Acceptance Sampling

Quality Control
Chapter 10- Acceptance

Sampling Systems
RMN
Outline
Lot-by-lot acceptance sampling plans for attributes
Acceptance sampling plans for continuous
production
Acceptance sampling plans for variables
Learning Objectives
Determine the sampling plan using ANSI/ASQ Z1.4.

Know the switching rules for ANSI/ASQ Z1.4.
Categorize the various sampling plan systems in terms
of lot-by-lot, continuous production, attributes or

variables.
Learning Objectives-contd.
Describe the various sampling plan systems and know
their function (advantages, disadvantages, purpose

etc.).
Determine the sampling plan using the Dodge Romig
Tables
Construct the OC Curve for a chain sampling plan.
Learning Objectives-contd.
Be able to use the Shainin Lot Plot Method.

Determine the sampling plan ANSI/ASQ S1
Determine whether a lot is accepted or rejected using
ANSI/ASQ Z1.9
Lot-by-Lot Acceptance Sampling Plans for

Attributes
Devised in 1942 at Bell Labs
Later became MIL-STD-105E

ISO-2859
ANSI/ASQ Z1.4
Wording & terminology changes
Additional tables added
ANSI/ASQ Z1.4
This standard is applicable to:
End items
Components and raw materials
Operations
Materials in process
Supplies in storage
Maintenance operations
Data or records
ANSI/ASQ Z1.4
Intended to be used for a continuing
series of lots, but may be designed for

isolated lots.
Standard provides for single, double, and
multiple sampling plans.

Provision is also provided for normal,
tightened, or reduced inspection.

Plan is specified by the AQL, and sample-
size code.
ANSI/ASQ Z1.4
Normal inspection is used at the start of
inspection with changes being a function of

recent quality history.
Tightened inspection:
Generally used when producers recent
quality history has deteriorated.
ANSI/ASQ Z1.4
Reduced inspection:
Used when the producers recent quality
history has been exceptionally good.

Decision concerning what type of plan to use is
left to the responsible authority.

Nonconformities are classified such as critical,
major
ANSI/ASQ Z1.4
Sample Size Code Letters
Comparison of Inspection levels

100
95
= 0.05
Percent of Lots Accepted (100Pa)
80
60
I = 1/2 n
II = n
III = 2n
40
III
II
20
100=10
4
6
Percent Nonconforming (100Pa)
10
ANSI/ASQ Z1.4
AQL
The AQL is the most important part of the
standard since the AQL and sample size dictate

the plan used.
AQL is defined as the maximum percent
nonconforming that can be considered

satisfactory as a process average.
Satisfactory = Producers risk,
Usually 0.05
ANSI/ASQ Z1.4
AQL
AQL is specified by contract or
responsible authority.
AQL may be determine from
historical data, empirical judgment,
engineering information,
experimentation, producers
capability, consumers
requirements.
ANSI/ASQ Z1.4
AQL
AQL is specified by contract or responsible
authority.
AQL may be determine from historical data,
empirical judgment, engineering information,

experimentation, producers capability,
consumers requirements.
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ANSI/ASQ Z1.4
Sample Size
Determined by lot size and inspection
level
Use of sample-size code
Inspection level is determined by the
responsible authority.
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ANSI/ASQ Z1.4
Sample Size
Different levels of inspection provide
approximately the same protection to the

producer, but different protections to the
consumer.
Plan provides for special levels to be
used where relatively small sample sizes

are necessary and large sampling risks
must be tolerated. (S-1, S-2, S-3, S-4)
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ANSI/ASQ Z1.4
Implementation
Determine lot size

Determine inspection level
Find sample-size code letter in table
Determine AQL
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ANSI/ASQ Z1.4
Implementation contd.
Determine type of sampling plan

Find sampling plan in appropriate table
Start with normal inspection and change to
tightened or reduced based on switching

rules
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AQL
What an AQL means is that as long as a supplier
maintains his/her process average (% defective)
at the assigned AQL or lower, there is a very high
probability that shipments from that supplier,
when inspected using ASQ Z1.4 sampling plans,
will be accepted.
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AQL
By the same token, there is a very high probability
that shipments, when inspected using ASQ Z1.4
sampling plans, will be rejected if a supplier's
process average (% defective) remains higher than
the assigned AQL.
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ANSI/ASQ Z1.4
Single sampling plans
Start by identification of AQL, lot size,
inspection level, and type of sampling

plan.
Locate appropriate plan parameters in
tables.
Double and Multiple Sampling
Similar procedures as single sampling
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ANSI/ASQ Z1.4
Normal, Tightened, and Reduced Inspection
Start with normal inspection
Switching Procedures
Normal to tightened
Institute when 2 out of 5 consecutive lots not accepted on
original inspection
Tightened to normal
Institute when 5 consecutive lots accepted
If not, then discontinue inspection under this plan
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ANSI/ASQ Z1.4
Normal to reduced
Institute when: (all of the following)
Preceding 10 lots on normal inspection have
been accepted
Total nonconforming in preceding 10 samples
is less than number identified in Table 10-5.
Production is at a steady rate
Reduced inspection is considered desirable
by responsible authority
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ANSI/ASQ Z1.4
Reduced to normal
Institute when: (any of the following)
A lot is not accepted
Sampling procedure terminates with neither
acceptance or rejection criteria have been met

Production is irregular or delayed
Other conditions
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ANSI/ASQ Z1.4
Standard is designed for use where units of product
are produced in a continuing series of lots or batches.

If a sampling plan is desirable for a lot or batch of an
isolated nature, it should be chosen based on the
Limiting Quality (LQ) and consumers risk, b.
These tables are included in the standard, but not
the textbook.
Or use ANSI/ASQ Standard Q3
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ANSI/ASQ Standard Q3
Standard is used for inspection of isolated
lots by attributes.
Provides indexed tables by Limiting Quality,
LQ.
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Two Schemes:
1. Used for lots that are isolated or mixed or

that have an unknown history as far as all
parties know.
Lot size and LQ must be known.
Nominal values of the LQ are based on
b=0.10
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Two Schemes:
2. Used when a vendor is producing a

continuous stream of lots and sends one or
a few to a customer who will consider them
as isolated lots.
Occurs frequently when purchasing
small quantities of raw materials.
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Dodge-Romig Tables
A set of inspection tables for lot-by-lot
acceptance sampling by attributes.

Tables are based on Limiting Quality (LQ) and
Average Outgoing Quality Limit (AOQL).
Tables for single and double sampling
Advantage that the plan provides a minimum
amount of inspection for a given inspection

procedure.
Desirable for in-house inspection
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Dodge-Romig Tables
Limiting Quality LQ
Based on the probability that a particular lot, which has
percent nonconforming equal to the LQ, will be accepted.
Probability is the consumers risk, = 0.10
LQ plans give assurance that individual lots of poor quality will
rarely be accepted.
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Dodge-Romig Tables
Observations about the LQ tables:
As the lot size increases, the relative
sample size decreases.

The tables extend until the process
average is one-half of the LQ.
As the process average increases, a
corresponding increase occurs in the
amount inspected.
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Dodge-Romig Tables
Average Outgoing Quality Limit AOQL
Applicable when the inspected lot is a
convenient subdivision of a flow of product

for materials handling purposes (nonhomogeneous)
AOQL plan limits the amount of poor
outgoing quality on an average basis, but
gives no assurance on individual lots.
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Dodge-Romig Tables
Process average
Obtained by the same techniques as for p-charts
First 25 lots the average percent nonconforming is
obtained
Type of nonconformance
Dodge-Romig tables do not provide for different
categories or tightened inspection

Different LQ or AOQL values may be used
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Chain Sampling Inspection Plan

A special type of lot-by-lot acceptance sampling plan
for attributes designated as Chain Sampling Plan

ChSP-1.
Applicable to quality characteristics which involve
destructive or costly tests.
Use of small sample sizes
Acceptance number, c=0
Poor shape of OC curve at the producers risk
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Chain sampling uses the cumulative results of
several samples
Determination of the value of i, the
number of previous samples, is determined

by analysis of the OC curves for a given
sample size.
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Procedure:
For each lot, select a sample of size
n and test each for conformance to

specifications.
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Procedure:
If the sample has 0 nonconforming units, accept the
lot; if the sample has 2 or more nonconforming units,
do not accept the lot; and if the sample has 1
nonconforming unit, it may be accepted provided that
there are 0 nonconforming units in the previous
i samples of size n.
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Chain Sampling Diagram

Current Lot
i previous lots
n=5
c=0
Secondto-Last
Lot
Last Lot
Accept if 0 Nonconforming Units &

in n =5 or if 1 Nonconforming Unit
Zero Nonconforming Units in i

Previous Lots
Figure 10-4 Chain Sampling Diagram
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Conditions for use of the Chain Sampling Plan:
1. The lot should be one of continuing
series of product that is sampled in

substantially the order of production
2. The consumer can normally expect
the lots to be essentially the same
quality.
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Conditions for use of the Chain Sampling Plan:
3. The consumer has confidence in the
producer not to occasionally send an

unacceptable lot that would have the
optimum chance of acceptance.
4. The quality characteristic is one that
involves destructive or costly tests.
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Sequential Sampling
Used for costly or destructive tests
Subgroup size of 1 item by item plan
Sequential sampling is similar to multiple sampling,
except sequential sampling can, in theory, continue

indefinitely.
In practice, the plan is truncated after the number
inspected is equal to three times the number inspected by

a corresponding single sampling plan.
Based on the Sequential Probability Ratio Test
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Sequential Sampling Plan
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Sequential Sampling Plan
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Skip Lot Sampling

Designated SkSP-1 and based on AOQL.
A single sampling plan for minimizing inspection
costs when there is a continuing supply of lots of

raw materials, component parts, subassemblies,
and finished parts from the same source.
Applicable to chemical and physical
characteristics that require laboratory analysis.
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Procedure for SkSP-1 Plans

Begin by inspecting every lot
When i consecutive lots are
found to be conforming
Discontinue inspection of every lot

Inspect a fraction, f, of the lots
In a random manner
When an inspected lot is found
nonconforming
Figure 10-7 Procedure SkSP-1 plans

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ANSI/ASQ S1
Provides procedures to reduce the
inspection effort when the suppliers

quality is superior.
A skip-lot scheme used in conjunction
with attribute lot-by-lot plans given in
ASQ Z1.4
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ANSI/ASQ S1
Requirements to use ANSI/ASQ S1
1. Have a documented system for controlling product
quality and design changes
2. Have instituted a system that is capable of detecting and
correcting changes that might adversely affect quality.
3. Not have experienced an organizational change that
might adversely affect quality
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ANSI/ASQ S1
Additional requirements of the product:
Be of stable design
Have been manufactured on a continuous basis for at least 6
months unless agreed to a longer period.
Have been on normal and reduced inspection during the
qualification period.
Have maintained a quality level at or less than the AQL for at
least 6 months.
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ANSI/ASQ S1
Other:
The previous 10 or more consecutive lots have been accepted
The min cumulative sample size for the last 10 or more consecutive
lots have been met.

The acceptance numbers for the last 2 lots have been met
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Sampling for Continuous Production

Acceptance sampling for continuous
production implies that manufacturing

operations do not create lots as part of the
normal part of the production process.
Parts are produced by a continuous
process on a conveyor or similar

system.
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Plans for continuous production consist of
alternating sequences of sampling inspection and

screening (100%) inspection.
Plans begin with 100% inspection and convert to
sampling after a stated number of items are free of

nonconformities.
Sampling continues until a stated number of
nonconforming units are found, at which time 100%
inspection in reinstated.
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Applicable to attribute, nondestructive
inspection of moving product.

Inspection should be easy and rapid
Process must be capable of manufacturing
homogeneous product
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Developed by Dodge
CSP-1, CSP-2, CSP-3

Later, MIL-STD-1235B
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CSP-1
Begins with 100% inspection of the
product in the order of production until a

certain number of successive units are
free of nonconformities.
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CSP-1
Sampling inspection is then instituted
Samples are selected in such a
manner as to minimize any bias
If a nonconformity occurs, sampling is
discontinued and 100% inspection

begins.
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CSP-1 and CSP-F Plans

Start
The Screening Crew Inspects 100% of the Units
When i Consecutive Units Are Found Free of
Nonconformities Concerned,
The Screening Crew is Released from 100% Inspection

and the Sampling Inspector Inspects a Fraction, f, of
the Units, Where the Sample Units are Selected in a
Random Manner.
When the Sampling Inspector Finds One of the
Nonconformities Concerned,
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MIL-STD-1235B
Standard is composed of five different
continuous sampling plans.

Designated by code letters
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MIL-STD-1235B
Inspection is by attributes for nonconforming
units using three classes of severity:

Critical
Major
Minor
Each of the plans incorporates a provision for
discontinuance of inspection
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Acceptance Sampling Plans for

Variables
Shainin Lot Plot
ANSI/ASQ Z1.9-2003
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Variables
Shainin Lot Plot
Random sample of 10 subgroups of 5 each

Find average and range
Construct a histogram
Calculate Xdouble bar, R bar

Calculate ULL and LLL
Compare to lot plots in Figure 10-15
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Variables
ANSI/ASQ Z1.9-2003 Sampling
Procedures and Tables for Inspection by
Variables for Percent Nonconforming is an
acceptance sampling system to be used on
a continuing stream of lots for Acceptance
Quality Limit (AQL) specified.
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Variables
ANSI/ASQ Z1.9-2003 provides tightened,
normal, and reduced plans to be used on
measurements which are normally
distributed. Variation may be measured by
sample standard deviation, sample range,
or known standard deviation. It is
applicable only when the normality of the
measurements is assured.
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Acceptance Sampling

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Quality Control

Chapter 10- Acceptance

Determine the sampling plan using ANSI/ASQ Z1.4.

of lot-by-lot, continuous production, attributes or

their function (advantages, disadvantages, purpose

Be able to use the Shainin Lot Plot Method.

Lot-by-Lot Acceptance Sampling Plans for

Later became MIL-STD-105E

series of lots, but may be designed for

multiple sampling plans.

tightened, or reduced inspection.

inspection with changes being a function of

quality history has deteriorated.

history has been exceptionally good.

left to the responsible authority.

Sample Size Code Letters

Comparison of Inspection levels

Percent of Lots Accepted (100Pa)

standard since the AQL and sample size dictate

nonconforming that can be considered

empirical judgment, engineering information,

Determined by lot size and inspection

Different levels of inspection provide

approximately the same protection to the

used where relatively small sample sizes

Determine lot size

2009 Pearson Education, Upper Saddle River, NJ 07458.

Determine type of sampling plan

tightened or reduced based on switching

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

Start by identification of AQL, lot size,

inspection level, and type of sampling

Similar procedures as single sampling

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

acceptance or rejection criteria have been met

2009 Pearson Education, Upper Saddle River, NJ 07458.

are produced in a continuing series of lots or batches.

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.

1. Used for lots that are isolated or mixed or

2009 Pearson Education, Upper Saddle River, NJ 07458.

2. Used when a vendor is producing a

small quantities of raw materials.

2009 Pearson Education, Upper Saddle River, NJ 07458.