What is the logic of

using both charts?

(mean and range)

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S6 1

Mean and Range Charts

(a)
(Sampling mean is
shifting upward but
range is consistent)

These
sampling
distributions
result in the
charts below
UCL

(x-chart detects
shift in central
tendency)

x-chart
LCL
UCL

(R-chart does not

detect change in
mean)

R-chart
LCL

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S6 2

Mean and Range Charts

(b)
These
sampling
distributions
result in the
charts below

(Sampling mean
is constant but
dispersion is
increasing)
UCL

(x-chart does not

detect the increase
in dispersion)

x-chart
LCL
UCL

(R-chart detects
increase in
dispersion)

R-chart
LCL

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S6 3

Control Charts for Attributes

Used when the process characteristic
is counted
no. of defective items in a sample

Measurement is typically counting

defectives and nondefectives
Charts may measure
Percent defective (p-chart)
Number of defects (c-chart)
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p-Charts
Used to monitor the proportion of defective
items
Appropriate when data consist of 2 categories
of items
Normal distribution provides a good
approximation

The center line represents the average fraction

defective in a population

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S6 5

Control Limits for p-Charts

UCLp = p + zsp^
LCLp = p - zsp^
where

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p
z
sp^
n

=
=
=
=

sp^ =

p(1 - p)
n

mean fraction defective in the sample

number of standard deviations
standard deviation of the sampling distribution
sample size

S6 6

P Chart Control Limits Example

Clarks at Meridian Data Systems key in
thousands of insurance records each day
for a variety of client firms. CEO Gloria
Aquino wants to set control limits to
include 99.73% of the random variation
in the data entry process when it is in
control.

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p-Chart for Data Entry

Sample
Number

1
2
3
4
5
6
7
8
9
10

Number
of Errors

Fraction
Defective

6
5
0
1
4
2
5
3
3
2

.06
.05
.00
.01
.04
.02
.05
.03
.03
.02

100 is the size of each sample

80
p = (100)(20) = .04

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2006 Prentice Hall, Inc.

Sample
Number

Number
of Errors

11
6
12
1
13
8
14
7
15
5
16
4
17
11
18
3
19
0
20
4
Total = 80

sp^ =

Fraction
Defective

.06
.01
.08
.07
.05
.04
.11
.03
.00
.04

(.04)(1 - .04)
= .02
100
S6 8

p-Chart for Data Entry

UCLp = p + zsp^ = .04 + 3(.02) = .10

Fraction defective

LCLp = p - zsp^ = .04 - 3(.02) = (.02) = 0

.11
.10
.09
.08
.07
.06
.05
.04
.03
.02
.01
.00

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2006 Prentice Hall, Inc.

UCLp = 0.10

p = 0.04

10

12

14

16

18

20

LCLp = 0.00

Sample number
S6 9

p-Chart for Data Entry

UCLp = p + zsp^ = .04 + 3(.02) = .10

Fraction defective

Possible
LCLp = p - zsp^ = .04 - 3(.02) =
0
assignable
causes present

.11
.10
.09
.08
.07
.06
.05
.04
.03
.02
.01
.00

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2006 Prentice Hall, Inc.

UCLp = 0.10

p = 0.04

10

12

14

16

18

20

LCLp = 0.00

Sample number
S6 10

Learning Exercise 3
Grace Roxas, a seasoned
inspector of LMN Company,
counted the number of
defective credit card monthly
billing statements in each of
20 samples. Using the
following information,
construct a p chart that will
describe 99.74 percent of the
chance variation in the
process when the process is
in control. Each sample
contained 100 statements.
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S6 11

Learning Exercise 3 Solution

- =
p

Total no. of defectives

230
-------------------------------- = ------------ = .11
Total no. of observations
20(100)

p (1 p)

.11(1 .11)
= .03
100

_
UCL = p + z(p) = .11 + 3.00 (.03) = .20
_
LCL = p - z (p) = .11 - 3.00 (.03) = .02

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Learning Exercise 3

p control chart

not in control

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S6 13

c-Charts
Used to control the number of
occurrences per unit
Units of automobiles, hotel rooms,
rolls of carpet
The underlying distribution is the
Poisson distribution

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Control Limits for c-Charts

UCLc = c + 3 c

LCLc = c - 3 c

where c = mean number defective in the sample

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c-Chart Example
Forgive Me 77 Company receives several
complaints per day about the behavior of
its drivers. Over a 9-day period (where the
days are the units of measure), the owner
El Alpha, received the following number of
calls from irate passengers: 3, 0, 8, 9, 6, 7,
4, 9, 8, for a total of 54 complaints. Alpha
wants to compute 99.73% control limits.

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c-Chart for Cab Company

c = 54 complaints/9 days = 6 complaints/day

LCLc = c - 3 c
=3-3 6
=0

UCLc = 13.35

6
4
2

c= 6

14
12
10
8

Number defective

UCLc = c + 3 c
=6+3 6
= 13.35

0 |

|
1 2

|
3

|
4

|
5

|
6

|
7

|
8

LCLc = 0
|
9

Day

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Learning Exercise
Rolls of coiled wire are monitored using a c-chart.
Eighteen rolls have been examined, and the
number of defects per roll has been recorded in
the table below. Is the process in control? Plot the
values on a control chart using 3-standard
deviation control limits.

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S6 19

Learning Exercise 4 Solution

c 45 / 18 2.5

UCL = c + 3c = 2.5 + 32.5 = 7.24

LCL = c - 3c = 2.5 + 32.5 = - 2.24 (0)
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S6 20

Learning Exercise 4 c-Chart

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S6 21

MANAGERIAL
CONSIDERATIONS

1. Select the points in the

process that need SPC

2. Decide what type of

control chart to use
3. Set clear and specific
SPC policies
2006 Prentice Hall, Inc.

S6 22

Patterns in Control Charts

Upper control limit

Target

Lower control limit

Normal behavior.
Process is in control.
Figure S6.7

2006 Prentice Hall, Inc.

S6 23

Patterns in Control Charts

Upper control limit

Target

Lower control limit

One plot out above (or
below). Investigate for
cause. Process is out
of control.
Figure S6.7

2006 Prentice Hall, Inc.

S6 24

Patterns in Control Charts

Upper control limit

Target

Lower control limit

Trends in either
direction, 5 plots.
Investigate for cause of
progressive change.
Figure S6.7

2006 Prentice Hall, Inc.

S6 25

Patterns in Control Charts

Upper control limit

Target

Lower control limit

Two plots very near
lower (or upper)
control. Investigate for
cause.
Figure S6.7

2006 Prentice Hall, Inc.

S6 26

Patterns in Control Charts

Upper control limit

Target

Lower control limit

Run of 5 above (or
below) central line.
Investigate for cause.
Figure S6.7

2006 Prentice Hall, Inc.

S6 27

Patterns in Control Charts

Upper control limit

Target

Lower control limit

Erratic behavior.
Investigate.
Figure S6.7

2006 Prentice Hall, Inc.

S6 28

A Final Word

Figure S6.7

2006 Prentice Hall, Inc.

S6 29

Group Learning Exercise

Using appropriate control chart, determine
two sigma control limits for each case:
1. An inspector found an average of 3.9 scratches in
the exterior point of each of the automobiles being
prepared for shipment to dealers.
2. Before shipping law mowers to dealers, an
inspector attempts to start each mower and notes
any that do not start on the first try. The lot size is
100 mowers, and an average of 4 did not start (4
percent).

Figure S6.7

2006 Prentice Hall, Inc.

S6 30

solution
The choice of the control charts relates to
whether types of results can be counted
(p-chart) or whether only occurrences can
be counted (c-chart).
1. The inspector can only count the scratches
that occurred, not the ones that did not occur.
Consequently, a c-chart is appropriate. The
sample average is 3.9 scratches per car. Two
sigma control limits are found using the
formulas

UCLc = c + z c
Figure S6.7

2006 Prentice Hall, Inc.

LCLc = c - z c
S6 31

solution
where c = 3.9 and z = 2. Thus,

Figure S6.7

UCLc = 3.9 + 2

3.9 = 7.85 scratches

LCLc = 3.9 - 2

3.9 = -.05 = 0 scratches

2006 Prentice Hall, Inc.

S6 32

solution
1. T
2. The inspector can count both the lawn mowers
that started and those that did not start.
Consequently, a p-chart is appropriate. The
sample average is 3.9 scratches per car. Two
sigma control limits are found using the
formulas

UCLp = p + zsp^
LCLp = p - zsp^
Figure S6.7

2006 Prentice Hall, Inc.

sp^ =

p(1 - p)
n

S6 33

solution
where p = .04, n = 100 and z = 2. Thus,

2006 Prentice Hall, Inc.

Figure S6.7

UCL = .04 + 2

(.04)(1 - .04)
100

= .079

LCL = .04 - 2

(.04)(1 - .04)
100

= .001

S6 34

Next Topic:

Process Capability and

Acceptance Sampling

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S6 35