Introduction

to Quality
Control

Definition of Quality
Quality Control Areas
Statistical Process Control

Handbook :

quality control
and improvement
Fundamental of

by : Amita Mitra

Evolution of Quality Control

Egyptians demonstrated quality

through construction of Pyramid

The greeks set high standard in arts
and crafts
Structural design created by Roman
for building cities, churches, bridges,
roads and so on.
In 1800s, the production of good
and services was predominantly to a
single individual or a small group
owned by person or a small group
3

Evolution of Quality Control

1900s to 1920s : - mass production

- principle of specialization
- process is relatively simple
1920 -1940 : - Inspection quality control
- process is more complicated
- Statistical aspects dealing with quality control
were being developed
1940 1960
: - Statistical Quality Control
- Standard sampling plan is introduced
1960 : - TQM era (involvement of several department in
quality
Control activities
1970s : - TQM Organizationwide ( partisipation of every one in
the
company )
- Fishbone diagram is introduced
- Taguchi Method is introduced
4

Evolution of Quality Control

1980s

: - The continued growth in computer

1990s
increased

: - expanded use of quality measures and

to customer needs

SIX SIGMA (DMAIC)

LEAN-SIGMA

Purposes
1.Ability to understand about Quality
2. Ability to recognize the quality control areas

3. Ability to diffrentiate between the assinable and comm

4. Ability to calculate the control limit
5. Ability to calculate the type 1 and type 2 error
6. Ability to analyse the control chart
6

Definition of Quality
Garvin (1984)

fa
u
an
M

Juran (1974)
Fitness for use

Us
er
-b

Quality

d
ase
ct-b

formance to requirements or specifications

du
Pro

Crosby (1979)

rin
u
ct

b
g-

ed
s
a

Transcendent
7

as
ed

Valu
e-ba
sed

Performance, features, reliability,

nformance,durability, serviceability,
aecthetics, and perceived quality

Definition of quality
The quality of a product or service is
the fitness of that product or service for
meeting its intended use as required by
the customers

Terms
Quality Characteristics : One or more
elements which define the intended quality
level of a product or service
Nonconformity : a quality characteristic
that does not meet its stipulated
specifications requirement.
A nonconforming unit : a unit that has one
or more nonconformities such that the unit
unable to meet the intended standard and
is unable to function as required.
9

Defect : a quality characteristic that does

not meet certain standard.
A Standard : a pricise statement that
formalize the requirements of the customer .
Specification : a set of conditions and
requirements of specific and limitted
application , that provide a detail description
of the procedure, process, material, product,
or service for use primarily in procurement
and manufacturing.

10

Quality Aspecs
Quality

Quality of
Conf
orma
nce

Quality of
Desi
gn

Quality of
Perfo
rman
ce

11

Quality of Design
The product or service must be designed to
meet at least minimally the needs of the
customer
Influenced by : product, cost, profit policy,
demand, availability of parts and materials, and
product safety.

12

Quality of Conformance
The manufactured product or the service
rendered must meet the standards
selected in the design phase.
Defect prevention, defect finding, and defect analysis and rectification.

13

Quality of Performance
Concerned with the operation of the product
when actually put to use or the service
when performed and measures the
degree to which it satifies the
consumer

14

Quality Control
Defined as a system that is used to
maintain a desired level of quality in a
product or service

15

Quality Control Areas

Off-line
Quality
Control

Statistical
Process
Control

Acceptanc
e
Sampling
Plan

16

Off-Line Quality Control

Choosing the product and

Process parameters
This task can be performed
through the product and
process design.
The design experiment and
Taguchi method gives the
off-line
quality
control
procedure.
17

Statistical Process Control

Comparing the process and service output

to the standard.
On-line SPC Taking the information
about the product, process, and service
when the system is functioning.
SPC uses the control chart for on-line SPC
procedure.

18

Acceptance Sampling Plan

Related to product or
service inspection.
Acceptance
sampling
plan is a planning in
determining the number
of item in the sample
and lot criteria for lot
acceptance based on a
specific condition, e.g.,
The
producen
or
customer risk.
19

Quality Assurance

A system that ensures that all

procedures that have been designed
and planned are followed
All those planned or systematic
actions necessary to provide
confidence that a product or service
will satisfy given needs

20

Quality Circle

An informal group of people that

consists of operators, supervisors,
managers, and so on, who get
together to improve ways to make
the product or deliver the services.

21

Benefits of Quality Control

1. The improvement in the quality of product and services
2. The system is continually evaluated and modified to meet the
changing needs of customer
3. A quality Control system improves the productivity
4. Reduce cost in the long run
5. The leadtime for producing parts and subassemblies is
reduced
6. A quality control system maintains an improvement
environment when everyone strives for improved quality and
productivity.
22

Chapter 6
Statistical Process
Control
Using Control Chart
23

1. Control Chart is a graphical tool for monitoring

the activity of an ongoing process
2. Sometimes referred to as Shewhart Control
Chart
3. The value of quality characteristic are plotted
along the vertical axis, and horizontal axis
represents the samples, or subgroups.

24

Quality Characteristics

Control Chart

18

UCL

15

CL

12

LCL

Subgroup
25

The chart indicate :

When to take the corrective actions

Type of remedial action necessary
When to leave the process alone
Process Capability
Possible means of quality
improvement.

26

Causes Of Variation

27

Assignable/Special Cause
The existing variability is not
from the process. It is not
effecting all the products.
Example: The use of the wrong
tool, bad quality of raw material,
or operator error.

If one observation locates

outside the control limits or
there
is
a
non-random
pattern, it is expected that
there is an assignable cause
process is out of control.
28

Common Cause
The existing variability comes from the
process it self.
It always exists as long as the process
does not change and effected all the
products.
It comes from alot of small causes and
can not totally eliminate.
Example: variability that come from the
raw material, mechanical vibration,
work condition fluctuation..
29

Control Limits Calculation

UCL

E( )
E() k ()

LCL

E( ) k ( )

CL

30

Example 1
The mean of part thickness of a
product is 30 mm with standard
deviation equal to 1.5 mm. Make
a control chart using the limits of
3 with sample size equal to 5
chosen ramdomly from the
process.
31

32

Error in Decision Making(1)

Type I error

To decide that a process is out

of control when it is not.
Probability of type I error is
represented by .

33

Error in Decision Making(2)

/2

Type 1 error

UCL

CL

LCL
/2
34

Error in Decision Making(3)

To decide that a process is in of

control when it is not.

Type II Error

Probability of type II error is

represented by .

35

Kesalahan Pengambilan
Kesimpulan (4)

UCL

Kesalahan Tipe II

CL

LCL
36

37

Error in Decision Making

38

Example 6-2. p.242

The control chart for nylon
strength will be made. A sample
with size 5 is taken randomly from
a process. The mean strength
and
standard
deviation
are
estimated by 120 kg and 8 kg,
respectively.
39

Example 6-2 (continuation)

a.

b.

c.

If the control limits uses the 3 sigma from

the mean of process, what is the
probability of type 1 error ?
If the process mean shifts to 125 kg,
What is the probability of type 2 error at
the first sample plotted since the shifting
existed ?
What is the probability to detect the shift
in the first two samples chosen randomly
and independently
40

The OC curve shows the

control chart ability to
detect the changing of
process parameter.
Plotting the probability of
type 2 error to the shift of
the process parameter
value
when
process
incontrol.

Probability of undetected

Operating Characteristic Curve

1.0

0.5

0.0
125

130

140

145

Process Parameters
41

The effects of Control Limits to

Type I and II Error
UCL
UCL

CL

LCL
LCL
42

The Effect of Sample Size to

The Control Limits

UCL
UCL
CL
LCL
LCL
43

Average Run Length (ARL)

To determining the average of the

number of Sample needed to detect
the out-of-control signal
ARL = 1/Pd
Pd: probability of plotted observation
otuside the control limits = alpha
44

Sampling
Choosing Sample item: instant-of-time
method and period-of-time method.
Sample size.
Frequency of Sampling.

45

Control Chart Pattern Analysis

(1)

Quality characteistics

If one or more located outside the

control limmits out of control.
18

UCL

15

CL

12

LCL

Subgroup

7
46

Control Chart Pattern

Analysis(2)
Quality characteristics

If two out three consecutive points located

outside 2 (warning limit) at the same side of the
CL out of control.

18

UCL
UWL

15

CL

12

LWL
LCL

Subgroup

7
47

Control Chart Pattern

Analysis(3)

Quality

characteristic
s

If four out five points consecutively located

outside 1 at the same side of CL out of
control.
18

UCL

15

limit 1
CL
limit 1
LCL

12

Subgroup

7
48

Control Chart Pattern

Analysis(4)
If nine or more of consecutive points located at
the same side of CL out of control.

Quality characteristics

18

UCL

15

CL

12

LCL

Subgroup

8
49

Control Chart Pattern

Analysis(5)
Quality characteristics

If six or more points consecutively has a tendency

to increase or decrease out of control.

18

UCL

15

CL

12

LCL

Subgroup

8
50

Application of the rules to

determine a simultanly out of
control
The application of the simultanly out of
control can increase the probability type I
error.
k
1 - (1 - i)
i1

k
i

: The total type I error

: the number of rules used
: type I error for the rule number i.

Assumptions : the rules are independently exist.

51

Example 1
The pin diameter produced by a
machine is the quality characteristic
that to be controlled . Based on the
historical data the mean diameter of
diameter is 15 mm with standard
deviation equal to 0,8 mm. If the
sample, with size 4, is taken randomly
from the process :
52

a.

b.

c.

d.

e.

Determine the control limits for , 2, dan 3 for

mean diameter of the pin.
Determine the probability of false alarm?
If the mean of the process shift to 14,5 mm, what
is the probability that the shift cant be detected
in the first sample plotted since the shift exist ?
What is the probability failing to detect the shift
for the second sample since the shift exist ?
Make the OC curve for the control chart.

53

Example 2
A quality engineering is asked to make a
control chart to control a process with mean
and standard deviation equal to 100 and 5
respectively. The control should use the
control limit 3 sigma and has the ability to
detect a shift from 100 to 105 with
probability equal to 0,75. ( the rule number
one is used to determine the out of control
condition).
54

a.

b.

Determine CL, LCL, dan UCL for the

control chart?
If the control chart application used in (a)
uses the rule number one and two
simultaneously for the out-of-control
condition, how is the effect in the
capabiltiy of the control chart in
detecting the shift the average from 100
to 105
55