CH 07

Chapter 7
Chapter 7
Learning Objectives
Chapter 7
P Control Chart
The most versatile and widely used attributes
control chart
-- used when the subgroup size is not constant
Used to evaluate fraction defective
Control limits are based on Binomial
Distribution
Chapter 7
P Control Chart
P CONTROL CHART ALCAS PEFLOW SOLDER MACHINE
90
PERCENT DEFECTIVE
80
70
UCL PERCENT
60
50
40
30
20
10
0
Chapter 7
10
12
14
16
18
SUBGROUP NUMBER
20
22
24
26
P Chart
Compute the control limits
UCL P 3
P (1 P )
n
P (1 P )
LCL P 3
n
The UCL and LCL are not straight lines,

they rise and fall with respect to the
subgroup size
Chapter 7
The P Chart
When to use:
Only when variable data cannot be obtained.
When charting fraction rejected as
nonconforming from a varying sample size.
When screening multiple characteristics for
potential monitoring on variable control charts.
When tracking the quality level of a process
before any rework is performed.
Chapter 7
How
The P Chart
By counting the number of defective items from a sample

and then plotting the percent that are defective.
Conditions
In order to be of help, there should be some rejects in each
observed sample.
The higher the quality level, the larger the sample size must
be to contain rejects. For example, if 20% of a product is
rejectable, a sample size of 5 will be needed. However, a
sample of 1,000 will give an average of only one reject per
sample if 0.1% of the product is rejectable.
Chapter 7
The P Chart
Table 1 Formulas for the P Chart
Chart
Control
limits
P (1 P )
UCL P 3
n
P (1 P )
LCL P 3
n
Chapter 7
Centerline
Summation of
plot po int s
p
Number of
plot po int s
Plot point
Sample
size
Number of
defective units
p
in a sample
Sample size(n)
Varying
The P Chart
To calculate Plot Points
The p plot point is the fraction defective in a
sample. The centerline is the average fraction
defective in series of samples. Figure 1 is a cross
section showing countersunk holes for rivet
installation.
Chapter 7
10
The P Chart
To calculate Plot Points
In a sheet metal assembly shop a common process
is bucking rivets. Because of the combined
variation in the rivets, the drilled holes, and the
bucking process, there are quality problems. After
the rivets in an assembly have been bucked into
place they are checked for nonconformity. A P
chart is used to track the first-time-through fraction
defective.
Chapter 7
11
Figure 1
Cross section of sheet metal plates with
countersunk holes for rivet installation
Chapter 7
12
P Chart
Chapter 7
13
P Chart
TOTALS
Chapter 7
14
X Relay
Chapter 7
15
Fluorocarbon Leak Test

FLUOROCARB. LEAK TEST
P Chart (%)
7
6
5
4
3
2
1
UCL
1 2 3 4 5 6 8 9 14 15 16 17 18 19 20 21 22 23 24 25 28 29
Chapter 7
16
NP Control Chart
Number of defectives
Used when subgroup size is constant (n)
The actual number of defects is represented by
pn (or np)
Chapter 7
17
NP Control Chart
NP Control Chart plating defects of assembled
parts
15
14
13
12
11
UCL
10
9
8
7
6
5
4
3
2
1
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Chapter 7
LOT NUMBER
18
NP Control Charts
Computations
Control limits are based on the Binomial
Distribution
Pn
1) Central line: nP
K
2) UCL nP 3 nP (1 P )
3) LCL nP 3 nP (1 P )
Chapter 7
Where
Pn
P
n
19
NP Charts
Chapter 7
20
4 Steps in control chat for Fraction

Rejected
I
II
III
IV
Preparatory Decisions
Starting the control chart
Continuing the control chart
Reports and Action based on control chart
Chapter 7
21
I. Preparatory Decisions
Purpose
Select Quality Characteristic
Selection of subgroup
P or NP chart
Control limit calculated
Chapter 7
22
II. Starting the control chart

Recording data
r
r
p n , p n Calculation
Trial limits
Plotting points
i
Chapter 7
23
III Continuing the control chart

P0 P
If chart in control
UCL P0
3 P0 1 P0
ni
Selection of P0
Calculation of control limits
Plotting the points/limits
Interpretation of lack of control
Periodic Review/Revision of Pi
Chapter 7
24
IV Reports and Action based on

control chart
Action to bring process into control-Pareto, high
spot/low spot.
Review of Design and specification
Information to Management(Quality level)
Sensitivity of p chart : 0.1% requires 1000s
Chapter 7
25
Example of Attribute control chart

LOT
1
2
3
4
5
Total
Number Number of
inspecting defectives
500
27
50
12
800
12
100
14
150
15
1600
80
Chapter 7
P
0.054
0.240
0.015
0.140
0.100
26
Example of Attribute Control Chart

Subgrou
p
Subgrou
p Size n
# of
Defectiv
es
Percent
Defectiv
e P (%)
UCL(%)
LCL
115
15
13.0
17.7
1.
220
18
8.2
15.4
3.
210
23
10.9
15.6
3.
220
22
10.0
15.4
3.
255
18
7.0
15.0
4.
365
15
4.1
255
44
300
13
4.3
280
33
11.7
14.8
10
330
42
12.7
14..3
Total
2550
243
P
15.0
Totlal defective
Total inspected
Chapter 7
4.
4.
4.
(100)
LCL P
3
n
P 100 P
UCL P
3
n
P 100 P
27
Purpose of maintaining attribute charts is to

continuously improve the processes for defect
free production by highlighting the key problems.
How to work on getting desirable pattern
Recommend working on 3 top problems for the day
or week of month as the time permits and solve
by a systematic problem solving method namely
(1) Define problems
(2) Find key causes
(3) Solution to cure the key causes demonstrated by
statistics
Chapter 7
28
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40
Design of the Fraction Nonconforming Chart
Three parameters must be specified

1. The sample size
2. The frequency of sampling
3. The width of the control limits
Common to base chart on 100% inspection

of all process output over time
Rational subgroups may also play role in
determining sampling frequency
Chapter 7
41
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46
Average sample size approach
Chapter 7
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Chapter 7
55
Charts for Nonconformities

C cart and U chart
Often times there is interest in knowing how
many defects an item has
-- C charts: total number of nonconformities in
subgroups of fixed size (defects per square
yard of cloth)
-- U charts: average number of nonconformities
per unit (defects per TV set)
Chapter 7
56
Charts for Nonconformities

Used during inspection of complex assemblies
Control limits based on Poisson Distribution
Chapter 7
57
C Control Chart
UCL and LCL are straight lines because of
fixed sample sizes
CL= c
UCL= c 3 c
LCL= c 3 c
Where c is the central line and equal to
Total Defects
Number of Subgroups
Chapter 7
58
The data in table 2 represent the types of

defects found on the first two boxes. Box 1 has
nine defects and box 2 has twelve.
Notice that the types and quantity of defects are
different for the two boxes; nevertheless, the
total number of defects is plotted on the C chart.
Chapter 7
59
Note:
A C chart (as well as any other attribute
chart) should only be used when there is
absolutely no way to obtain variable data
from the characteristic in which measurable
data is available.
To get started, this data can be analyzed on
an attribute chart to get ideas (using the Pareto
analysis) on the characteristics.
Chapter 7
60
U Control Chart
As the subgroup size varies, UCL and LCL varies
CL= u
UCL=
LCL=
3 u
u
n
3 u
u
n
where u is the central line and equal to

Total Defects
Total Units
Chapter 7
61
The U Chart
When to use:
Only when variable data cannot be
obtained.
When plotting the average number of defects
found per unit.
When screening multiple characteristics for
potential monitoring on variable control
charts.
How:
Each unit is examined and the average
number of defects found are plotted.
Chapter 7
62
The U Chart
Conditions:
Constant unit size, but any convenient number of
units per plot point. Unit size is different from
samples size. For example, one unit could be
defined as 1 square-foot of material.
On a particular day, 12.3 square-feet of material
is inspected. The plot point would represent the
average number of defects per unit, but the
sample size would be 12.3.
Chapter 7
63
The U Chart
There are potentially several different types
of defects per unit, but none of which would
necessarily render the part a defective.
For example: paint blemishes on a skin
panel, or various electrical faults on a
circuit board. A unit can be single part, an
assembly of several parts, an area of
material, or any rational grouping in which
the likelihood of defect(s) is constant from
unit to unit.
Chapter 7
64
In order for this type of analysis to be of

help, there should be some defects in each
observed unit.
Chapter 7
65
The U Chart
To Calculate Plot Points:
The u plot point is the average number of
defects per unit in a sample of n units. The
centerline is the average of all the plot points
on the chart. Figure 6-17 shows a roll of
composite material/dyed cloth with potential
multiple
defects.
Chapter 7
66
The U Chart
Composite materials are generally made up of
several layers of materials that are bonded to
form the desired characteristics.
Prior to lay up, are used each day, the number
of rolls inspected for defects. Since different
amounts of the material are used each day, the
number of rolls inspected also changes
daily.
Chapter 7
67
Attribute Control Charts

Chart
type
Names/remarks
Central
line
Control
Limits
p 1 p
n
p 1 p
LCL p p 3
n
UCL p p 3
Fraction defective
np
Number defectives
np
UCLnp np 3 np 1 p
UCLc c 3 c
LCLc c 3 c
Number of defects
per subgroup
Number of defects
per
inspection
unit
Chapter 7
LCLnp np 3 np 1 p
UCLu u 3 u
LCLu u 3 u
68
Attribute
data
Variable data
N>50
N not constant
Fraction
defective
N>50
N is constant
Fraction
defective
n1
n not constant
Defects
per unit
X-bar chart
R chart
P chart
np chart
n<6
n>6
n>25
X-bar chart
S chart
X-bar chart
S2 chart
u chart
n=1
n1
Is constant
Defects per unit
Individual
chart
c chart
Chapter 7
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Low Defect Levels
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Actions taken to improve a process
Chapter 7
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Chapter 7
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Learning Objectives
Chapter 7
111

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Chapter 7

The UCL and LCL are not straight lines,

By counting the number of defective items from a sample

Fluorocarbon Leak Test

4 Steps in control chat for Fraction

II. Starting the control chart

III Continuing the control chart

IV Reports and Action based on

Example of Attribute control chart

Example of Attribute Control Chart

Purpose of maintaining attribute charts is to

Design of the Fraction Nonconforming Chart

Three parameters must be specified

Common to base chart on 100% inspection

Average sample size approach

Charts for Nonconformities

Charts for Nonconformities

The data in table 2 represent the types of

where u is the central line and equal to

In order for this type of analysis to be of

Attribute Control Charts

Low Defect Levels

Actions taken to improve a process

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