HOW TO DEVELOP AND USE X

BAR AND R CONTROL CHARTS?

AN EXAMPLE
 Example: Control Charts for Variable Data
Slip Ring Diameter (cm)
Sample 1 2 3 4 5 X R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15
 DETERMINE CENTERLINE

• The centerline should be the population mean, µ

• Since it is unknown, we use X Double bar, or the
grand average of the subgroup averages.

∑ X i

X = i=1
m
 DETERMINE CONTROL LIMITS
Xbar chart
• The normal curve displays the distribution
of the sample averages.
• A control chart is a time-dependent pictorial
representation of a normal curve.
• Processes that are considered under control
will have 99.73% of their graphed averages
fall within 6σ.
 UCL & LCL calculation

UCL = X + 3σ
LCL = X − 3σ
σ = standard deviation
DETERMINING THE VALUES OF THE
CONTROL LIMITS USING RANGE
m

∑ R i
R = i=1

UCL = X + A 2 R

LCL = X − A 2 R
 3-Sigma Control Chart Factors

Sample size X-chart R-chart

n A2 D3 D4
2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
 DETERMINE CONTROL LIMITS
R chart
• The range chart shows the spread or dispersion
of the individual samples within the subgroup.
– If the product shows a wide spread, then the
individuals within the subgroup are not similar to
each other.
– Equal averages can be deceiving.
• Calculated similar to x-bar charts;
– Use D3 and D4
 Calculation
From Table above:
• Sigma X-bar = 50.09
• Sigma R = 1.15
• m = 10
Thus;
• X-Double bar = 50.09/10 = 5.009 cm
• R-bar = 1.15/10 = 0.115 cm
Note: The control limits are only preliminary with 10 samples.
It is desirable to have at least 25 samples.
 CONTROL LIMITS

• UCLx-bar = X-D bar + A2 R-bar = 5.009 +

(0.577)(0.115) = 5.075 cm
• LCLx-bar = X-D bar - A2 R-bar = 5.009 -
(0.577)(0.115) = 4.943 cm

• UCLR = D4R-bar = (2.114)(0.115) =

0.243 cm
• LCLR = D3R-bar = (0)(0.115) = 0 cm
n=5
For A2, D3, D4: see Table
 X-bar Chart
5.10
UCL
5.08
5.06
5.04
X bar

5.02
5.00 CL
4.98
4.96 LCL
4.94
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
 R Chart
0.25 UCL

0.20

0.15
Range

CL

0.10

0.05
LCL
0.00
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
 WHAT DO YOU DO NOW ?
• Revise Control Limits ?

• The concept of Trial Control Limits

 HOW TO REVISE CONTROL
LIMITS ?
• One or two points outside ?

• Quite a few points outside ?

 THREE CATEGORIES OF
VARIATION
• Within-piece variation
– One portion of surface is rougher than another
portion.
• Piece-to-piece variation
– Variation among pieces produced at the same
time.
• Time-to-time variation
– Service given early would be different from
that given later in the day.
 SOURCES OF VARIATION

• Equipment
– Tool wear, machine vibration, …
• Material
– Raw material quality
• Environment
– Temperature, pressure, humadity
• Operator
– Operator performs- physical & emotional
 CONTROL CHART VIEWPOINT

• Variation due to
– Common or chance causes
– Assignable causes
• Control chart may be used to discover
“assignable causes”
 TYPICAL OUT-OF-CONTROL
PATTERNS
• Point outside control limits
• Sudden shift in process average
• Cycles
• Trends
• Hugging the center line
• Hugging the control limits
• Instability

20
Shift in Process Average
Identifying Potential Shifts
Cycles
8-3 Introduction to Control Charts
8-3.4 Analysis of Patterns on Control Charts
8-3 Introduction to Control Charts
8-3.4 Analysis of Patterns on Control Charts
Trend
 Process in Control
• When a process is in control, there occurs a
natural pattern of variation.
• Natural pattern has:
– About 34% of the plotted point in an imaginary
band between 1σ on both side CL.
– About 13.5% in an imaginary band between 1σ
and 2σ on each side of CL.
– About 2.5% of the plotted point in an imaginary
band between 2σ and 3σ on both side CL.
 The Normal
Distribution
σ = Standard deviation

Mean
-3σ -2σ -1σ +1σ +2σ +3σ
68.26%
95.44%
LSL USL 99.74%

-3σ +3σ
CL
 Control Chart Design Issues
• Basis for sampling
• Sample size
• Frequency of sampling
• Location of control limits

29
Setting Control Limits
 Pre-Control
LTL UTL

Red Red
Zone Green Zone Zone

nominal
value

Yellow Zones 31