IENG 486 - Lecture 21

Short Run SPC

09/22/16

IENG 486 Statistical Quality & Process Control

Assignment
Reading:

Chapter 6

Section 6.4: pp. 259 - 265

Chapter 9

Sections 9.1 9.1.5: pp. 399 - 410

Sections 9.2 9.2.4: pp. 419 - 425
Sections 9.3: pp. 428 - 430

Homework:

CH 9 Textbook Problems:

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1a, 17, 26

Hint: Use Excel charts!

IENG 486 Statistical Quality & Process Control

Review
Shewhart Control charts

Are for sample data from an approximate Normal distribution

Three lines appear on all Shewhart Control Charts

UCL, CL, LCL

Two charts are used:

X-bar for testing for change in location
R or s-chart for testing for change in spread

We check the charts using 4 Western Electric rules

Attributes Control charts

Are for Discrete distribution data

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Use p- and np-charts for tracking defective units

Use c- and u-charts for tracking defects on units
Use p- and u-charts for variable sample sizes
Use np- and c-charts with constant sample sizes
TM 720: Statistical Process Control

Short Run SPC

Many products are made in smaller quantities than
are practical to control with traditional SPC

In order to have enough observations for statistical control

to work, batches of parts may be grouped together onto a
control chart

This usually requires a transformation of the variable on

the control chart, and a logical grouping of the part
numbers (different parts) to be plotted.

A single chart or set of charts may cover several different

part types

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TM 720: Statistical Process Control

DNOM Charts
Deviation from Nominal

Variable computed is the difference between the

measured part and the target dimension

xi M i Tp
where:

Mi is the measured value of the ith part

Tp is the target dimension for all of part number p

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TM 720: Statistical Process Control

DNOM Charts
The computed variable (xi)
is part of a sub-sample of
size n

xi is normally distributed

n is held constant for all part

numbers in the chart group.

Charted variables are x and

R, just as in a traditional
Shewhart control chart,
and control limits are
computed as such, too:

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UCL x A2 R A2 R
CL x 0
LCL x A2 R A2 R

UCL D4 R
CL R
LCL D3 R

TM 720: Statistical Process Control

DNOM Charts
Usage:

A vertical dashed line is used to mark the charts at the point at

which the part numbers change from one part type to the next
in the group

The variation among each of the part types in the group

should be similar (hypothesis test!)

Often times, the Tp is the nominal target value for the process
for that part type

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Allows the use of the chart when only a single-sided

specification is given
If no target value is specified, the historical average (x) may
be used in its place
TM 720: Statistical Process Control

Standardized Control Charts

If the variation among the part types within a
logical group are not similar, the variable may be
standardized

This is similar to the way that we converted from any normally

distributed variable to a standard normal distribution:

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Express the measured variable in terms of how many units of

spread it is away from the central location of the distribution

TM 720: Statistical Process Control

Standardized Charts x and R

Standardized Range:

Plotted variable is

Ri
R
Rj
s
i

where:

Ri is the range of measured values for the ith

sub-sample of this part type j
Rj is the average range for this jth part type

UCL D4
CL R j
LCL D3

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TM 720: Statistical Process Control

Standardized Charts x and R

Standardized x:

Plotted variable for the sample is

s
i

x
where:

M i Tj
Rj

Mi is the mean of the original measured values for

this sub-sample of the current part type (j)
Tj is the target or nominal value for this jth part type

UCL A2
CL 0
LCL A2
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TM 720: Statistical Process Control

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Standardized Charts x and R

Usage:

Two options for finding Rj:

Prior History
Estimate from target :

Examples:

d2

R j
c4

Parts from same machine

with similar dimensions
Part families similar part
tolerances from similar
setups and equipment

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TM 720: Statistical Process Control

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Standardized Charts Attributes

Standardized zi for Proportion Defective:

Plotted variable is

Control Limits:

zi

pi p
p (1 p )
n

UCL 3
CL 0
LCL 3

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TM 720: Statistical Process Control

12

Standardized Charts Attributes

Standardized zi for Number Defective:

Plotted variable is

zi

Control Limits:

npi n p
n p (1 p)

UCL 3
CL 0
LCL 3

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TM 720: Statistical Process Control

13

Standardized Charts Attributes

Standardized zi for Count of Defects:

Plotted variable is

zi

Control Limits:

ci c
c

UCL 3
CL 0
LCL 3

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TM 720: Statistical Process Control

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Standardized Charts Attributes

Standardized zi for Defects per Inspection
Unit:
ui u
Plotted variable is
zi
u
n
UCL 3

Control Limits:

CL 0
LCL 3

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TM 720: Statistical Process Control

15

Guidelines for Implementing

Control Charts
1.

Determine which process or product characteristic(s) to

control

2.

Determine where the charts should be implemented in

process

3.

Choose proper type of control charts

4.

Decide what actions should be taken to improve processes

5.

Select data-collection systems and computer software

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IENG 486 Statistical Quality & Process Control

16

Determine Which Characteristic to

Control and Where to Put Charts
1.
2.

3.
4.

To start, apply charts to any process or product

characteristics believed important.
Charts found unnecessary are removed; others that may be
required are added.
(Usually more charts to start than after process has
stabilized)
Keep current records of all charts in use, i.e., types and
parameters of each.
If charts used effectively number of charts for variables
increases and number of attributes charts decreases

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IENG 486 Statistical Quality & Process Control

17

Determine Which Characteristic to

Control and Where to Put Charts
5.

6.

At beginning, use more attributes charts applied to finished

units, i.e., near end of process.
As more is learned about the process, these are replaced
with variables charts earlier in process on critical process
characteristics that affect nonconformities.
Rule of thumb: the earlier in the process that control can be
established, the better.
Control charts are an on-line process monitoring
procedure; Maintain charts as close to work center as
possible.
Operators and process engineers should be directly
responsible for using, maintaining and interpreting charts

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IENG 486 Statistical Quality & Process Control

18

Choosing Proper Type of

Control Chart: Variables Charts

Use (x & R) or (x & S) charts when:

1.
2.
3.
4.
5.
6.
7.
8.

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New process or product coming online

Chronically troubled process
Wish to reduce downstream acceptance sampling
Using attributes charts but yield still unacceptable
Very tight specifications
Operator decides whether or not to adjust process
Change in product specs desired
Process capability (stability) must be continually
demonstrated

IENG 486 Statistical Quality & Process Control

19

Choosing Proper Type of

Control Chart: Attributes Charts

Use p, np, c or u charts when:

1.
2.

3.
4.

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Operators control assignable causes and it is necessary to

reduce fallout
Process is complex assembly operation and product quality
measured in terms of occurrence of nonconformities: e.g.
computers, automobiles
Measurement data cannot be obtained
Historical summary of process performance is necessary.
Attributes charts are effective for summarizing a process for
management

IENG 486 Statistical Quality & Process Control

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Choosing Proper Type of

Control Chart: Individuals Charts

Use (x & MR), MA, EWMA, or CUSUM charts when:

1.
2.
3.
4.

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Repeated measures do not make sense

Inconvenient / impossible to obtain more than one
measurement per sample
Automated testing allows you to measure every unit
(EWMA chart may be best)
Data becomes available very slowly and waiting for a larger
sample is impractical.

IENG 486 Statistical Quality & Process Control

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