Control Charts for Variables

Quality Control in Textiles

Control charts were invented to serve one purpose to identify process changes as quickly as possible after the change occurs. They do nothing more and nothing less.

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Selection of Characteristics for Investigation

A single component has several quality characteristics.

It is not feasible to maintain a control chart for each characteristic.

Base selection of quality characteristics on priority:

1. Those that cause more nonconforming items

2. Those that increase cost. Select vital few from trivial many: Use Pareto Analysis.

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Chart for Variables

X and R charts: for sample averages and ranges.

X and s charts: for sample means and standard deviations.

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range The two types of charts go together when monitoring variables, because they measure the two critical parameters: central tendency and dispersion. 1. An x chart is used if the quality of the output is measured in terms of a variable such as length, weight, temperature, and so on. An R chart is used to monitor the range of the measurements in the sample.

2.

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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts

Step 1 For each sample, calculate the sample mean and range using the formula: X = Xi n Where: Xi is the ith observation n is the number of sample size Xmax is the largest observation
Engr. Fareha Asim Xmin is the smallest observation

and R = Xmax - Xmin

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts

Step 2 Obtain and draw the centre line and the trial control limits for each chart. For the X-bar chart, the centre line is given by: X = Xi / g For the R chart, the centre line is found from: R = R /g Where g represents the number of samples.
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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts

Step 3 Conceptually: the 3 control limits for X-bar charts are X +/- 3x the 3 control limits for R-charts are R +/- 3R

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

For an x-bar chart, the mean of each sample is computed and plotted on the chart; the points are sample means. The samples tend to be small, usually around 4 or 5.

n is the sample size (or number of observations)

k is the number of samples

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

R-chart In an R-chart, the range is the difference between the smallest and largest values in a sample. This range reflects the process variability instead of the tendency toward a mean value.

R is the range of each sample k is the number of samples.

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts X bar charts control limits Step 3

UCL x x A R LCL x x A R
Range for sample i

From Table

xi n

Mean for sample i

R
# Samples
Engr. Fareha Asim

i 1

Ri n

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts R charts control limits Step 3

UCL R D4 R
From Table

LCL R D3R

i 1

Ri n
Engr. Fareha Asim

Range for Sample i

# Samples

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

n 5 6 7 8 9 10 . .

d2 2.326 2.534 2.704 2.847 2.970 3.078 . .

A2 0.577 0.483 0.419 0.373 0.337 0.308 . .

d3 0.864 0.848 0.833 0.820 0.808 0.797 . .

D3 0 0 0.076 0.136 0.184 0.223 . .

D4 2.114 2.004 1.924 1.864 1.816 1.777 . .

[Tabulate A2, D3 and D4 from Table A.23, Probability & Statistics for Engineers and Scientists, 8 th Edition. Walpole Myers}

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Special Metal Screw Sample Number 1 2 3 4 5 1 0.5014 0.5021 0.5018 0.5008 0.5041 2 0.5022 0.5041 0.5026 0.5034 0.5056 Sample 3 0.5009 0.5024 0.5035 0.5024 0.5034 4 0.5027 0.5020 0.5023 0.5015 0.5047

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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Special Metal Screw

Sample Number 1 2 3 4 5 1 0.5014 0.5021 0.5018 0.5008 0.5041 Sample 2 3 0.5022 0.5009 0.5041 0.5024 0.5026 0.5035 0.5034 0.5024 0.5056 0.5034 4 0.5027 0.5020 0.5023 0.5015 0.5047 Average Range 0.0018 0.0021 0.0017 0.0026 0.0022 0.0021 Mean 0.5018 0.5027 0.5026 0.5020 0.5045 0.5027

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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Special Metal Metal Control Charts - Special Screw Screw

R - Charts

R = 0.0021

UCLR = D4R = 2.282(0.0021) = 0.00479 LCLR = D3R = 0(0.0021) = 0

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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Control Chart Factors (Three Sigma Limits)

Factor Special Screw Screw Special Metal Metal ControlCharts -for UCL Metal Screw Factor Charts -Special Factor for Control Size of and LCL for LCL for UCL for Sample R-Charts R-Charts RR 0.0020 RR - Charts - Charts x-Charts= = 0.0021 D4 = 2.2080

(n)

UCLR = D41.8802.282(0.0021) = 0.00479 R= 2 0 3.268 LCLR = D3R = 0(0.0021) = 0 3 1.023 0 2.575

4 5 6 7 0.729 0.577 0.483 0.419
Engr. Fareha Asim

(A2)

(D3)

(D4)

0 0 0 0.076

2.282 2.115 2.004 1.924

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Range Chart - Special Metal Screw

0.005
0.004 UCLR = 0.00479

Range (in.)

0.003
0.002 0.001 0 1 2 3 4 5 6 LCLR = 0 R = 0.0021

Sample number
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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Control Charts - Special Metal Screw x - Charts

R = 0.0021 x = 0.5027

UCLx = x + A2R = 0.5027 + 0.729(0.0021) LCLx = x - A2R = 0.5027 - 0.729(0.0021) UCL = 0.5042 LCL = 0.5012
Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

Control Chart Factors (Three Sigma Limits)

Factor for UCL Factor for Factor Control ChartsLCL for Size of and - Special Metalfor LCL Screw UCL for Sample R-Charts R-Charts R x - Charts x-Charts= 0.0020 (n) (A2) x = 0.5025 (D3) (D4) 2 1.880 UCLx = x + A2R 3 1.023 LCLx = x - A2R 4 0.729 5 6 7 0.577 0.483 0.419
Engr. Fareha Asim

0 0 0 0 0 0.076

3.268 2.575 2.282 2.115 2.004 1.924

Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range

X bar Control Charts - Special Metal Screw

0.5050
0.5045 0.5040 UCLx = 0.5042

Average (in.)

0.5030
x = 0.5027 0.5020 0.5010 LCLx = 0.5012

Sample number
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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts

Step 4 An R chart is analyzed before the X bar chart to determine out of control situations. A R-chart reflects process variability, which should be brought to control first. If R-chart shows an out of control situation, the limits on Xbar chart may not be meaningful.

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Control Charts for Variables

Quality Control in Textiles

Control Charts for Mean and Range Development of Charts

Step 5 Delete the out of control points for which remedial actions have been taken to remove special causes and use the remaining samples to determine the revised centre line and control limits for the X and R charts. These are revised control limits.

These are trial control limits for immediate future until the limits are revised again.
Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

It is possible that an out-of-control signal will appear on one kind of chart and not the other.

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for the Mean and Standard Deviation

X-bar cart is exactly the same

Standard deviation instead of range for the spread

Preferred over x-bar and R-charts since standard deviation is a better measure of variation than the range. Also requires slight modification of control limit formulas

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for the Mean and Standard Deviation Control limits for X-bar chart

Engr. Fareha Asim

Control Charts for Variables

Quality Control in Textiles

Control Charts for the Mean and Standard Deviation Control limits for s-bar chart

Example 17.2
[Tabulate A3, B3 and B4 from Table A.23, Probability & Statistics for Engineers and Scientists, 8th Edition. Walpole Myers}

Engr. Fareha Asim