LUT Engineering Science

BJ02A2020 Process Control

Prof. Satu-Pia Reinikainen
Task 2

Computation of Control Charts

(Fertilizer data Case 1)

Mohammadamin Esmaeili 0445024

Nnaemeka Ezeanowi
0445037
April 12, 2015

Table of Contents
1. Introduction ......................................................................................................................................... 3
2. Aim ..................................................................................................................................................... 3
3. Computation Routine .......................................................................................................................... 3
4. Results ................................................................................................................................................. 6
4.1 Results for mass fraction of particles less than 0.03mm ............................................................... 6
4.1.1 Using X-bar and R control Chart ........................................................................................... 6
4.1.2 Using X-bar and S control Chart............................................................................................ 8
4.1.3 Using the general model ........................................................................................................ 9
4.2 Results for mass fraction of particles less than 4.0mm ............................................................... 10
4.2.1 Using X-bar and R control Chart ......................................................................................... 10
4.2.2 Using X-bar and S control Chart.......................................................................................... 11
4.2.3 Using the general model ...................................................................................................... 12
5. Conclusion ........................................................................................................................................ 13
6. References ......................................................................................................................................... 13

1. Introduction
Control charts are charts used in the study of process change with respect to time. There are
different charts available for various process control analysis and decisions as most charts data
set are plotted in time order. Here, we consider the case of granulation of fertilizer powders
into different sizes to reduce probable hazards within the manufacture of fertilizers thereby
improving the handling and monitoring of the amount of fine particles released. Twenty five
(25) batches were considered for calibration having five (5) sub samples each for the particle
diameters considered. The calibration samples were based on mass fractions of particles with
diameters less than 0.03mm and 4.0mm.
The control chart is adopted with the intention of accepting or rejecting data sets from an array
of batches which would fit for proper calibration. The Averages (X-bar) & Range (R) control
chart and Averages (X-bar) & Sigma (S) control chart are the variable control charts that have
been employed based on the data set properties. The control limits set in the control charts
would be used to determine the batches that would probably be rejected based on an identified
cause.

2. Aim
The aim of computing the control charts for the calibration test data sets for granulation of
fertilizer powders is to:
Determine if the test samples gotten at different batches are within the operating limits
highlighting if the batch is to be accepted or rejected.
Investigate the consistency pattern of the variables in the fertilizer granulation process
and reasons for causes that may be observed when some data points are found outside
the control limits.
Control the granulation process within the operating limits and rejecting batches which
are out of control.
Predict if the particle test data set from the calibration set is suitable.

3. Computation Routine
The two control charts to be computed are The Averages & Range (X-bar/R) control chart and
Averages & Sigma (X-bar/S) control charts.
3

Firstly, the mean (or average), range and standard deviation of the five sub samples were
calculated for each batch on a row which was done for mass fraction of particles with diameter
less than 0.03mm and 4.0mm. This was done using the following formulae;
=1
, =

, =
, =

=1( )2
1

,
=
=
=
=
When these values have been determined then the average of the mean, range and standard
deviation of each batch would be calculated. At this point, the basic values necessary to create
plots have been calculated.
For the Averages & Range (X-bar/R) control chart plots, the upper control limits (UCL) and
lower control limits (LCL) for the X-bar chart and the R-chart can be calculated thus;
= + 2
= 2
= 4
= 3
,
& =
& =
=
4

 =
The mean values of each batch, the average of the mean values, the upper and lower control
limits are plotted against the number of batches for d < 0.03mm and d < 4.0mm which produces
the X-bar chart while plots of the range of each batch, the average of the range, the upper and
lower control limits against the number of batches for d < 0.03mm and d < 4.0mm produces
the R-chart. The R-chart is analysed to locate any outlier or out of control point because the Xbar chart is dependent on the average range. If outliers are observed, the batch can be rejected
and then values would be recomputed afresh to ensure there is no data set which is outside the
operating control limits.
For the Averages & Sigma (X-bar/S) control charts plots, the upper control limits (UCL) and
lower control limits (LCL) for the X-bar chart is derived from the average standard deviation;
= + 3
= 3
= 4
= 3
,
& =
& =
=
=

Though this type of control chart is mainly used for subgroups greater than ten but this gives a
better estimate of the subgroup variation. The mean values of each batch, the average of the
mean values, the upper and lower control limits are plotted against the number of batches for
d < 0.03mm and d < 4.0mm which produces the X-bar chart which is dependent on the standard
deviation while plots of the standard deviation of each batch, the average of the standard
deviation, the upper and lower control limits against the number of batches for d < 0.03mm
and d < 4.0mm produces the s-chart. The s-chart is studied to locate any outlier or out of control
point because the X-bar chart is dependent on the value of the average of the standard deviation.
If outliers are observed, the batch can be rejected and then values can then be recomputed
afresh to ensure there is no data set which is outside the operating control limits.

Furthermore, the general model of control charts which can be defined on the 3-sigma control
chart can also be used to ensure that accepted batches are within the warning and action limits
which are the normal operating conditions. The formula used are;
, = 2
, = 3
The upper and lower warning limits (UWL & LWL) and the upper and lower action limits
(UAL & LAL) are set by the formulae above.

The values for the formula constants used in calculating control limits in the X-bar & R-chart
and the X-bar & S-chart are shown in Table 1 below and the values for five sub groups
highlighted
Table 1: Formula constants for control charts (Pqsystems.com, 2015)

4. Results
4.1 Results for mass fraction of particles less than 0.03mm
4.1.1 Using X-bar and R control Chart

Firstly, the data sets for the mass fraction of particles less than 0.03mm (d < 0.03) was analysed
for the 25 batches. The plot gotten is shown in Fig. 1

Figure 1: X-bar and R control chart for d < 0.03mm

Looking at the range chart first, it is observed that the batch numbers 20, 21, 22 and 24 are out
of control which probably has been caused by high variations between the maximum and
minimum value of the subsamples thereby showing a higher range as compared to other
batches. Also, though computational observations, the batch 16, 18 and 25 have higher mass
fractions compared to most batches within the calibration set for particles less than 0.03mm.
These batches would be rejected from the calibration set and the average of the mean, the
average of the range, upper and lower control limits would be recomputed to put the process
within the operational control limits.

Figure 2: Recomputed X-bar and R control chart for accepted batches in the calibration set for d <
0.03mm

The above figure shows that operational values are within the set control limits for the
calibration set for mass fraction of particles less than 0.03mm.

4.1.2 Using X-bar and S control Chart

Here, the X-bar and S control Chart is used to analyse the test data set having mass fraction of
particles less than 0.03mm.

Figure 3: X-bar and S control chart for d < 0.03mm

Observing the instability in the process from the sigma chart, the batch numbers 20, 21, 22 and
24 has been seen to be outliers which probably can deter the calibration for the granulation
process. While investigating if those four outliers can be removed based on a special cause,
observations showed that the batches 16, 18 and 25 would still be out of control due to a
common cause which has come up probably during the sampling that has brought about mean
values of these batches to be out of limits. Working with the remaining batches, the average of
the mean, the average of the range, upper and lower control limits would be recomputed to put
the process within control.

Figure 4: Recomputed X-bar and S control chart for accepted batches in the calibration set for d <
0.03mm

4.1.3 Using the general model

The general model of control charts with 2-sigma as the warning limit and 3-sigma as the action
limit would be used in buttressing how stable the values of the accepted batches are within the
normal operating conditions.

Figure 5: Accepted batches fitted within the normal operating condition for d < 0.03mm

4.2 Results for mass fraction of particles less than 4.0mm

The second calibration set for the case in hand is based on the mass fraction of particles below
4.0mm. The two types of control charts used in the former calibration set would also be used.

4.2.1 Using X-bar and R control Chart

The data sets for the mass fraction of particles less than 4.0mm (d < 4.0) of the 25 batches
would be analysed by the chart using the computation routine used for the mass fraction of
particles less than 0.03mm. The derived plot is shown in Fig. 6

Figure 6: X-bar and R control chart for d < 4.0mm

Taking a look at the R-chart, batch 17 seems to push the process out of control which was as a
result of the fact that the mass fraction of the particles in this batch varied widely in comparison
with the maximum and minimum value of the available subgroups. Then to the X-bar chart,
the batch 18 is way outside the control limit owing to the fact that the average mass fraction of
the particles in the batch was quite smaller than the lowest allowable amount. These two
batches are rejected to produce a process within the operational limits. Necessary values for
the plots are being recomputed as described in the computation routine.

10

Figure 7: Recomputed X-bar and R control chart for accepted batches in the calibration set for d <
4.0mm

4.2.2 Using X-bar and S control Chart

The X-bar and S control Chart is used to analyse the test data set having mass fraction of
particles less than 4.0mm. This would be analysed for the 25 batches and afterwards, necessary
rejections would be done if there are probabilities of a special or common cause.

Figure 8: X-bar and S control chart for d < 4.0mm

From observations on the chart, the S-chart looks to be within control but a bit below for batch
18 which would probably disrupt the process. The batch 18 was rejected and the necessary
values for the plot was now recomputed in Fig. 9.

11

Figure 9: Recomputed X-bar and S control chart for accepted batches in the calibration set for d <
4.0mm

4.2.3 Using the general model

The general model of control charts with 2-sigma as the warning limit and 3-sigma as the action
limit would be used in buttressing how stable the values of the accepted batches are within the
normal operating conditions.

Figure 10: Accepted batches fitted within the normal operating condition for d < 4.0mm

12

5. Conclusion
Within the limits of possible sampling errors, it can be concluded that the charts have been able
to help control the data sets for calibration. The two types of variable control charts which have
been employed has approximately given same results in that the rejected batches in both cases
were similar. For the two situations considered (mass fraction of particles less than 0.03mm
and 4.0mm), as the control limits were set to define the boundaries, the variations showed
consistency after out of control batches were rejected. The X-bar and S control Chart is said to
provide a better estimate than the X-bar and R control Chart but this was not really the case
because the number of subgroups were less than ten which was within the statistical coverage
of the X-bar and R control Chart.

6. References
Pqsystems.com, (2015). X-bar and range chart formulas | Formulas and tables | Quality Advisor.
[online] Available at: http://www.pqsystems.com/qualityadvisor/formulas/x_bar_range_f.php
[Accessed 12 Apr. 2015].

Reinikainen, S., Process Control. Introduction to Control Charts Lecture note, Lappeenranta

University of Technology, 2015, pp. 3-17.

Reinikainen, S., Process Control. Lecture note 1, Lappeenranta University of Technology,

2015, pp. 20-30.

13