide to Selecting the Right Control Chart

Just because the data are available does not mean that all the data belong on a control chart. There needs to be a
reasonable amount of natural variation to take place between each plot point, otherwise, you’ll wind up with too-tight
control limits.

Limitations of Excel and Pen/Paper Methods

Many quality practitioners still rely on Excel spreadsheets or even pen and paper to collect and chart sampling data.
However these manual methods have significant limitations which software and automated methods overcome. If
you are currently using manual methods for some or all of your analysis, consider the limitations listed below. An
automated SPC software solution is simpler, more efficient, faster, easier to manage and less expensive. Isn’t it time you
take control by implementing an SPC software solution?

Limitations of Excel Limitations of Pen and Paper

Not Real Time Not Real Time

Manual Data Entry Prone to Error/Deletion Highly susceptible to manual errors

Difficult to Compare and Consolidate Data Impossible to Consolidate Data

Cumbersome to Manage Multiple Parts/Process Stream

Time Consuming Analysis and Reporting
Data

Limited Visibility Easily Lost or Misplaced, Extremely Limited Visibility

Lack of Security, Permissions, and Change History Difficult and Costly to Maintain and Store

No Alert or Alarm Capability No Alert or Alarm Capability

Learn More >> Learn More >>

InfinityQS International, Inc. | 12601 Fair Lakes Circle | Suite 250 | Fairfax, VA 22033 | www.infinityqs.com 20