Pp08a

Quality Control
Chapter 8- Control
Charts for Attributes
PowerPoint presentation to accompany
Besterfield
Quality Control, 8e
PowerPoints created by Rosida

Coowar
Besterfield: Quality Control, 8th ed..
2009 Pearson Education, Upper Saddle River, NJ 07458.

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Outline
Attribute
Control Charts for Nonconforming Units
Control Charts for Count of
Nonconformities
A Quality Rating System

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Learning Objectives
When you have completed this chapter you
should:
Know limitations of variable control charts and
the different types of attribute charts.

Know the objectives of the p chart group and the
applicable distribution.
Be able to construct a:
Fraction defective chart- fixed subgroup size
Fraction defective chart-variable subgroup size
Percent defective chart
Number defective chart


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Learning Objectives contd.

When you have completed this chapter you
should:
Know how to minimize the effect of variable
subgroup size.
Know the applications of the c chart group, the
applicable distribution and two conditions.

Be able to construct a c chart and a u chart
and know the difference between them.

Know the three classes of defect severity

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Attribute
The term Attribute refers to those quality
characteristics that conform to

specifications or do not conform to
specifications.
Attribute are used:
1. Where measurements are not possible.
2. Where measurements can be made but
are not made because of time, cost, or

need.

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Attribute
A nonconformity is a departure of a
quality characteristic from its intended

level or state that occurs with a severity
sufficient to cause an associated
product or service not to meet a
specification requirement.
Defect is concerned with satisfying
intended normal, or reasonably

foreseeable, usage requirement.

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Attribute
Defect is appropriate for use when
evaluation is in terms of usage.

Nonconformity is appropriate for
conformance to specifications.
The term Nonconforming Unit is used to
describe a unit of product or service

containing at least one nonconformity.

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Attribute
Defective is analogous to defect and is
appropriate for use when unit of

product or service is evaluated in terms
of usage rather than conformance to
specifications.
Limitations of variable control charts:
These charts cannot be used for quality

characteristics which are attributes.

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Attribute
Types of Attribute Charts:
1.
Nonconforming Units (based on the

Binomial distribution): p chart, np
chart.
2.
Nonconformities (based on the

Poisson distribution): c chart, u chart.

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The P Chart
The P Chart is used for data that consist of
the proportion of the number of

occurrences of an event to the total
number of occurrences.
It is used in quality to report the fraction or
percent nonconforming in a product,

quality characteristic, or group of quality
characteristics.

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The P Chart
Formula:
np
p
n
The fraction nonconforming, p, is usually
small, say, 0.10 or less.

Because the fraction nonconforming is
very small, the subgroup sizes must be

quite large to produce a meaningful
chart.

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The P Chart
It can be used to control one quality
characteristic, as is done with X bar and R

chart,
Or to control a group of quality characteristics
of the same type or of the same part,

Or to control the entire product.
It can be established to measure the quality
produced by a work center, by a department,

by a shift, or by an entire plant.

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The P Chart
It is frequently used to report the
performance of an operator, group of

operators, or management as a means
of evaluating their quality performance.
The subgroup size of the P chart can be
either variable or constant.

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The P Chart
Objectives of the P Chart:
1. Determine the average quality level:
This information provides the process

capability in terms of attributes.
2. Bring to the attention of management
any changes in the average.

3. Improve the product quality: Ideas for
quality improvement.

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The P Chart
Objectives of the P Chart contd:
4. Evaluate the quality performance of
operating and management personnel.

5. Suggest places to use X bar and R chart:
They are more sensitive to variation.

6. Determine acceptance criteria of a
product before shipment to the customer.

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The P Chart
P-Chart Construction for Constant
Subgroup Size
1. Select the quality characteristic(s):
a) Single quality characteristic.
b) Group of quality characteristics.
c) A part.
d) An entire product.
e) A number of products.
f) It can be established for performance control of
an
operator, work center, department, shift, plant,
or corporation

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The P Chart
P Chart Construction for Constant Subgroup
Size contd.
2. Determine the subgroup size and
method:
The size of the subgroup is a function
of the proportion nonconforming.

A minimum size of 50 is suggested as
a starting point.

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The P Chart
P Chart Construction for Constant Subgroup
Size contd.
3. Collect the data:
At least 25 subgroups.
Different sources (Check sheet).
For each subgroup the proportion
nonconforming is calculated by the

formula P = np/n

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The P Chart
P Chart Construction for Constant Subgroup Size
4. Calculate the trial central line and the control
limits:
p
np
n
UCL p 3
LCL p 3
p (1 p )
n
p (1 p )
n

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The P Chart
P Chart Construction for Constant Subgroup Size
contd.
5. Establish the revised central line and control
limits.
pnew p0
np np
n n
p0 (1 p0
UCL p0 3
n
p0 (1 p0 )
LCL p0 3
n

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The P Chart
The P Chart is most effective if it is
posted where operating and quality

personnel can view it.
The control limits are usually three
standard deviations from the central

value. Therefore, approximately 99% of
the plotted points, P, will fall between the
upper and lower control limits.

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The P Chart
A P Chart will also indicate long-range
trends in quality, which will help to

evaluate changes in personnel,
methods, equipment, tooling,
materials, and inspection techniques.
P-chart is based on the binomial
distribution.

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The P Chart
P Chart Construction for Variable Subgroup
Size
1. Collect the data.
2. Determine the trial central line and control
limits: Since the subgroup size changes

each day, limits must be calculated for
each day.

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The P Chart
Size contd.
2. As the subgroup size gets larger, the
control limits are closer together.

3. Establish revised central line and control
limits:

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The P Chart
Size contd.
If Po is known, the process of data
collection and trial control limits is not

necessary.
P is the proportion (fraction)
nonconforming in a single subgroup.

P is the average proportion (fraction)
nonconforming of many subgroup.


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The P Chart
P Chart Construction for Variable
Subgroup Size contd.
Po is the standard or reference value of
the proportion (fraction)

nonconforming based on the best
estimate of PBar.
is the population proportion
(fraction) nonconforming.

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The P Chart
Minimizing the Effect of Variable Subgroup Size
1. Control limits for an average subgroup size: By using an
average subgroup size, one limit can be calculated and

placed on the control chart.
nav
p0 (1 p0
UCL p0 3
nav
p0 (1 p0 )
LCL p0 3
nav

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The P Chart
contd.
Case I: This case occurs when a point (subgroup
fraction nonconforming) falls inside the limits and
its subgroup size is smaller than the average
subgroup size.
Case II: This case occurs when a point (subgroup
fraction nonconforming) falls inside the average
limits and its subgroup size is larger than the
average subgroup size.

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The P Chart
contd.
Case III: This case occurs when a point (subgroup
fraction nonconforming) falls outside the limits
and its subgroup size is larger than the average
subgroup size.
Case IV: This case occurs when a point (subgroup
fraction nonconforming) falls outside limits and
its subgroup size is less than the average
subgroup size.

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The np Chart
Number Nonconforming Chart (np):
The np chart is easier for operating
personnel to understand than the p

chart.
The limitation that this chart has is that
the subgroup size needs to be constant.

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The np Chart
Central Line = np0
Control Limits = np0 3 np0 (1 p0 )

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The np Chart
Number Nonconforming Chart (np):
If the fraction nonconforming po is
unknown, then it must be determine by

collecting data, calculating trial control
limits, and obtaining the best estimate
of po.

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Process Capability
For an attribute this process is much simpler.
The process capability is the central line of
the control chart.

Management is responsible for the
capability.
When the plotted point is outside the control
limit, operating personnel are usually

responsible.

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Non-conformities
The nonconformities chart controls the
count of nonconformities within the product

or service.
An item is classified as a nonconforming
unit whether it has one or many

nonconformities.
Count of nonconformities (c) chart.
Count of nonconformities per unit (u) chart.

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Control Charts for Count of Nonconformities

Since these charts are based on the
Poisson distribution, two conditions

must be met:
1. The average count of nonconformities
must be much less than the total

possible count of nonconformities.
2. The occurrences are independent.

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Objectives:
1. Determine the average quality level: This
information gives the initial process

capability.
2. Bring to the attention of management any
changes in the average.

3. Improve the product quality: Ideas for
quality improvement.

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Non-conformities
Objectives contd.:
4. Evaluate the quality performance of
operating and management personnel.

5. Suggest places to use X bar and R
chart.
6. Determine acceptance criteria of a
product before shipment to the

customer.

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C Chart construction:
1. Select the quality characteristic(s):
a)
Single quality characteristic.
b)
Group of quality characteristics.
c)
A part.
d)
An entire product.
e)
A number of products.
f)
It can be established for performance control of

an: operator, work center, department, shift,
plant, or corporation

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Non-conformities
C Chart construction contd:
2. Determine the subgroup size and
method:
3. Collect the data:
At least 25 subgroups.
Different sources.

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Non-conformities
c-Chart Construction contd:
4. Calculate the trial central line and the control limits:
c
c
g
UCL c 3 c
LCL c 3 c

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Non-conformities
C chart construction contd:
5. Establish the revised central line and
control limits
c new = c0
c-c
UCL = c0 +3
LCL = c0 - 3
g - gd
c0
c0

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Non-conformities
C chart construction contd:
6. Achieve the objectives: The reason for
the control chart is to achieve one or

more of the previously stated objectives.

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Non-conformities/Unit
Chart for Count of Nonconformities/Unit (u
Chart)
c
u
n
c
n
UCL u 3
u
n
LCL u 3
u
n

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Non-conformities
Chart for Count of Nonconformities/Unit
(u Chart)
Scale selected is continuous for the u
chart. For the c chart is discrete.

Subgroup size for the u chart can vary. For
the c chart is 1.
The u chart is limited in that we do not
know the location of the nonconformities.


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A Quality Rating System

Nonconformity Classification:
1. Critical nonconformities: Unsafe conditions for
individuals using, maintaining, or depending

upon the product.
2. Major nonconformities: Result in failure or reduce
materially the usability of the product for its

intended purpose.
3. Minor nonconformities: Reduce materially the
usability of the product for its intended purpose.

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Control Charts for

Demerits/Unit
D wc uc wma uma wmi umi
when wc , wma and wmi are 9, 3 and 1
D 9uc 3uma 1umi
D0 9u0 c 3u0 ma 1u0 mi
0u
9 2 u0 c 32 u0 ma 12 u0 mi
UCL D0 3 0 u
LCL D0 3 0 u

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Control Chart Selection

Quality Characteristic
Variable
Attribute
Defective
n>1?
no
x and MR
yes
n>=10?
Defect
no
yes
x and s
x and R
constant
sample
size?
yes
no
p-chart with
variable sample
size
constant
sampling
unit?
p or
np
yes
no

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Quality Control

PowerPoints created by Rosida

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

the different types of attribute charts.

Fraction defective chart- fixed subgroup size

Fraction defective chart-variable subgroup size

Percent defective chart

Number defective chart

2009 Pearson Education, Upper Saddle River, NJ 07458.

Learning Objectives contd.

applicable distribution and two conditions.

and know the difference between them.

2009 Pearson Education, Upper Saddle River, NJ 07458.

characteristics that conform to

are not made because of time, cost, or

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

quality characteristic from its intended

intended normal, or reasonably

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

evaluation is in terms of usage.

describe a unit of product or service

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

appropriate for use when unit of

These charts cannot be used for quality

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

Nonconforming Units (based on the

Nonconformities (based on the

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

the proportion of the number of

percent nonconforming in a product,

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

The fraction nonconforming, p, is usually

small, say, 0.10 or less.

very small, the subgroup sizes must be

2009 Pearson Education, Upper Saddle River, NJ 07458.

characteristic, as is done with X bar and R

of the same type or of the same part,

produced by a work center, by a department,

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

performance of an operator, group of

either variable or constant.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

This information provides the process

any changes in the average.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

operating and management personnel.

They are more sensitive to variation.

product before shipment to the customer.

Besterfield: Quality Control, 8th ed..

2009 Pearson Education, Upper Saddle River, NJ 07458.

2009 Pearson Education, Upper Saddle River, NJ 07458.