STATISTICAL QUALITY CONTROL (SQC)

Refers to the technique for controlling the quality of manufactured products & the items that are purchased from outside suppliers. Every manufacture process is subject to large no. of random disturbances which causes production to deviate from quality set. variability due to chance factors. There may be other factors like wrong setting of m/c,defective raw material etc.,responsible for lower product quality. variability due to assignable causes. Therefore aim of SQCfind out the assignable causes &remove them.(this is done through control charts) SQC proves prevention is better than cure. a stitch in time in save nines. SQC prevents the occurrence of defectives by exercising control over the process rather than inspecting goods for conformance after having been produced. A control chart is a visual display of the inspection results of the samples of a product. it corporate carefully derived statistical limits which help to assignable variability.

Control charts are based on the concept that the avg.of sample of several items tend to cancel out the normal process variability & undesirable changes due to assignable causes thereafter become visible. Inspection-- 1.100% 2.sampling (acceptance sampling)

Sampling inspection----1.single 2.double 3.multiple 4.sequential Sampling insp----1.sampling by attributes 2.variables 3.lot by lot 4.continuous QUALITY CONTROL (DIMENSIONS OF PRODUCT QUALITY) 1.Performancespeed of car 2.featurespower steering of an automobile 3.realibilitylikelihood of breakdown 4.servicabilitymalfunction is need for repairs. 5.appearanceFeel,look,smell,taste,sound. 6.costurmer servicebefore,during,after sales 7.safety Control charts | | Attributes variables P-chart X-chart nP-chart R-chart C-chart SIGMA chart u-chart Variables-wt,ht,dimensions etc.,attributes-Y/N,acceptable/non-acceptable(eg:picture tube of TV-working/defective) (color,appearance,texture,cracks,burns etc.,) X-chart UCL=X+A R CL=X LCL=X-A R Where A =3/d n R=R /n x=x /n i=1,2.n R-chart UCL =R+3d R/d =RD CL =R LCL=R-3d R/d =RD (d ,d factor whose value is based on sample size n)

x arithmetic mean ith sample eg:1.sample no. (sample size 5) 1 2 3 4 5 6 7 8 9 10 3.5 4 ____ x=76 x 7 7.5 8 10 9.5 2 3 4 3 2 11 11.5 4 3 2 ____ R=26 R 2 3 2

A =0.58,D =0,D =2.115.calculate x,R Charts Sol: x = x/n of samples =76/10=7.6 R = R/n =26/10 =2.6 X-chart UCL = X+A R =7.6+(0.58*2.6) =9.11 CL = 7.6 LCL =7.6-(0.58*2.6) = 6.09

RANGE CHART UCL =D R =2.115*2.6 =5.499 CL =2.6

LCL =D R 0*2.6 =0

X,R charts quality within control P-CHART UCL =P+3P(1-P)/n CL =P LCL =P -3P(1-P)/n can be fraction defective (p) or percent defective (100p) can be used for varying sample sizes also. P= total no. of defective pieces found Total no. of pieces uninspected E.g.: date No of pieces Inspected (a) Nov 4 300 5 300 6 300 7 300 8 300 10 300 11 300 12 300 13 300 14 300 No. of pieces defective found (b) 25 30 35 40 45 35 40 30 20 50 Fraction Defective P=(b)/(a) 0.0834 0.1000 0.1167 0.1333 0.1500 0.1167 0.1333 0.1000 0.0666 0.1666 % defective 100p 8.34 10 11.67 13.33 15 11.67 13.33 10 6.66 16.66

n=sample size=300 p=350/3000=0.1167 LCL =0.1167+30.1167(1-0.1167)/300 =0.1167+3*0.01856 UCL =0.1167+0.05561

=0.1723 LCL =0.1167-0.05561 =0.06109 CL =0.1167

(within range) Quality is maintained. nP chart CL =P UCL =nP+3nP(1-P) LCL = nP -3nP(1-P) E.g. 1): an automatic m/c sorts letters in a large postoffice.a manual check is kept on m/c.about 200 letters are checked each hr.to see if there have been sorted correctly.thedata from one days work are given below. construct a P-chart & examine the data.
s.no 1 2 3 4 5 6 7 8 9 10 11 12 time of sample 9am 10 11 12 1pm 2pm 3 4 5 6 7 8 Sample size 205 206 195 200 210 195 208 200 205 195 200 195 2406 No. of defectives in sample 12 14 12 15 14 12 15 16 13 14 15 14 166

CL = P =166/2406=0.06899 n=total no. of pieces inspected = 2406/12 =200.5 no. of lots inspected UCL = P +3P(1-P)/n =0.06 + 3 0.06899(1-0.06899)/200.5 = 0.1128 LCL = 0.0251483 (or) UCL = nP + 3nP(1-P) =200.5*0.06899 + 3200.5*0.06899(1-0.06899) =24.3 LCL =200.5*0.06899 - 3200.5*0.06899(1-0.06899) =2.93 CL = n*P =200.5*0.06899 =13.83 E.g. 2):10 samples each of size 50,of a pipe were inspected in pressure testing. the results of the inspection are given below. Sample no: 1 2 3 4 5 6 7 8 9 10 No. of Defectives :2 3 2 0 2 3 2 1 2 3 Draw nP chart & comment on the same. Sol: P = total no of defective pieces Total no. of pieces inspected =sum of defective pieces in all samples N0.of sample*sample size =20/10*50 =0.04

CL = nP = 50*0.04 = 2 UCL = nP + 3nP(1-P) = 2+350*0.04(1-0.04) =6.17

LCL =2-350*0.04(1-0.04) = -2.17~ 0 Eg3):6 consecutives lots recovered from a vendor inspected by sampling process by in ward inspected buyer. the sample size were varied as per variable the lot size. the no. of defectives are given Sample No. 1 2 3 4 5 6 Samples(no. of Pieces inspected) 125 125 50 80 200 125 Defective pieces 1 3 0 2 4 1 Lot size 2850 1860 480 970 4385 2560

Construct a control chart for fraction defective & no. of defectives Sol: Since sample size is varying for each lot, there fore we need to calculate n (are no. of pieces inspected per lot) n = total no. of pieces inspected no. of lots inspected 125+125+50+80+200+125/6 = 705/6 =117.5 P = 1+3+0+2+4+1/125+125+50+80+200+125 =0.016 P-chart: CL = P = 0.016 UCL = P + 3P(1-P)/n = 0.016 + 30.016(1-0.016)/117.5 = 0.051 LCL = P - 3P(1-P)/n = -0.019~ 0 nP chart: CL = n.P = 0.016*117.5 = 1.88 UCL = n.P+ 3n.P(1-P) = 5.96 LCL = -2.2 ~ 0 C-chart UCL = C + 3C CL = C LCL = C-3C E.g.: the foll.table gives the inspection result of 25 similar glass tubes for the no. of defects in them.

Tube no

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 defects 2 1 2 6 8 2 4 9 3 4 5 3 3 7 4 5 2 4 3 7 2 4 5 3 2

Draw the requisites chart & comment. Total no . of defects = C =100 C = 100/ 25 = 4 CL = 4 UCL = 4+34 = 10 LCL = 4 + 34 = 0

Eg 1):a sample of 40 pieces is drawn from the hourly production of a semi-automatic m/c & each item is checked. the no. of defective items found is 24 successive samples of this type are 1,0,3,4,0,0,2,3,4,1,1,2,4,5,0,2,1,1,2,4,3,5,2,4 a)construct a control chart for proportion defective b)construct a control chart for fraction defective 2)a co. manufacture a product which is packed in 1kg tins. it utilizes an automatic filling equipment. it takes a sample of 5 cans every r hrs & measures the filling in each of 5 cans. the foll.table gives the measurements if filings(gms) in the last 5 samples. set up a CC & state whether the process is under control. assume A = 0.58; D = 2.115 individual Measurem -ent Sample no. a b c d e 1 1001 1002 1000 998 999 2 999 998 1001 998 999 3 995 1002 1003 1001 1002 4 1000 1001 999 998 1002 5 994 996 996 1000 999

3) the no. of defectives on 20 items are Item no:1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 No. of Defects:2 0 4 1 0 8 0 1 2 0 6 0 2 1 0 3 2 1 0 2 Devise a suitable control chart scheme for the future. Ans) C = 1.75 UCL = 5.178 LCL = 0 The process in control 4)five hundred bicycle mudguards were observed for paint defects,scratch,foreign particles etc.,in all 1100 defects were found in 500 mudguards if the sample size is 10 compute the control limits by using the appropriate control chart Sol) samples = 500/10 = 50;C = 1100/50 =22