Chapter 7

STATISTICAL CONTROL CHARTS

 Introduction - Control Chart
A graphical method for evaluating whether a
process is or is not in a state of statistical control.
Introduction - Control Chart
For Example: If you write your name ten times,
your signatures will all be similar, but no two
signatures will be exactly alike.
There is a variation, but it varies between
predictable limits.
However, if as you are signing your name,
someone bumps your elbow, you get an unusual
variation due to what is called a "special cause".
Introduction - Control Chart
For many, many processes, it is important to
notice special causes of variation as soon as they
occur.
There's also "common cause" or common
variation.
Happily, there are easy-to-use charts which make
it easy to see both special and common cause
variation in a process.
They are called control charts.
Introduction - Control Chart
In Control Chart, there are two types of variations:
(a) Special Variation (Special Cause)
(b) Common Variation (Common Cause)
Introduction - Control Chart
All control charts have three basic components:
(a) a centerline, the average of all the samples
plotted.
(b) a upper and lower statistical control limits
( c) performance data plotted over time.
Control Chart - Things to look
for:
The point of making control charts is to look at
variation, seeking special causes and tracking
common causes.
It is a tool used to distinguish between process
variation resulting from common causes and
variation resulting from special causes.
Identifying Special causes
(a) 1 data point falling outside the control limits.
(b) 6 or more points in a row steadily increasing or
decreasing,
(c ) 8 or more points in a row on one side of the
centerline,
(d) 14 or more points alternating up and down.
Special Variation or Special
Cause
When a process is being affected by special cause
OR variation, it is called "unstable", or "out of
control".
Removing special causes is an important part of
process improvement.
Note: Most special causes have a negative impact
on the output of the process and need to be
removed.
Common Cause or Common
Variation
Common causes of variation often lie hidden
within the system, and are sometimes assumed to
be unavoidable.
Note: To improve processes, common cause or
variation should be removed.
PDCA is always used to identify and remove
common cause or variation.
Types of Control Chart

Two types of control charts:

1. Control Chart for variables.
2. Control Chart for attributes.
Control Chart for variables
(measurements)
A single measurable quality characteristic, such as
a dimension, weight, or volume, is called a
Variable.
Lead to more efficient control procedures and
provide more information about process
performance than attributes control charts.
A standard practice to control both the mean value
of the quality characteristic and its variability.
Control Chart for variables
(measurements)
Control of the process average or mean quality
level is usually with the control chart for means, or
the x bar chart.
The control of the process range is done by using
the control chart for range, or the R chart.
X Bar Chart,
Developed from the average of each subgroup data.
Notation for variables control charts
n - size of the sample (sometimes called a
subgroup) chosen at a point in time.
m - number of samples selected.
xi, average of the observations in the ith sample
(where i = 1, 2, ..., m).
x , grand average or average of the averages
(this value is used as the center line of the control
chart)
Control Limits for the X Bar Chart
Given by:

UCL x A2 R
Center Line x
LCL x A2 R
Note: A2 is found in Table A.23 for various
values of n.
R Chart
Developed from the ranges of each subgroup data,
which is calculated by subtracting the maximum
and the minimum value in each subgroup.
Notation and values
Ri = range of the values in the ith sample.
(Ri = xmax xmin)
R = average range for all m samples.
is the true process mean.
is the true process standard deviation.
Control Limits for the R Chart

Given by:
UCL D4 R
Center Line R
LCL D3 R
D3 and D4 are found in Table A.23 for
various values of n.
Example 1 - Page 82
Out of Control
Control Chart for attributes (Counts)
Many quality characteristics cannot be conveniently
represented numerically.
Each item inspected is classified as either
conforming or nonconforming to the
specifications on that quality characteristic.
Quality characteristics of this type are called
attributes.
Inspection by attribute is based ON a simple "GO,
NO-GO" evaluation of the product.
Types of Attribute Control Chart

Attributes control charts are the p charts, np charts

and c charts.
p chart shows the fraction of nonconforming or
defective product produced by a manufacturing
process.
It is also called the control chart for fraction
nonconforming.
Types of Attribute Control Chart

c Chart shows the number of defects or

nonconformities produced by a manufacturing
process.
Control Chart Pattern

Case (a) - Normal

(Causes are random variables)
Control Chart Pattern

Case (b) - Lack of stability, Out of control condition.

Cause: assignable causes. (E.g. tool, material, operator)
 Control Chart Pattern

Case (c) - Cumulative trend, Out of control condition.

Cause: assignable causes. (E.g. tool wears, depletion
of reactant)
 Control Chart Pattern

Case (d) - Cyclical trend, out of control condition.

Cause: assignable causes. (E.g. different work shift,
voltage fluctuation, seasonal effects)
 Control Chart Pattern
Case (e) - A run.
Cause: assignable causes. (E.g. change in material,
operator, new machine setting)
Uses of Control Chart

By accounting section to analysis costs.

By inspection and testing section to analysis
quality of product or incoming materials.
By engineering section to determine machine and
process capabilities.
By manufacturing section to monitor production
operators.