Statistical methods

Exercise Examples for Quality Control Charts

1. Quality control charts x , R

Shafts are being worked on a grinder. A part of the shaft gets a fit for a ball-bearing.
The outside diameter is controlled with a control chart. 5 shafts are taken out every
hour to determine the diameter (n=5). The five measurements become a group of
measurements. Altogether, 100 measurements are made in 20 samples. These
measurements are used to make up the quality control chart and to calculate the
percentages.

1. Step – Calculate x Exercise

Determine the value x for every group of data. Use this method, to calculate x
for every group.

x 1 + x2 + . . . + x n
x = 
n x = 

or
x1 = 1. measurement
x2 = 2. measurement
xn = measurement number n
n = number of classes

The result should be rounded to the next

possible integer.

2. Step – Calculate R Exercise

Determine the range R for every class. Calculate the range of all classes.

R = (xmax) - (xmin)

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3. Calculate the Tolerance Limits Exercise

Median Line calculate:
control chart x :

∑x
x =  x = 
k

control chart R:

∑R
R =  R = 
k

where k is equal to the number of classes.

The action limits are rounded to two digits more
accurate than the measurements.

Action Limits
Determine the values for the factors A2, D3 and
D4, which are listed in table 4.2.1, depending on The table 4.2.1 lists the values A2,
the sample size. D3 and D4, which are needed for
These are factors, which make it easier to the calculation.
calculate the action limits. When n = 5,
Then:

A2 =
The part x :
D3 =
Upper control limit D4 =
(UCL) = x + A2 R
The results for part x are:
Lower control limit
UCL =
(LCL) = x - A2 R
LCL =
The part R:
For part R:
Upper control limit (UCL) = D4R
Lower control limit (LCL) = D3R UCL =
(The range R is rounded to one digit more LCL = - neglectable
accurate than the measurements).

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Table with the Constants for the Calculation of x , R

Random x R
Sample
Size n
A2 D3 D4
2 1,880 0 3,27
3 1,023 0 2,27
4 0,729 0 2,28
5 0,577 0 2,11
6 0,483 0 2,00
7 0,419 0,076 1,92
8 0,373 0,136 1,86
9 0,337 0,184 1,82
10 0,308 0,223 1,78

4. Step – Drawing of the Control Chart Exercise

Enter the average level, the upper and lower Construct a control chart
action limits and the appropriate measurements x - R.
for the x -part in the control chart.

The same strategy is used for the R-part.

5. Step – Evaluation and Analysis Exercise

Evaluate the process regarding the process In the control chart x , the value
capability. of the 9. class is outside of the
UCL and the value for the 17.
class is below the LCL.

This suggests smaller problems

in the processes.

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Exercise Qualitätsregelkarte
Quality Control Chart
x x/R
/R
product referene 88-F-210 description shaft customer NN N° of
mean machine M12 range grinding operation AK the
lot docket A001 lot D19 Pp Cp Cpk Ppk Cp Cpk chart
value outside diameter (18.5 mm) last chart
SPC x UCL LCL R UCLR random sample size 20

date 15/09 16/09 17/09 18/09 19/09

time 09.00 10.00 11.00 12.00 9.00 10.00 11.00 12.00 09.00 10.00 11.00 12.00 09.00 10.00 11.00 12.00 09.00 10.00 11.00 12.00
x1 25 23 25 25 24 24 28 26 30 26 28 25 27 25 26 23 25 23 27 25
x2 30 28 26 27 24 27 29 28 26 29 26 27 29 24 25 24 26 27 23 25
x3 23 25 23 23 25 23 25 27 30 27 24 24 26 28 26 27 30 24 24 26
x4 28 24 26 26 25 28 26 25 28 27 25 26 25 26 27 24 20 28 25 24
x5 27 22 24 27 23 27 24 28 32 28 25 27 23 21 25 28 27 22 24 28
sum
x
R

1
2
3
4
5
_
X

5
4
3
2
1
5
4
R 3
2
1
Process log sheet

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