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University of Hail College of Engineering

ME 418 – Quality in Manufacturing

ISE 320 - Quality Control and Industrial Statistics

CHAPTER 07
ACCEPTANCE SAMPLING PLANS

Professor Mohamed Aichouni

http://cutt.us/maichouni

Acceptance Sampling
• Acceptance sampling is a method used to accept or reject
product based on a random sample of the product.

• The purpose of acceptance sampling is to sentence lots (accept

or reject) rather than to estimate the quality of a lot.

• Acceptance sampling plans do not improve quality. The nature

of sampling is such that acceptance sampling will accept some
lots and reject others even though they are of the same quality.

• The most effective use of acceptance sampling is as an auditing

tool to help ensure that the output of a process meets
requirements.

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Acceptance Sampling
Take a Sample
Size ‘n’,
Accept if ‘c’ or less.

Producer Consumer

Risk is a ‘good’ lot will be Risk is a ‘bad’ lot

rejected and sent back. will be accepted.

Acceptance
Sampling Flow
Chart

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Acceptance Sampling

N : sample size

Inspect the
sampling sample

‫عدد القبول‬c :

Acceptance number

Accept the lot Reject the lot

N
5

Terminology
• As mentioned acceptance sampling can reject “good”
lots and accept “bad” lots. More formally:

• Producers risk refers to the probability of rejecting a

good lot.

• AQL (Acceptable Quality Level) - the numerical

definition of a good lot; associated with Producer`s risk.

• The ANSI/ASQC standard describes AQL as “the

maximum percentage or proportion of nonconforming
items or number of nonconformities in a batch that can
be considered satisfactory as a process average”

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Terminology
• Consumers Risk refers to the probability of accepting a
bad lot where:

• LTPD (Lot Tolerance Percent Defective) - the numerical

definition of a bad or poor lot .
• described by the ANSI/ASQC standard as “the
percentage or proportion of nonconforming items or
noncomformities in a batch for which the customer
wishes the probability of acceptance to be a specified low
value.

• Limiting Quality Level - Numerical definition of a ‘poor’

lot, associated with the consumer’s risk.

Types of Sampling Plans

Sampling Plans by
Attributes:
• Single sampling plan by
attributes

• Double sampling plan by

attributes

• Sequential sampling plan

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Single Sampling

Operating Characteristic (OC) curve

The Operating
Characteristic Curve is
typically used to
represent the four
parameters (Producers
Risk, Consumers Risk,
AQL and LTPD) of the
sampling plan.
P on the x axis represents
the percent defective in
the lot.

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Ideal Operating Characteristics Curve

(100% Inspection)

P(Accept Whole
Shipment)
100%
P of Acceptance

Always
Accept Always Reject

0%
0 1 2 3 4 5 6 7 8 9 10
Proportion of non Conforming

Actual OC Curves
• Are determined by sample size [n] and
acceptance number [c].
– Accept the lot if ‘c’ or fewer
nonconforming are obtained, reject if
more.
• OK to assume Binomial distribution (if lot
size is 10x sample size).
• Calculate P accept for range of incoming
p levels.

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Actual OC Curves

P(Accept Whole Shipment)

P < 100 %
Risk to accept bad lot
100% and/or reject a good lot

Accept the
lot Reject the lot

0%
0 1 2 3 4 5 6 7 8 9 10
Cut-Off Proportion of non Conforming

13

Actual OC Curves and the Producer`s Risk and

Consumer`s Risk

100
 = 0.05 AQL
95
P of acceptance

75

50

25

10

= 0.10 0
LTPD for0 1 2 3 4 5 6 7 8 Proportion of non
AQL conforming
LTPD Bad
Good
Indifference zone lot
lot
14

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Sample problem
• Given a lot size of N=2000, a
sample size n=50, and an
acceptance number c=2.
• Calculate the OC curve for this
plan.

Probability of accepting is
obtaining c=2 or less non-
conforming items in samples
of size n=50.

Vary p from 0 to 0.15

(what if p = ….)

OC for possible sampling plans

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Vary n and c

Double Sampling
• In an effort to reduce the amount of inspection double
(or multiple) sampling is used. Whether or not the
sampling effort will be reduced depends on the
defective proportions of incoming lots. Typically, four
parameters are specified:

n1 = number of units in the first sample

c1 = acceptance number for the first sample
n2 = number of units in the second sample
c2 = acceptance number for both samples

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Procedure
• A double sampling plan proceeds as follows:

A random sample of size n1 is drawn from the lot.

If the number of defective units (say d1 )  c1 the lot
is accepted.
If d1 c2 the lot is rejected.
If neither of these conditions are satisfied a second
sample of size n2 is drawn from the lot.
If the number of defectives in the combined samples
(d1 + d2) > c2 the lot is rejected. If not the lot is
accepted.

Double Sampling Plan

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Double Sampling Plan

• Application of double sampling requires that a first sample of
size n1 is taken at random from the (large) lot. The number of
defectives is then counted and compared to the first sample's
acceptance number a1 and rejection number r1. Denote the
number of defectives in sample 1 by d1 and in sample 2 by d2,
then:
– If d1<= a1, the lot is accepted.
If d1 >= r1, the lot is rejected.
If a1 < d1 < r1, a second sample is taken.

• If a second sample of size n2 is taken, the number of defectives,

d2, is counted. The total number of defectives is D2 = d1 + d2.
Now this is compared to the acceptance number a2 and the
rejection number r2 of sample 2. In double sampling, r2 = a2 + 1
to ensure a decision on the sample.
– If D2 <= a2, the lot is accepted.
If D2 >= r2, the lot is rejected.
–

Designing Acceptance Plans

• This should be performed on agreement between the

producer and the consumer.
• Each party work to reduce the risk, by varying n and c
to obtain different OC curves.

• Single and multiple sampling plans can be used.

• Refer to standard published Standards (MIL-STD-

105D, Dodge Romig Tables).

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Acceptance Sampling Plans on Minitab

• Minitab perform all the

necessary calculations to
design acceptance
sampling plans.

• http://blog.minitab.com/bl
og/applying-statistics-in-
quality-projects/attribute-
acceptance-sampling-
for-an-acceptance-
number-of-0

Examples will be worked out next

• sessions

International Standards on Sampling Plans

ISO 2859 - 0:1995 Sampling procedures for inspection by attributes -- Part 0:
Introduction to the ISO 2859 attribute sampling system

ISO 2859 - 1:1999 Sampling procedures for inspection by attri butes -- Part 1:
Sampling schemes indexed by acceptance quality limit
(AQL) for lot - by - lot inspection

ISO 2859 - 1:1999/Cor 1:2001 Sampling procedures for inspection by attributes -- Part 2:
ISO 2859 - 2:1985 Sampling plans indexed by limiting quality (LQ) for isolated
lot i nspection

ISO 2859 - 3:1991 Sampling procedures for inspection by attributes -- Part 3:

Skip - lot sampling procedures

ISO 2859 - 4:2002 Sampling procedures for inspection by attributes -- Part 4:

Procedures for assessment of declared quality levels

ISO 3951:1989 Sampling procedures and charts for inspection by variables

for percent nonconforming

ISO 8422:1991 Sequential sampling plans for inspection by attributes

ISO 8422:1991/Cor 1:1993 Sequential sampling plans for inspection by variables for
ISO 8423:1991 percent nonconforming (known stan dard deviation)

ISO 8423:1991/Cor 1:1993 Guide for the selection of an acceptance sampling system,
ISO/TR 8550:1994 scheme or plan for inspection of discrete items in lots

ISO 10725:2000 Acceptance sampling plans and procedures for the

inspection of bulk materials

ISO 11648 - 1:2003 Statistical aspects of sampling from bulk materials -- Part
1: General principles

ISO 11648 - 2:2001 Statistical aspects of sampling from bulk materials -- Part
2: Sampling of particulate materials

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Conclusion Lecture Finished

"Quality control truly

Any No
begins and ends Question?
with education",
K. Ishikawa (1990). Yes
Ask questions

Teachers answers

Train your self (Google, YouTube,

course webpage

End
(See you next lecture)

University of Hail College of Engineering

ME 418 – Quality in Manufacturing

ISE 320 - Quality Control and Industrial Statistics

CHAPTER 06 – PART 2
ACCEPTANCE SAMPLING PLANS
EXAMPLES ON MINITAB

Professor Mohamed Aichouni

http://faculty.uoh.edu.sa/m.aichouni/me418-quality
http://faculty.uoh.edu.sa/m.aichouni/ise230-quality/

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Acceptance Sampling Plans on Minitab

• http://blog.minitab.com/blog/applying-statistics-in-quality-projects/attribute-
acceptance-sampling-for-an-acceptance-number-of-0

Acceptance Sampling Plans on Minitab

This graph represents the

probability to accept a batch for
a given proportion of defectives.

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Acceptance Sampling Plans on Minitab

Acceptance Sampling Plans on Minitab

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Acceptance Sampling Plans on Minitab

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