CHAPTER 3-Process Control
CHAPTER 3-Process Control
Total Quality
Management and
Process Control
Acceptance Sampling
Sampling
Control • Sample Size
(SPC) • Time between successive samples
• Decision rules that determine
when action should be taken
Statistical
Process
Control
(SPC)
x = mean
• Categories of Variation
Statistical
• Common cause - The purely
Process Control random, unidentifiable
(SPC) sources of variation that are
unavoidable with the current
process
• Assignable cause - Any
variation-causing factors that
can be identified and
eliminated
A process distribution can be
characterized by its location, spread
and shape. Location is measured by
Statistical
the mean of the distribution, while
spread is measured by the range or
Process Control
standard deviation. The shape of
(SPC)
the distribution can be
characterized as either symmetric
or skewed.
Control
Charts
Figure 5.9 Control Chart
Examples
Control
Charts
(a) Normal –
No action
Figure 5.9 [continued]
Control Charts
(c) Sudden
change –
Monitor
Control
Charts
(d) Exceeds
control limits
– Take action
Type I error
• An error that occurs when the employee
concludes that the process is out of
control based on a sample result that
falls outside the control limits, when in
Control fact it was due to pure randomness
Charts Type II error
• An error that occurs when the employee
concludes that the process is in control
and only randomness is present, when
actually the process is out of statistical
control
• Variable Control Charts
• R-Chart – Measures the variability of the
process
• x -Chart – Measures whether the process is
generating output, on average, consistent
with a target value
Control Charts • Attribute Control Charts
• p-chart – Measures the proportion of
defective services or products generated by
the process
• c-chart – Measures the number of defects
when more than one defect can be present
in a service or product
Control Charts for Variables- R Chart
R-Chart
UCLR =D4R and LCLR =D3R
Were
Source: Reprinted with permission from ASTM Manual on Quality Control of Materials, copyright ©
ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428.
Example 3.1 (1 of 5)
Sample
Number Observation 1 Observation 2 Observation 3 Observation 4 R x
x-bar
1 0.5014 0.5022 0.5009 0.5027 0.0018 0.5018
2 0.5021 0.5041 0.5024 0.5020 0.0021 0.5027
3 0.5018 0.5026 0.5035 0.5023 0.0017 0.5026
4 0.5008 0.5034 0.5024 0.5015 0.0026 0.5020
5 0.5041 0.5056 0.5034 0.5047 0.0022 0.5045
Blank Blank Blank Blank Average 0.0021 0.5027
Example 3.1 (2 of 5)
Comments: The two new samples are below the LCL of the chart implying that the
average time to serve a customer has dropped. Therefore, the new process is an
improvement. Assignable cause should be explored to see what cause the
improvement.
Control Charts for Attributes (1 of 2)
p p 1 p / n
p 1 p
p= = 0.0049(1 0.0049)/2,500 = 0.0014
n
Figure 5.12 The p-Chart from POM for Windows for Wrong Account Numbers,
Showing that Sample 7 Is Out of Control
Comments: Sample 7 is out of UCL. Thus, the process is NOT in statistical control.. The reason should be
determined.
Exercise Problem 17: Page 210(1 of 2)
A sticky scale brings Webster’s attention to whether caulking tubes are
being properly capped. If a significant proportion of the tubes aren’t
being sealed, Webster is placing their customers in a messy situation.
Tubes are packaged in large boxes of 144. Several boxes are inspected,
and the following numbers of leaking tubes are found:
Draw the p chart. The process is in control as the p values for the samples
all fall within the control limits.
Control Charts for Attributes: C-Chart(1
of 4)
• c-charts – A chart used for controlling the number of
defects when more than one defect can be present in a
service or product.
• The mean of the distribution is c and the
standard deviation is c.
The process is technically out of control due to Sample 6. However, Sample 6 shows that
the new supplier is a good one. Because, the number of defects dropped below the LCL.
Exercise Problem 18: page 210:( 1 0f 2)
At Webster Chemical, lumps in the caulking compound could cause
difficulties in dispensing a smooth bead from the tube. Even when
the process is in control, there will still be an average of 4 lumps per
tube of caulk. Testing for the presence of lumps destroys the product,
so Webster takes random samples. The following are results of the
study:
6+5+0+4+6+4+1+6+5+0+9+2
c = =4
12
c = 4 = 2
LCLc =c z c = 4 2(2) = 0
Draw c-chart. The process is technically out of control due to
Sample 11.