Quality Control

Chapter 8
Control Charts for
Attributes

Quality Control –Lecture8 Mechatronics- Batch 3

 Outline
 Attribute
 Control Charts for Nonconforming Units
 Control Charts for Count of Nonconformities
 A Quality Rating System

Quality Control –Lecture8 Mechatronics- Batch 3

 Learning Objectives
When you have completed this chapter you should:
 Know limitations of variable control charts and the
different types of attribute charts.
 Know the objectives of the p chart group and the
applicable distribution.
 Be able to construct a:
 Fraction defective chart- fixed subgroup size
 Fraction defective chart-variable subgroup size
 Percent defective chart
 Number defective chart
Quality Control –Lecture8 Mechatronics- Batch 3
 Learning Objectives cont’d.

When you have completed this chapter you should:

 Know how to minimize the effect of variable subgroup
size.
 Know the applications of the c chart group, the
applicable distribution and two conditions.
 Be able to construct a c chart and a u chart and know
the difference between them.
 Know the three classes of defect severity

Quality Control –Lecture8 Mechatronics- Batch 3

 Attribute
 The term Attribute refers to those quality characteristics that conform to
specifications or do not conform to specifications(e.g. OK-NG, Accept-Reject).
 Classify each item inspected: conforming or nonconforming.
nonconforming A quality
characteristic that does not meet certain prescribed standards (or specifications) is
said to be a nonconformity or defect.
 Fraction nonconforming: is the ratio of #{nonconforming items} in a
population to the total number of items in that population.
 The sample fraction nonconforming is the ratio of the number of
nonconforming units in the sample to the sample size n
 Attribute types of usage are :
1. Where measurements are not possible: i.e, visually inspected items such as
color, missing parts, scratches, and damage.
2. Where measurements can be made but are not made because of time, cost,
or needs.
e.g. use: “go–no go gauge, fitting jig”.
Quality Control –Lecture8 Mechatronics- Batch 3
 Attribute
 Important terms to differentiate defect and defective, nonconformity
and nonconforming units.
 Consider a wafer with a number of chips on it. The wafer is referred
to as an "item of a product". The chip may be referred to as "a specific
point". There exist certain specifications for the wafers. When a
particular wafer (e.g., the item of the product) does not meet at least
one of the specifications, it is classified as a nonconforming item.
Furthermore, each chip, (e.g., the specific point) at which a
specification is not met becomes a defect or nonconformity.
 Defect ~ items that contribute to nonconformity of a quality
characteristics.
 Defective ~ part/product inspected not conforming or meeting
specification (can have > 1 defects)

Quality Control –Lecture8 Mechatronics- Batch 3

 Attribute
 A nonconforming unit contains at least one nonconformity.
A nonconforming item: is a product or item with one or
more nonconformities, such that it is unable to meet the
intended standards and is unable to function as required. On
the other hand, it should be pointed out that a wafer can
contain several defects but still be classified as conforming.
 A nonconformity:
nonconformity is a departure of a quality
characteristic from its intended level or state that occurs
with a severity sufficient to cause an associated product or
service not to meet a specification requirement.
Nonconformity is concerned with satisfying intended normal
or reasonably foreseeable usage requirement.

Quality Control –Lecture8 Mechatronics- Batch 3

 Attribute
 Defect is appropriate for use when evaluation is in terms of
usage.
 Nonconformity is appropriate when evaluation is in terms of
conformance to specifications.
 The term Defective Unit is used to describe a unit of product
or service containing at least one Defect. It is analogous to
defect and is appropriate for use when unit of product or service
is evaluated in terms of usage rather than conformance to
specifications.
 The term Nonconforming Unit is used to describe a unit of
product or service containing at least one nonconformity.

Quality Control –Lecture8 Mechatronics- Batch 3

 Control Chart for Attributes
 Advantages of attribute control charts:
 Sometimes, the quality control engineer has a choice between
variable control charts and attribute control charts.
1. Allowing for quick summaries: that is the engineer may simply
classify products as acceptable or unacceptable, based on
various quality criteria.
2. Attribute charts sometimes find a way around the need for:
expensive, precise devices and time-consuming measurement
procedures.
3. More easily understood by managers unfamiliar with quality
control procedures.

Quality Control –Lecture8 Mechatronics- Batch 3

 Why Control Chart for Attributes?
 Limitations of variable control charts:

⁕ Variable control charts cannot be used for quality

characteristics which are attributes & the converse is not true.
In other words, non-conformities such as missing parts,
incorrect color, and so on, are not measureable, and a variable
control chart is not applicable.
⁕ Another limitation concerns the fact that there are many
variables in a manufacturing entity ~1000 variable quality
characteristics. Clearly, this would be too expensive and
impractical.
⁕ A control chart for attributes can also minimize this limitation
by providing overall quality information at a fraction of the cost
Quality Control –Lecture8 Mechatronics- Batch 3
Control Chart for Attributes
 Advantages of variable control charts :
1. More sensitive than attribute control charts.
2. Variable control charts may alert us to quality problems
before any actual "unacceptable" (as detected by the
attribute chart) will occur.
3. Montgomery (1985) calls the variable control charts
leading indicators of trouble that will sound an alarm
before the number of rejects (scrap) increases in the
production process.

Quality Control –Lecture8 Mechatronics- Batch 3

 Types of Attribute Charts:
 The attribute control charts are grouped into two categories.
 Control charts for fraction defective/
defective non-conforming units,
which are based on binomial distributions and focus on:
n p-chart for the proportion of nonconforming/defective items (p), and
n np-chart for the number of nonconforming/defective items (np).
 Control charts focus on the defects/
defects nonconformities itself, based
on Poisson distributions. Control charts involving counts can be
either for the total number of nonconformities (defects) for the
sample of inspected units, or for the average number of defects per
inspection unit and includes:
n c-chart for the total number of nonconformities/
nonconformities defects.
defects
n u-chart for nonconformities/defects per unit.

Quality Control –Lecture8 Mechatronics- Batch 3

 Types of Attribute Charts:
We may describe the outcome of the inspection in two
distinct ways:
1.Control Charts for Defectives or Nonconforming Units
(Binomial distribution): p chart, np chart.
2.We may examine each piece and record it as a "good" one
if it contains no defects, or record it as a "defective" one if it
contains any defects. In this scoring, every piece is either a
good one or a defective one.
3.After inspecting n pieces we will have found say d of them
to be defectives and n-d of them to be good ones.
4.We emphasize that a defective piece may have one defect or
several, but it still counts as just one defective.
Quality Control –Lecture8 Mechatronics- Batch 3
 Types of Attribute Control Charts:
2. Control Charts for Defects or Nonconformities (based on the Poisson
distribution): c chart, u chart.
 Count and record the number of defects we find on a single piece. This
count may be 0,1,2, ... Such an approach of counting defects on a piece
becomes especially useful if most of the pieces contain one or more
defects.
 Then the count tells not only that the piece is a defective, but how
defective it is.
 Examples of defect counting might be: (a) defects in a complicated
electronic or mechanical assembly, (b) typographical errors on a page,
(c) accidents in a month, (d) flaws on a sheet of paper or metal.
 We may count the defects on a single unit or on a sample of n units,
recording the count as c defects. We thus count defects on a field of
opportunity for defects to occur.
Quality Control –Lecture8 Mechatronics- Batch 3
Types of Attribute control charts
Four types of attributes control charts include the following:
1. P-charts  A single chart that tracks the percentage of
nonconforming items in each sample
 Sample sizes, n, are large, usually 100 pieces or more.
2. np-charts  Tracks the number of nonconforming items in each
sample
 Easier to use than the p-chart because the percentage of
defective items does not have to be calculated, but it has
one restrictions: All the samples must be the same size
3. c charts  Graphs the total number of nonconformance found in
each piece or unit that is inspected
4. u charts  Samples are taken and the total number of
nonconformance in the sample is determined
 Tracks the average number of nonconformance per unit

Quality Control –Lecture8 Mechatronics- Batch 3

Quality Control –Lecture8 Mechatronics- Batch 3
Quality Control –Lecture8 Mechatronics- Batch 3
Quality Control –Lecture8 Mechatronics- Batch 3
 The P Chart
 The P Chart is used for data that consist of the proportion of
the number of occurrences of an event to the total number of
occurrences.
occurrences p is the fraction nonconforming (defective) in a
lot or population, which is defined as the ratio of the number of
nonconforming items in the population to the total number of
items in that population.
population
 It is used in quality to report the fraction or percent
nonconforming in a product, quality characteristic, or group of
quality characteristics.
 The sample size n should be equal to or larger than 20 and the
probability of a single success, p, should be smaller than or
equal to 0.05. If n≥100, the approximation is excellent if np is
alsoControl
Quality ≤10.–Lecture8 Mechatronics- Batch 3
 The P Chart
np
p 
n

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
 It can be used to control one quality characteristic,
as is done with X bar and R chart,
 Or to control a group of quality characteristics of
the same type or of the same part,
 Or to control the entire product.
 It can be established to measure the quality
produced by a work center, by a department, by a
shift, or by an entire plant.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
 It is frequently used to report the
performance of an operator, group
of operators, or management as a
means of evaluating their quality
performance.
 The subgroup size of the P chart can
be either variable or constant.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
Objectives of the P Chart:
1. Determine the average quality level: This
information provides the process
capability in terms of attributes.
2. Bring to the attention of management any
changes in the average.
3. Improve the product quality: Ideas for
quality improvement.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
Objectives of the P Chart cont’d:
4. Evaluate the quality performance of operating
and management personnel.
5. Suggest places to use X bar and R chart: They
are more sensitive to variation. In other words,
the chart for nonconforming units suggests the
source of difficulty, and the X-bar and R
charts find the cause.
6. Determine acceptance criteria of a product
before shipment to the customer.
Quality Control –Lecture8 Mechatronics- Batch 3
 The P Chart

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
P Chart Construction for Constant Subgroup Size
cont’d.
2. Determine the subgroup size and method:
 The size of the subgroup is a function of
the proportion nonconforming.
 A minimum size of 50 is suggested as a
starting point.

Quality Control –Lecture8 Mechatronics- Batch 3

The P Chart: size of the subgroup

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
P Chart Construction for Constant Subgroup Size & no Standard Specified.
4.Calculate the trial central line and the control limits:

p
 np  For a binomial distribution to be strictly

n valid, the probability of obtaining a

nonconforming item must remain constant
from item to item. The samples must be
p (1  p )
UCL  p  3 identical and are assumed to be
n independent.
 The proportion nonconforming is defined
p (1  p ) as: where x is the number of
LCL  p  3 nonconforming items in the sample
n and n represent ts the sample size.

 The distribution of the number of

nonconforming items in a sample, as given
by a binomial distribution, is
Quality Control –Lecture8 Mechatronics- Batch 3
 Example

Quality Control –Lecture8 Mechatronics- Batch 3

 Example

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
P Chart Construction for Constant Subgroup Size
cont’d.
5. Establish the revised central line and control limits.

pnew  p0 
 np  np d

n  n d

p0 (1  p0
UCL  p0  3
n
p0 (1  p0 )
LCL  p0  3
n

Quality Control –Lecture8 Mechatronics- Batch 3

Quality Control –Lecture8 Mechatronics- Batch 3
 The P Chart
 The P Chart is most effective if it is posted
where operating and quality personnel can view
it.
 The control limits are usually three standard
deviations from the central value. Therefore,
approximately 99% of the plotted points, P, will
fall between the upper and lower control limits.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
 A P Chart will also indicate long-range trends in
quality, which will help to evaluate changes in
personnel, methods, equipment, tooling, materials,
and inspection techniques.
 P-chart is based on the binomial distribution:
Because the p chart is based on the binomial
distribution, there must be a constant chance of
selecting a nonconforming unit. In some operations,
if one nonconforming unit occurs, all units that
follow will be nonconforming until the condition is
corrected.
Quality Control –Lecture8 Mechatronics- Batch 3
 The P Chart
P Chart Construction for Variable Subgroup Size
1. Collect the data.
2. Determine the trial central line and control
limits: Since the subgroup size changes each day,
limits must be calculated for each day.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
P Chart Construction for Variable Subgroup Size

Quality Control –Lecture8 Mechatronics- Batch 3

The P Chart for Variable Subgroup Size

Quality Control –Lecture8 Mechatronics- Batch 3

Quality Control –Lecture8 Mechatronics- Batch 3
Quality Control –Lecture8 Mechatronics- Batch 3
Quality Control –Lecture8 Mechatronics- Batch 3
 The P Chart
P Chart Construction for Variable Subgroup Size
cont’d.
2. As the subgroup size gets larger, the control limits
are closer together.
3. Establish revised central line and control limits:

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
P Chart Construction for Variable Subgroup Size
cont’d.
 If Po is known, the process of data collection
and trial control limits is not necessary.
 P is the proportion (fraction) nonconforming in
a single subgroup.
 ¯P is the average proportion (fraction)
nonconforming of many subgroup.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
Minimizing the Effect of Variable Subgroup Size
1. Control limits for an average subgroup size: By using an average
subgroup size, one limit can be calculated and placed on the control
chart.

nav 
 n
g
p0 (1  p0
UCL  p0  3
nav
p0 (1  p0 )
LCL  p0  3
nav
Quality Control –Lecture8 Mechatronics- Batch 3
Quality Control –Lecture8 Mechatronics- Batch 3
 The P Chart

Minimizing the Effect of Variable Subgroup Size cont’d.

Case I: This case occurs when a point (subgroup fraction
nonconforming) falls inside the limits and its subgroup size
is smaller than the average subgroup size. Therefore, in this
case individual control limits are not needed.
Case II: This case occurs when a point (subgroup fraction
nonconforming) falls inside the average limits and its
subgroup size is larger than the average subgroup size.
Therefore, when there is a substantial difference in the
subgroup size, individual control limits are calculated.

Quality Control –Lecture8 Mechatronics- Batch 3

 The P Chart
Minimizing the Effect of Variable Subgroup Size cont’d.
Case III: This case occurs when a point (subgroup fraction
nonconforming) falls outside the limits and its subgroup size is
larger than the average subgroup size. Therefore, in this case
individual control limits are not needed. If p is out of control
when nave, it must also be out of control when ni > nave.
Case IV: This case occurs when a point (subgroup fraction
nonconforming) falls outside limits and its subgroup size is
less than the average subgroup size. Therefore, when there is
a substantial difference in the subgroup size, individual
control limits are calculated. It is seen that the point is on the
individual control limit and is assumed to be in control.
It is not always necessary to calculate the individual control limits in cases II and IV. Only when the value
Quality Control –Lecture8 Mechatronics- Batch 3
of p is close to the control limits is it necessary to determine the individual limits.
 The P Chart
Standard Specified: If the target value of the proportion of
nonconforming items is known or specified, the centerline is
selected as that target value. In other words, the centerline is given
by :
where po represents the standard or target value. The control
limits in this case are also based on the target value. Thus,

Quality Control –Lecture8 Mechatronics- Batch 3

 OC Function and ARL

Quality Control –Lecture8 Mechatronics- Batch 3

 The np Chart
Number Nonconforming Chart (np):
 The np chart is easier for operating personnel to
understand than the p chart. np chart, also,
inspection results are posted directly to the
chart without any calculations.
 If the subgroup size is allowed to vary, the
central line and the control limits will vary,
which presents a chart that is almost
meaningless. Therefore, the limitation that this
chart has is that the subgroup size needs to be
constant.
Quality Control –Lecture8 Mechatronics- Batch 3
 The np Chart

Central Line = np0

Control Limits = np0  3 np0 (1  p0 )

Quality Control –Lecture8 Mechatronics- Batch 3

 The np Chart
Number Nonconforming Chart (np):
 If the fraction nonconforming po is unknown,
then it must be determine by collecting data,
calculating trial control limits, and obtaining
the best estimate of po.

Quality Control –Lecture8 Mechatronics- Batch 3

 Example
A government agency
samples 200 documents
per day from a daily lot
of 6000. From past
records, the standard or
reference value for the
fraction nonconforming
Po is 0.075.
Central line and control
limit calculations are

Quality Control –Lecture8 Mechatronics- Batch 3

 Process Capability
 For an attribute this process is much simpler.
 The process capability is the central line of the
control chart.
 Management is responsible for the capability.
 When the plotted point is outside the control
limit, operating personnel are usually
responsible.

Quality Control –Lecture8 Mechatronics- Batch 3

Quality Control –Lecture8 Mechatronics- Batch 3
Control Charts for Count of Nonconformity/Defects

 The nonconformities chart controls the count of

nonconformities within the product or service.
 An item is classified as a nonconforming unit
whether it has one or many nonconformities.
1. c-Chart: Count total number of nonconformities.
2. u-Chart: Count average number of
nonconformities per unit.
 Assume: the occurrence of nonconformities in
samples of constant size ∼ Poisson distribution

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
 Control Charts for Count of Nonconformity/Defects

 Since these charts are based on the Poisson distribution,

two conditions must be met:
1. The average count of nonconformities must be much
less than the total possible count of nonconformities.
The opportunity for nonconformities is large, whereas
the chance of a nonconformity at any one location is
very small
2. The occurrences are independent. The occurrence of one
nonconformity does not increase or decrease the chance
of the next occurrence being a nonconformity.

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
 Control Charts for Count of Non-
Conformities
Objectives:
1. Determine the average quality level: This
information gives the initial process capability.
2. Bring to the attention of management any
changes in the average.
3. Improve the product quality: Ideas for quality
improvement.

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities
Objectives cont’d.:
4. Evaluate the quality performance of
operating and management personnel.
5. Suggest places to use X bar and R chart.
6. Determine acceptance criteria of a product
before shipment to the customer.

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
 Control Charts for Count of Non-
Conformities
C Chart construction:
1. Select the quality characteristic(s):
a) Single quality characteristic.
b) Group of quality characteristics.
c) A part.
d) An entire product.
e) A number of products.
f) It can be established for performance control of an:
operator, work center, department, shift, plant, or
corporation
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities
C Chart construction cont’d:
2. Determine the subgroup size and method:The
sample size of a c chart is one inspected unit.
3. Collect the data:
 At least 25 subgroups.
 Different sources.

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities
c-Chart Construction cont’d:

4. Calculate the trial central line and the control limits:

c
c
g
UCL  c  3 c
LCL  c  3 c

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities
C chart construction cont’d:
5. Establish the revised central line and control
limits
c ne w = c 0 =
c - cd
g - gd
UCL = c 0 + 3 c0
LCL = c 0 - 3 c0

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities
C chart construction cont’d:

6. Achieve the objectives: The reason for the

control chart is to achieve one or more of the
previously stated objectives.

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities/Unit
u-Chart for count average number of nonconformities/unit.

u 
c
u 
c
n n
u
UCL  u  3
n
u
LCL  u  3
n

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Control Charts for Count of Non-
conformities
u-Chart for count average number of nonconformities/unit.

 Scale selected is continuous for the u chart.

For the c chart is discrete.
 Subgroup size for the u chart can vary. For
the c chart is 1.
 The u chart is limited in that we do not know
the location of the nonconformities.

Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
 A Quality Rating System
Nonconformity Classification:
1. Critical nonconformities: Unsafe conditions for
individuals using, maintaining, or depending
upon the product.
2. Major nonconformities: Result in failure or
reduce materially the usability of the product for
its intended purpose.
3. Minor nonconformities: Reduce materially the
usability of the product for its intended purpose.
Minor nonconformities are usually associated
with appearance.
Quality Control –Lecture8 Mechatronics- Batch 3
 A Quality Rating System
To summarize:
 A critical nonconformity will affect usability; a major
nonconformity might affect usability; and a minor
nonconformity will not affect usability of the unit.
 Other classification systems use four classes or two classes,
depending on the complexity of the product. A catastrophic
class is sometimes used.
 Once the classifications are determined, the weights to assign
to each class can be established. Although any weights can be
assigned to the classifications, 9 points for a critical, 3 points
for a major, and 1 point for a minor are usually considered to
be satisfactory, because a major is three times as important as
a Quality
minor and a critical is three times as important as a Mechatronics-
Control –Lecture8 major.Batch 3
 Control Chart Selection
Quality Characteristic
Variable Attribute
Defective Defect
no
n>1? x and MR
yes constant
yes constant
p or sampling
sample
np unit?
no size?
n>=10? x and R
yes no
no
yes
p-chart with c u
x and s variable sample
size

Quality Control –Lecture8 Mechatronics- Batch 3

 Control Chart Selection

Quality Control –Lecture8 Mechatronics- Batch 3