Quality Basics

6th Edition

Chapter 6
Variables Control
Chart

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 Chapter 6: Variable Control Charts
• Dr. Walter Shewhart (1891-1967)
– Father of Statistical Process Control
– Inventor of Control Charts
– Proposed concept of common cause and special cause
variation

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• Dr. Walter Shewhart (1891-1967)
– A phenomenon will be said to be controlled when, through the use
of past experience, we can predict, at least within limits, how the
phenomenon may be expected to vary in the future. Here it is
understood that prediction within limits means that we can state,
at least approximately, the probability that the observed
phenomenon will fall within the given limits.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• Controlled variation, chance, or common causes:
– Variation present in a process due to the very nature of
the process.
– Small random changes in the process that cannot be
avoided.
– Consistently affect the process and its performance
day after day, every day.
– This type of variation can be removed from the process
only by changing the process.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• Uncontrolled variation, special, or assignable
causes
– Come from sources external to the process.
– This type of variation is not normally part of the
process.
– Assignable causes are variations in the process that
can be identified and isolated as the specific cause of a
change in the behavior of the process.
– This type of variation arises because of special
circumstances.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• Control charts serve two basic functions:
1. Decision-making tools that provide an economic basis for
making a decision as to whether to investigate for
potential problems, to adjust the process, or to leave the
process alone.
a. Control charts provide information for timely decisions
concerning recently produced items.
b. Control chart information is used to determine the process
capability, or the level of quality the process is capable of
producing. Samples of completed product can be statistically
compared with the process specifications. This comparison
provides information concerning the process’s ability to meet
the specifications set by the product designer.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
2. Problem-solving tools that point out where
improvement is needed.
a. Control chart information can be used to help locate and
investigate the causes of the unacceptable or marginal quality.
By observing the patterns on the chart the investigator can
determine what adjustments need to be made.
b. During daily production runs, the operator can monitor machine
production and determine when to make the necessary
adjustments to the process or when to leave the process alone
to ensure quality production.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• Several types of variation are tracked with statistical
methods. These include:
1. Within-piece variation, or the variation within a single item or
surface.
2. Piece-to-piece variation, or the variation that occurs among
pieces produced at approximately the same time.
3. Time-to-time variation, or the variation in the product produced at
different times of the day.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• The centerline of a variable control chart shows where the process
average is centered, the central tendency of the data.
• The upper control limit (UCL) and lower control limit (LCL) describe the
spread of the process.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• To create a variable control chart:
1. Define the problem to be studied.
2. Select the quality characteristic to be measured.
3. Choose a rational subgroup size to be sampled.
4. Collect the data.
5. Determine the trial centerline for the X-bar chart.
6. Determine the trial control limits for the X-bar chart.
7. Determine the centerline and control limits for the R chart.
8. Examine the process control charts and interpret.

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts

m
 Xi
i1
X
m
UCL X  X  A 2 R
LCL X  X  A 2 R

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts

m
 Ri
i1
R
m
UCL R  D 4 R
LCL R  D3R

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts
• A control chart exhibits a state of control when:
1. Two-thirds of the points are near the center value.
2. A few of the points are on or near the center value.
3. The points appear to float back and forth across the centerline.
4. The points are balanced (in roughly equal numbers) on both sides of the
centerline.
5. There are no points beyond the control limits.
6. There are no patterns or trends on the chart.

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 Chapter 6: Variable Control Charts

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Chapter 6: Variable Control Charts

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 How to select your control chart

Chapter 6: Variable Control Charts

Control charts for

variables

Control chart for

atributes

Page 207 online text

Page 194 international edition
Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Formulas – X bar and R chart

Page – 208 – online text

Page – 195 – international edition

X Bar – Std Deviation charts – non

examinable

Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.
 Appendix 2 – Pg 491 – online text
Appendix – Pg 220 – International edition
Copyright © 2018, 2012, 2007 Pearson Education, Inc. All Rights Reserved.