CHAPTER – 20

Statistical Quality Control

 Introduction to SQC.
 Methods of sampling inspection, types of sampling plan.
 Operating characteristic curves.
 Control charts and their applications. Types of control charts.
 Plotting of X and R charts and their importance.
 Plotting of P and C charts and their importance.
 Utilization of control charts.
 Statistical process control.
 Pareto principle, cause and effect analysis (fish – bone
diagram).
Introduction to Statistical Quality Control
Application of statistical techniques is the main criteria in SQC
method for acceptance or rejection of processed or under process
materials. The important components of SQC are as follows:
1) Acceptance sampling.
2) Statistically proven control.
3) Control charts.
4) Process flow chart, histogram, graphs.
5) Pareto Analysis, cause and effect diagram.

The quality characteristic of inspection are three viz (a) Attributes

(b) Count of defects and (c) Variables.
Sampling and Inspection
 Sampling is a fair and reliable assessment. However in
some evaluation this is the appropriate or only method.
 Certain items can be tested by every piece. For example
Breaking strength of chains, ammunition, crackers etc.
 Low value items made in millions (like, plugs, sockets,
Starters, bulbs) cannot be tested in full.
 Sampling is successful if production process is under
control.
 Sampling saves time, cost, as method does not disturb
production.
 Sampling is disadvantageous if production process and
system are too erratic and unreliable.
Acceptance Sampling
Types of Sampling Plan:
i. Single Sampling Plan
ii. Double Sampling and Multi Sampling Plans
iii. Sequential Sampling
Sample Decision Errors
a) Type-I Errors: A sample taken out from a lot may lead to
decision that the process is out of control. The reality may be
that the process and quality is going on as desired. Such
decision error is known as Type-I Error.
b) Type-II Errors: A sample taken out from a lot may lead to
decide an acceptance of the lot. The situation may be that the
process quality is not as desired. This situation is reverse of
Type-I errors and is called Type-II Error.
c) Producer’s Risk: A lot inspection may show higher
proportion of risk leading to take a decision to reject the lot.
However the situation may be that the whole lot is of
acceptable level. Since producer is likely to loose on sampling
decision this situation is called as ‘Producer’s Risk’.
d) Consumer’s Risk: A sample lot show lesser proportion of risk
and decision leads to acceptance of the lot. The situation may
be that the lot is rejectable. This situation is reverse of
producer’s risk and the consumer is likely to suffer buying a
bad lot. Hence the name ‘Consumer’s Risk’.
Control Charts and their Applications
 Based on samples drawn at random, readings of inspection are
taken to draw control charts. This is on random sampling.
 Any process whether manual, semi-automatic or automatic is
likely to give variations in output due to various factors.
 The variations in the output could be due to manual error, tool
error, machine wear and tear, material defects or power supply
problems. Control charts enable to understand the variations

Plotting the Control Charts

 Control Chart is a graphical presentation based on data
collected on sample lot inspection.
 This data is obtained to control the variation and to take
corrective action in the process. The variation picture will be
very clear by plotting a chart.
 Chart or graph enable to keep the control on operating it is
called as control chart. It is diagnostic method
Advantages of Control Charts
 It enables to specifically understand if the process is within
control limits or not.
 One can identify abnormalities, unusual variations.
 Since it is done batch-wise timely warning is available for
corrective actions.
 The system develops employees’ scientific thinking.
 Top management gets an opinion of process under control
or not.
Types of Control Charts
A. Based on variables * X BAR chart
Characteristics * R chart
(measurements) * SIGMA chart

B. Based Attributes * p chart

(Yes or No criteria) * np Chart
* C chart
* u chart
BAR Chart and its Importance
It enables to identity erratic and cyclic shift in
the process.
It is possible to see change in process
variabilities.
This chart is for the measure of central tendency.
From the data an experienced executive can
identify if it is due to tooling, manual error or
material defect.
This is a standard chart to find out variations
R – Chart and its Importance
R – Chart and its Importance
 This is a chart for measure of spread.
 This controls general variability of the process and is
affected by changes in process variability.
 Normally this and x charts are used together for analysis.

Combined and R-Chart usage

 It enables to decide on continuing the good process or go
on chasing the readings to find causes for deviations.
 Information collected enables to establish the process or
modify the process.
 This can be used for controlling incoming materials as well.
P Chart and its Importance
 In this method each item is classified as good or bad.
 P chart checks if the fluctuations in product quality due to
chance cause.
 P chart is drawn by calculating first the fraction defective
and then the control limits.
 The process is approved as in control if fraction defective
values fall within the control limits
 In case if the process is out of control then investigation
continues
C-Chart and its Importance
 In this chart the number of defects in a sample are plotted.
 Chart controls number of defects observed per unit per
sample.
 This method is preferred for large number of complicated
components.
 Both number of defective pieces and number of defects in a
piece are taken into account.
Utilisation of Control Charts
In industrial working real cases the applications are many.
Some of the examples and type of charts are explained here
as a guideline
 Manufactured components (studs,
shafts, pin holes, slots, keyways—etc. - variable charts
 Sub-Assemblies, Assemblies - variable charts
 Welded, Soldered joints - attribute charts
 Forgings, castings - attribute charts
 Wear and tear of tooling - variable charts
 Incoming Materials - variable and
attribute charts
Statistical Process Control (SPC)
 Application of Statistical Control is made in getting consistency in quality by
consistency in production process at all stages.
 This type of control measure is referred to as statistical process control. Let us
take an example of machining operation
 statistical quality control is studied. In fact both SQC and SPC are two
branches of TQC. The job is better care taken in the process by SPC and
evaluation is best attended by SQC techniques.
 SPC is a strategy for reducing viability in a process,
 Variations could be in material specifications, in human resources in operating
method
 Process control is an important activity in SPC and should be adjusted at all
levels of operations
 The important aspects of SQC and SPC are summarized as under.
 Flow charts of the process will make us understand what is being done.
 Statistical data enables to know the frequency of occurrence of deviations or
process under control.
 Pictorial presentation through graphs enables to read the situation at one
glance.
 Pareto principle method enables to separate out serious major problems and
minor problems
 Cause and effect analysis enables to understand major causes and minor
Pareto Principle
Mr. Pareto has advised his principle “vital few and trivial
many”. This means in quality problems solving more attention
to be given to solve vital or more serious problems and this
may automatically solve small problems or else the trivial
problems can be attended by junior level employees. The
following example gives how vital few cause more rejections
in a machined carburetor casting.
Advantages and Applications of Pareto Analysis
 It enables to bring out from employees various major and
minor causes to a problem.
 The list is plotted on fish-bone diagram and has a repetition
of some causes writing is avoided.
 Since causes are identified it becomes easy to do brain
storming exercise to find out solutions.
 It’s effective for diagnosing any problem.
 Employees get opportunity to contribute ideas and hence
feel motivated.
 This method can be applied in any type of industrial works,
HRM problems, marketing problems, purchasing problems
and financial problems.