Statistical Process

Control
With Usage of X Bar
charts and R charts.
By,
Pradeep Nayar(Roll No-24/2009).
Abhishek Kumar(Roll No- 13/2009)
Rohit Siddhu(Roll No-18/2009).
 Why It is Required?
• All processes are subject to some variation — this variation can either be
inherent in the process or imposed on the process by some outside force. By
observing the variability in the process output and comparing this to
statistically calculated limits, objective decisions about when to take action
can be made. Without truly understanding the cause of the process variation,
resources may be wasted reacting to variation that is normal.
• All manufacturing processes, where the process requires inputs, something is
done to those inputs to form outputs. This is a process and there will be
variation in this process. The challenge is to statistically determine what is
“normal” versus when some corrective action or more attention is required;
internet processes, Statistical Process Control is used to determine click-
fraud also, Statistical Process Control can help one better understand whether
or not the process is performing as statistically expected. If not, then it is a
signal for corrective action or more attention.
Statistical Process
Control
• Statistical Process Control (SPC) can be
thought of as the application of statistical
methods for the purposes of quality control
and improvement

• Quality Improvement is perhaps foremost

among all areas in business for application
of statistical methods.
 Types of Variation
• Common Cause Variation is fluctuation caused by many random
factors resulting in random distribution of the output around a mean.
Common cause variation is a measure of the process’s potential or
how well the process will perform when all the special cause
variation is removed. Common cause variation is also called random
variation, noise, non-controllable variation, within-group variation,
inherent variation, or an in statistical control process.
• Special Cause Variation is caused by a specific factor that results
in a non-random distribution of output. Special Cause Variation can
cause a shift or trend in the output and can usually be reduced or
eliminated through local actions. Special Cause variation is also
referred to as “exceptional” or “assignable” variation. Variation due
to an identifiable out-of-the-ordinary event, not a usual part of the
process.
Control Charts are often used as part of process control systems. They were
developed by W. A. Shewhart in 1924 while working for Bell Telephone
Laboratories.
Control Charts consists of a center line and two boundary lines placed above
and below the center line (the control limits). Control limits are based on the
variability within the data. Values are plotted to determine the state of the
process. Control Charts tell we how the process is performing – they do not
contain Specification Limits.
Control charts can be viewed as a distribution plotted on its side – if we created
a histogram of the points, we would expect this to show a normal distribution
(assuming the process stays in control.in this case the Lower Control Limit
(LCL) and Upper Control Limit (UCL), then the process is said to be
performing as statistically expected. But, more attention needs to be had if the
outputs of this process go beyond the LCL and UCL
Control Charts: Recognizing Sources
of Variation
Why Use a Control Chart?
– To monitor, control, and improve process performance over time by
studying variation and its source.
What Does a Control Chart Do?
– Focuses attention on detecting and monitoring process variation over
time;
– Distinguishes special from common causes of variation, as a guide to
local or management action;
– Serves as a tool for ongoing control of a process;
– Helps improve a process to perform consistently and predictably for
higher quality, lower cost, and higher effective capacity;
– Provides a common language for discussing process performance.
 Two Types of Control Charts
• Variable Control Charts
• Attribute Control Charts

• Deal with items that

Control charts that can be measured .
factor in the quality • Examples
attributes of a 1) Weight
process to
2) Height
determine if the
process is 3) Speed
performing in or 4) Volume
out of control. X Bar,R Chart, and MA
P Chart, C Chart, U Chart.
Chart.
X-bar and R-range chart: What is
An X-bar and R (range) chart is a pair of control charts used with processes that
have a subgroup size of two or more. The standard chart for variables data, X-
bar and R charts help determine if a process is stable and predictable.

The X-bar chart shows how the mean or average changes over time and the R
chart shows how the range of the subgroups changes over time. It is also used
to monitor the effects of process improvement theories. As the standard, the X-
bar and R chart will work in place of the X-bar and s or median and R chart.
Assumptions:
•Used for measurement data.
•Assumes population is normally Distributed
•Upper and lower control limits usually 3 standard deviations above and
below the mean of the process
X-bar and
range chart:
What does it
look like?
The X-bar chart, on top,
shows the mean or average
of each subgroup. It is used
to analyze central location.
The range chart, on the
bottom, shows how the data
is spread. It is used to study
system variability.
X-bar and range chart: When is it
used?
We can use X-bar and R charts for any process with a subgroup size greater
than one. Typically, it is used when the subgroup size falls between two and
ten, and X-bar and s charts are used with subgroups of eleven or more.
Use X-bar and R charts when we can answer yes to these questions:
•Do we need to assess system stability?
•Is the data in variables form?
•Is the data collected in subgroups larger than one but less than eleven?
•Is the time order of subgroups preserved?
X-bar and range chart: How to use?
•Collect as many subgroups as possible before calculating control limits. With smaller
amounts of data, the X-bar and R chart may not represent variability of the entire
system. The more subgroups we use in control limit calculations, the more reliable the
analysis. Typically, twenty to twenty-five subgroups will be used in control limit
calculations.
•X-bar and R charts have several applications. When beginning to improve a system,
use them to assess the system’s stability.
•After the stability has been assessed, determine if we need to stratify the data. We may
find entirely different results between shifts, among workers, among different
machines, among lots of materials, etc. To see if variability on the X-bar and R chart is
caused by these factors, collect and enter data in a way that lets we stratify by time,
location, symptom, operator, and lots.
•We can also use X-bar and R charts to analyze the results of process improvements.
Here we would consider how the process is running and compare it to how it ran in the
past. Do process changes produce the desired improvement?
•Finally, use X-bar and R charts for standardization. This means we should continue
collecting and analyzing data throughout the process operation. If we made changes to
the system and stopped collecting data, we would have only perception and opinion to
tell we whether the changes actually improved the system. Without a control chart,
there is no way to know if the process has changed or to identify sources of process
variability.
When to Use an X-bar / R Chart
X-bar / Range charts are used when you can rationally collect measurements in groups
(subgroups) of between two and ten observations. Each subgroup represents a
"snapshot" of the process at a given point in time. The charts' x-axes are time based, so
that the charts show a history of the process. For this reason, you must have data that is
time-ordered; that is, entered in the sequence from which it was generated. If this is not
the case, then trends or shifts in the process may not be detected, but instead attributed
to random (common cause) variation.
For subgroup sizes greater than ten, use X-bar / Sigma charts, since the range statistic is
a poor estimator of process sigma for large subgroups. In fact, the subgroup sigma is
ALWAYS a better estimate of subgroup variation than subgroup range. The popularity
of the Range chart is only due to its ease of calculation, dating to its use before the
advent of computers. For subgroup sizes equal to one, an Individual-X / Moving Range
chart can be used, as well as EWMA or Cu Sum charts.
X-bar Charts are efficient at detecting relatively large shifts in the process average,
typically shifts of +-1.5 sigma or larger. The larger the subgroup, the more sensitive the
chart will be to shifts, providing a Rational Subgroup can be formed. For more
sensitivity to smaller process shifts, use an EWMA or Cu Sum chart.
 How to Calculate the control
limits ?
• X-bar Chart: • R chart:
– Lower Control Limit:
Lower Control Limit: • R-Bar – 3*d3*sigma
• Mean – 3*sigma – Center Line:
n(1/2) • R-Bar
Center Line:
– Upper Control Limit:
• Process mean
• R-Bar + 3*d3*sigma
Upper Control Limit:
• Mean + 3*sigma
n(1/2)
 Sample
Size
• First Step: Determine
• The sample set of data what type of data you are
should be greater than working with.
28. • Second Step: Determine
• The data should have what type of control
been collected uniformly chart to use with your
• The data should contain data set.
multiple capable points • Third Step: Calculate the
average and the control
of data, or the
limits.
information is incorrect.
Interpreting the Range
Chart
• Always look at the Range chart first. The
control limits on the X-bar chart are derived
from the average range, so if the Range chart
is out of control, then the control limits on
the X-bar chart are meaningless.
• After reviewing the Range chart, interpret
the points on the X-bar chart relative to the
control limits and Run Tests. Never consider
the points on the X-bar chart relative to
specifications, since the observations from
the process vary much more than the
subgroup averages.
• Interpreting the Range Chart
• On the Range chart, look for out of control points. If there are any, then the special causes must
be eliminated. Brainstorm and conduct Designed Experiments to find those process elements
that contribute to sporadic changes in variation. To use the data you have, turn Auto Drop ON,
which will remove the statistical bias of the out of control points by dropping them from the
calculations of the average Range, Range control limits, average X-bar and X-bar control limits.
• Also on the range chart, there should be more than five distinct values plotted, and no one value
should appear more than 25% of the time. If there are values repeated too often, then you have
inadequate resolution of your measurements, which will adversely affect your control limit
calculations. In this case, you'll have to look at how you measure the variable, and try to measure
it more precisely.
• After reviewing the Range chart, look for out of control points on the X-bar Chart. If there are
any, then the special causes must be eliminated. Brainstorm and conduct Designed Experiments
to find those process elements that contribute to sporadic changes in process location. To use the
data you have, turn Auto Drop ON, which will remove the statistical bias of the out of control
points by dropping them from the calculations of the average X-bar and X-bar control limits.
• Look for obviously non-random behavior. Turn
on the Run Tests, which apply statistical tests for
trends to the plotted points.
• If the process shows control relative to the
statistical limits and Run Tests for a sufficient
period of time (long enough to see all potential
special causes), then we can analyze its capability
relative to requirements. Capability is only
meaningful when the process is stable, since we
cannot predict the outcome of an unstable process.
Average
The Average, sometimes called X-Bar, is calculated for a set of n data values
as:

An example of its use is as the plotted statistic in an X-Bar Chart. Here, the
n is the subgroup size, and x-bar indicates the average of the observations
in the subgroup.
When dealing with subgrouped data, you can also calculate the overall
average of the subgroups. It is the average of the subgroups' averages, so is
sometimes called X-doublebar.

where n is the subgroup size and m is the total number of subgroups

included in the analysis.
When the subgroup size is 1, this equation simplifies to:
X Bar Chart Calculations
Plotted statistic
UCL , LCL (Upper and Lower Control Limit)

where x-double bar is the Grand Average and 

where R-bar is the Average Range , or

where S-bar is the Average Sigma .

x is Process Sigma, which is calculated using the Subgroup Range or

Subgroup Sigma statistic.
Range Chart Calculations
Plotted statist

where R-bar is the Average Range , d3 is a function of n (available in any

statistical quality control textbook), and 

where x1, x2, … are the n observations in subgroup j

Center Line
Average Range
UCL , LCL (Upper and Lower Control Limit)

x is Process Sigma, which is calculated using the Subgroup Range .

where D3 and D4 are a function of n.

 Final Step
• Make a recommendation to your company.
– The process is capable
– The process is not capable
• The following errors were found.
• The process needs improvement
• The variations are normal in the system and we must
accept them.