CONTROL CHARTS

INTRODUCTION
Introduced in 1926 by WALTER SHEWART, who concluded that a

distribution can be transformed into normal shape by estimating

mean and standard deviation.

Control chart is a device which specifies the state of statistical control.

Control chart detects the variation in processing and warns if there is

any deviation from the specified tolerance limits.

The purpose of using control chart is to stabilize process by keeping it

under control and carrying out necessary adjustments (on line).

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ADVANTAGES
A control chart indicate whether the process is in control or out of

control.

It determines the process variability and detects unusual variations

in a process.

It ensures product quality level.

It warns in time and if process is rectified at that time percentage of

rejection can be reduced.

It provides information about selection of process and setting up of

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CLASSIFICATION
CONTROL
CHART

VARIABLE ATTRIBUTE
CONTROL CONTROL
CHART CHART

X- BAR & R X-BAR & X&mR PERCENTAGE NO OF

CHART S CHART CHART OF DEFECTS DEFECTIVIES
1.P-CHART 1.C-CHART
2.np- CHART 2.U-CHART

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Variation
 No two natural items in any category are the
same.
 Variation may be quite large or very small.
 If variation very small, it may appear that
items are identical, but precision instruments
will show differences.
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3 Categories of variation
 Within-piece variation
• One portion of surface is rougher than another portion.
 A piece-to-piece variation
• Variation among pieces produced at the same time.
 Time-to-time variation
• Service given early would be different from that given later
in the day.

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Source of variation
 Equipment
• Tool wear, machine vibration, …

 Material
• Raw material quality

 Environment
• Temperature, pressure, humidity

 Operator
• Operator performance- physical & emotional

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Control Chart Viewpoint

 Variation due to
 Common or chance causes
 Assignable causes

Control chart may be used to discover “assignable

causes”

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Control chart functions
 Control charts are powerful aids to
understanding the performance of a process
over time.
Input Output

PROCESS

What’s causing variability?

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Control charts identify variation
 Chance causes - “common cause”
• inherent to the process or random and not controllable

• if only common cause present, the process is

considered stable or “in control”

 Assignable causes - “special cause”
• variation due to outside influences

• if present, the process is “out of control”

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Control charts help us learn more about
processes

 Separate common and special causes of variation

 Determine whether a process is in a state of
statistical control or out-of-control
 Estimate the process parameters (mean, variation)
and assess the performance of a process or its
capability
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Control charts to monitor processes
 To monitor output, we use a control chart
• we check things like the mean, range, standard

deviation
 To monitor a process, we typically use two
control charts
• mean (or some other central tendency measure)

• variation (typically using range or standard deviation)

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 Types of Data

 Variable data
• Product characteristic that can be measured
 Length, size, weight, height, time, velocity

 Attribute data
Product characteristic evaluated with a discrete choice
• Good/bad, yes/no
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CONTROL CHARTS FOR
VARIABLES

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Introduction
A single measurable quality characteristic ,such as dimension,

weight, or volume, is called variable.

Since statistical control for continuous data depends on both the

mean and the variability, variables control charts are constructed to

monitor each.

The most commonly used chart to monitor the mean is called the X-

BAR chart.

There are two commonly used charts used to monitor the

variability: the R chart and the S chart.

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Variable control charts
X-BAR Chart:
This chart is called the X-BAR chart because the
statistic being plotted is the sample mean.
 The reason for taking a sample is because we are
not always sure of the process distribution.
 By using the sample mean we can "invoke" the
central limit theorem to assume normality.
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Variable control charts
R Chart

 The R chart is used to monitor process variability when

sample sizes are small (n<10), or to simplify the

calculations made by process operators.

 This chart is called the R chart because the statistic being

plotted is the sample range.

 Using the R chart, the estimate of the process standard
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Variable control charts
S Chart

 The s chart is used to monitor process variability

when sample sizes are large (n*10), or when a
computer is available to automate the calculations.

 This chart is called the s chart because the statistic

being plotted is the sample standard deviation.

 Using the s chart, the estimate of the process

standard deviation, σ, is
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X-bar and R charts
 The X- bar chart is developed from the average
of each subgroup data.
• used to detect changes in the mean between subgroups.

 The R- chart is developed from the ranges of

each subgroup data
• used to detect changes in variation within subgroups

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X-bar and S charts
 The X- bar chart is developed from the average
of each subgroup data.
• used to detect changes in the mean between subgroups.

 The S- chart is developed from the standard

deviation of each subgroup data
• used to detect changes in variation within subgroups

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PROCEDURE FOR USING VARIABLES CONTROL CHARTS:

I. Determine the variable to monitor.

II. At predetermined, even intervals, take samples of size n (usually n=4 or 5).
III. Compute X BAR and R (or s) for each sample, and plot them on their respective
control charts. Use the following relationships:

IV. After collecting a sufficient number of samples, k (k>20), compute the control
limits for the charts. The following additional calculations will be necessary:

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V. If any points fall outside of the control limits, conclude that the process is out
of control, and begin a search for an assignable or special cause. When the
special cause is identified, remove that point and return to step 4 to re-evaluate
the remaining points.
VI. If all the points are within limits, conclude that the process is in control, and
use the calculated limits for future monitoring of the process.

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EXAMPLE PROBLEM
A large hotel in a resort area has a housekeeping staff that cleans and prepares all of
the hotel's guestrooms daily. In an effort to improve service through reducing
variation in the time required to clean and prepare a room, a series of measurements
is taken of the times to service rooms in one section of the hotel. Cleaning times for
five rooms selected each day for 25 consecutive days appear below:

Day Room 1 Room 2 Room 3 Room 4 Room 5

1 15.6 14.3 17.7 14.3 15
2 15 14.8 16.8 16.9 17.4
3 16.4 15.1 15.7 17.3 16.6
4 14.2 14.8 17.3 15 16.4
5 16.4 16.3 17.6 17.9 14.9
6 14.9 17.2 17.2 15.3 14.1
7 17.9 17.9 14.7 17 14.5
8 14 17.7 16.9 14 14.9
9 17.6 16.5 15.3 14.5 15.1
10 14.6 14 14.7 16.9 14.2

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11 14.6 15.5 15.9 14.8 14.2

12 15.3 15.3 15.9 15 17.8

13 17.4 14.9 17.7 16.6 14.7

14 15.3 16.9 17.9 17.2 17.5

15 14.8 15.1 16.6 16.3 14.5

16 16.1 14.6 17.5 16.9 17.7

17 14.2 14.7 15.3 15.7 14.3

18 14.6 17.2 16 16.7 16.3

19 15.9 16.5 16.1 15 17.8

20 16.2 14.8 14.8 15 15.3

21 16.3 15.3 14 17.4 14.5

22 15 17.6 14.5 17.5 17.8

23 16.4 15.9 16.7 15.7 16.9

24 16.6 15.1 14.1 17.4 17.8

25 17 17.5 17.4 16.2 17.9

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CALCULATE THE MEAN, RANGE, STANDARD DEVIATION

Day Average Range St. Dev 11 15 1.7 0.69

12 15.9 2.8 1.13
1 15.4 3.4 1.41
13 16.3 3 1.39
2 16.2 2.6 1.19
14 17 2.6 1
3 16.2 2.2 0.85 15 15.5 2.1 0.93
16 16.6 3.1 1.26
4 15.5 3.1 1.27
17 14.8 1.5 0.65
5 16.6 3 1.19 18 16.2 2.6 0.98
6 15.7 3.1 1.4 19 16.3 2.8 1.02
20 15.2 1.4 0.58
7 16.4 3.4 1.69
21 15.5 3.4 1.37
8 15.5 3.7 1.71 22 16.5 3.3 1.59

9 15.8 3.1 1.24 23 16.3 1.2 0.51

24 16.2 3.7 1.56
10 14.9 2.9 1.16
25 17.2 1.7 0.64

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CALCULATE THE CONTROL LIMITS

X R s
15.94 2.7 1.14

X-BAR , R CHART X- BAR ,S CHART

x Chart Control Limits

UCL = x + A 2 R
LCL = x - A 2 R

R Chart Control Limits

UCL = D 4 R
LCL = D 3 R
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TABLE FOR CONSTANTS

SQC A MODERN
INTRODUCTION
6th Edition,
D.C. Montgomery
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CONSTANTS FOR X-BAR ,R & X-BAR, S CHARTS

X-BAR , R CHART X-BAR , S CHART

A2 D4 D3 A3 B4 B3
0.577 2.004 0 1.427 2.089 0

X-BAR CHART X-BAR CHART

CL =15.94 CL =15.94
UCL = 15.94+ 0.577(2.7) = 17.49 UCL = 15.94+ 1.427(1.14) = 17.56
LCL = 15.94 – 0.577(2.7) = 14.38 LCL = 15.94 – 1.427(1.14) = 14.31

R CHART S CHART

CL = 2.7 CL = 1.14
UCL = 2.004(2.7) = 5.41 UCL = 2.089(1.14) = 2.38
LCL = 0 (2.7) = 0 LCL = 0 (1.14) = 0
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X-BAR , R CONTROL CHART

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X-BAR,S CONTROL CHART

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