WHAT IS CONTROL CHART ?

1. Also called as Statistical Process Control (SPC).

2. It is a tool used to determine if
a manufacturing or business process is in a state
of control.
3. To monitor how a process changes over time.
4. To reveal the Stability or Variability in a process.
5. To distinguish Random and Assignable variation.
Fact
Random Variation= Natural variation that present in every
system.
Assignable Variation=Special causes of the variation.
WHY CONTROL CHART USEFUL ?
1. Pinpointing erratic or unpredictable processes.
2. Obtaining warning of impending trouble, such as an unexpected
change in a process.
3. Evaluating product (service) consistency over time.
4. Decreasing performance variability in a process, thereby
decreasing the level of post-process inspection of the output
generated by the process.
5. Determining the cause of trouble when a process is generating
output which has errors and mistakes.
6. Knowing when a process is doing the best that can be expected
from it.are Erratic mean for ? =not even or regular in
What
pattern or movement
FATHER OF THE CONTROL CHART

Walter A. Shewhart
American engineer

Walter Andrew Shewhart was an American physicist,

engineer and statistician, sometimes known as the
father of statistical quality control and also related to
the Shewhart cycle.

Born: March 18, 1891, New Canton, Illinois, United

States

Died: March 11, 1967, Parsippany-Troy Hills, New

Jersey, United States
EXAMPLE OF THE CONTROL CHART
CONTROLLED VARIATION
Controlled variation is
characterized by a stable and
consistent pattern of
variation over time, and is
associated with common
causes. A process operating
with controlled variation has
an outcome that is
predictable within the bounds
of the control limits.
UNCONTROLLED VARIATION

Uncontrolled variation is
characterized by variation
that changes over time and
is associated with special
causes. The outcomes of
this process are
unpredictable; a customer
may be satisfied or
unsatisfied given this
unpredictability.
BENEFITS OF CONTROL CHART

1. Reduce the margin of error: Because control charts allow operators to

detect manufacturing problems before they occur, this greatly reduces the
need for product rework or additional product expenditures to fix an
offering.

Example: Control charts serve as the early warning detection system, telling
you that now is the time to go in and make a change. That way, you dont
finish the whole run only to find out you should have made some
adjustments three hours ago and now have to eat the costs associated with
this problem.
BENEFITS OF CONTROL CHART
2. Prevent over-tampering: It is just as important to know
when your process is running inefficiently as it is to know
when it is running smoothly.

Example: When you/operator trying to detect if problems

exist, operators can quite frequently over-tamper with a
process that was running correctly, which can lead to more
variances. After analyzing a control chart, operators need
to determine whether to do something (i.e. adjust a
behavior in the process) or do nothing, (i.e. let the
process run as is). Oftentimes, learning that they can do
nothing prevents operators from over-tampering with their
processes.
Example of x-bar and R charts
 HOW TO CONSTRUCT X-BAR AND
R CHART

The following collection of data represents samples of

the amount of force applied in a gluing process:

Determine if the process is in control

by calculating the appropriate upper and lower
control limits of the X-bar and R charts.
X-BAR AND R CHART EXAMPLE
Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5
1 10.68 10.689 10.776 10.798 10.714
2 10.79 10.86 10.601 10.746 10.779
3 10.78 10.667 10.838 10.785 10.723
4 10.59 10.727 10.812 10.775 10.73
5 10.69 10.708 10.79 10.758 10.671
6 10.75 10.714 10.738 10.719 10.606
7 10.79 10.713 10.689 10.877 10.603
8 10.74 10.779 10.11 10.737 10.75
9 10.77 10.773 10.641 10.644 10.725
10 10.72 10.671 10.708 10.85 10.712
11 10.79 10.821 10.764 10.658 10.708
12 10.62 10.802 10.818 10.872 10.727
13 10.66 10.822 10.893 10.544 10.75
14 10.81 10.749 10.859 10.801 10.701
15 10.66 10.681 10.644 10.747 10.728
Example of x-bar and R charts
Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5 Avg Range
1 10.68 10.689 10.776 10.798 10.714 10.732 0.116
STEP 1. 2 10.79 10.86 10.601 10.746 10.779 10.755 0.259
3 10.78 10.667 10.838 10.785 10.723 10.759 0.171
CALCULATE 4
5
10.59
10.69
10.727
10.708
10.812
10.79
10.775
10.758
10.73
10.671
10.727
10.724
0.221
0.119
SAMPLE MEANS, 6
7
10.75
10.79
10.714
10.713
10.738
10.689
10.719
10.877
10.606
10.603
10.705
10.735
0.143
0.274
SAMPLE 8
9
10.74
10.77
10.779
10.773
10.11
10.641
10.737
10.644
10.75
10.725
10.624
10.710
0.669
0.132
RANGES, MEAN 10
11
10.72
10.79
10.671
10.821
10.708
10.764
10.85
10.658
10.712
10.708
10.732
10.748
0.179
0.163
OF MEANS, AND 12
13
10.62
10.66
10.802
10.822
10.818
10.893
10.872
10.544
10.727
10.75
10.768
10.733
0.250
0.349
MEAN OF 14
15
10.81
10.66
10.749
10.681
10.859
10.644
10.801
10.747
10.701
10.728
10.783
10.692
0.158
0.103

RANGES. Averages 10.728 0.220400

Example of x-bar and R charts

STEP 2. DETERMINE CONTROL LIMIT

FORMULAS AND NECESSARY TABLED
n A2 D3 D4
VALUES
R Chart Control Limits 2 1.88 0 3.27
3 1.02 0 2.57
UCL = D 4 R
4 0.73 0 2.28
LCL = D 3 R 5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
x Chart Control Limits
8 0.37 0.14 1.86
UCL = x + A 2 R 9 0.34 0.18 1.82
10 0.31 0.22 1.78
LCL = x - A 2 R 11 0.29 0.26 1.74
Example of x-bar and R charts
UCL = x + A2 R 10.728 .58( 0.2204 )=10.856

STEPS 3&4. CALCULATE LCL = x - A2 R 10.728-.58( 0.2204 )=10.601

X-BAR CHART AND PLOT

VALUES 10.900

10.850

10.800

10.750
Means

Sample
10.700 mean
UCL

10.650 LCL

grand
10.600
mean of x

10.550
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample
Example of x-bar and R charts
UCL = D 4 R ( 2.11)(0.2204) 0.46504
STEPS 5&6: CALCULATE
R-CHART AND PLOT
LCL = D3 R (0)(0.2204) 0
VALUES
0.800
0.700
0.600
0.500 Range
UCL
R 0.400
LCL
0.300 R-bar

0.200
0.100
0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample
THANK YOU