STATISTICAL QUALITY CONTROL (S.Q.C.

ContentsContents-:
Meaning. Definitions Characteristics Causes of variations. Methods of S.Q.C.. Process Control-: ControlControl Chart.. Purpose & uses of control charts. Types of control charts Control charts for variables-: variablesChart R Chart Chart

Control chart for attributes-: attributesp-chart npnp-chart...... C-Chart Product Control/Acceptance Sampling-: SamplingMeaning.. Definition. Risks in Acceptance Sampling-: SamplingProducers Risk. Consumers Risk. Types of Sampling Inspection plans-: plansSingle Sampling plan Double Sampling Plan.. Multiple Sampling Plan. Advantages of S.Q.C Limitations of S.Q.C.

MEANINGMEANING-:
 manufactured

Refers to the use of statistical techniques in controlling the quality of goods. of establishing & achieving quality specification, which requires use of tools & techniques of statistics.

 Means

DEFINATIONDEFINATION-:
Statistical quality control can be simply defined as an economic & effective system of maintaining & improving the quality of outputs throughout the whole operating process of specification, production & inspection based on continuous testing with random samples. ByBy-: YA LUN CHOU

DefinitionDefinition-:
Statistical quality control should be viewed as a kit of tools which may influence decisions to the functions of specification, production or inspection. ByBy-: EUGENE L. GRANT

CHARACTERISTICS OF S.Q.C.-: S.Q.C.

Designed to control quality standard of goods produced for marketing. Exercise by the producers during production to assess the quality of goods. Carried out with the help of certain statistical tools like Mean Chart, Range Chart, P-Chart, C-Chart etc. PCDesigned to determine the variations in quality of the goods & limits of tolerance.

CAUSES OF VARIATIONS IN QUALITYQUALITY-:

1.

2.

ASSIGNABLE CAUSES-: It refers to those CAUSESchanges in the quality of the products which can be assigned or attributed to any particular causes like defective materials, defective labour, etc. CHANCE CAUSES-: These causes take place CAUSESas per chance or in a random fashion as a result of the cumulative effect of a multiplicity of several minor causes which cannot be identified. These causes are inherent in every type of production.

METHODS OF S.Q.C.-: S.Q.C.1.

PROCESS CONTROL-: Under this the CONTROLquality of the products is controlled while the products are in the process of production. The process control is secured with the technique of control charts. Control charts charts. are also used in the field of advertising, packing etc. They ensures that whether the products confirm to the specified quality standard or not.

Control Chart
A control chart is a time plot of a statistic, such as a sample mean, range, standard deviation, or proportion, with a center line and upper and lower control limits. The limits give the desired range of values for the statistic. When the statistic is outside the bounds, or when its time plot reveals certain patterns, the process may be out of control.
Value This point is out of the control limits

UCL
3W 3W

Center Line LCL

Time

A process is considered in statistical control if it has no assignable causes, only natural variation.

PURPOSE & USES OF CONTROL CHARTS

1. 2.

3. 4. 5.

Helps in determining the quality standard of the products. Helps in detecting the chance & assignable variations in the quality standards by setting two control limits. Reveals variations in the quality standards of the products from the desired level. Indicates whether the production process is in control or not. Ensures less inspection cost & time in the process control.

TypesTypes-:
Types of Control Charts

Control Charts for Variables

Control Charts for Attributes

Chart

R-Chart

-Chart

p-Chart

np-Chart

C-Chart

CONTROL CHATS FOR VARIABLES



CHART/ MEAN CHART-: This chart is CHARTconstructed for controlling the variations in the average quality standard of the products in a production process. R-CHART-: This chart is constructed for controlling the variations in the dispersion or variability of the quality standards of the products in a production process.

EXAMPLEEXAMPLE-:
Sample No. 1 2 3 4 5
D4=2.115

Weights 15 10 11 14 12 18 10 8 22 21 19 17 10 13 15 12 19 14 20 20 19 26 12 23
20

Conversion factors for n=5, A2 =0.577, D3 =0,

SolutionSolution-:
Sample no. Weights (X) Total Weights ( X) 70 70 80 80 100 =( X/5) Range R=(LR=(L-S)

1 2 3 4 5 K=5

15 10 11 14 12 18 10 8 22 21 19 17 10 13 15 12 19 14 20 20 19 26 12 23
20

14 14 16 16 20 =80

10 14 11 8 14 R=57

Grand

/K = 80/5=16

Grand Chart Grand = 16 (Central line) Control limits-: limitsUCL = Grand + A2 = 16 + 0.577 x 11.4 = 22.577 LCL = Grand - A2 = 16 0.577 x 11.4 = 9.423

R/K = 57/5 = 11.4

Range Chart = 11.4 (Central line) Control limits-: limitsUCL = D4. = 2.115 x 11.4 = 24.09 LCL = D3. = 0 x 11.4 =0

 Chart-: This chart is constructed to get a better picture of Chartthe variations in the quality standard in a process than that is obtained from the range chart provided the standard deviation( ) of the various samples are readily available.

the help of standard deviation chart. Ten items are chosen in every sample. 18 samples in all were chosen whose S was 8.28. Determine the three sigma limits of - chart. You may use the following-: followingn = 10, B3 = 0.28, B4 = 1.72, K = 18.
S/K = 8.28/18 = 0.46 UCL = B4. LCL = B3. = 1.72 x 0.46 = 0.28 x 0.46 = 0.7912 = 0.1288

ExampleExample-: Quality control is maintained in a factory with

SolutionSolution-:

Control Charts for Attributes-: Attributes

p-chart-: chart-

This chart is constructed for controlling the quality standard in the average fraction defective of the products in a process when the observed sample items are classified into defectives & nonnondefectives. the quality standard of attributes in a process where the sample size is equal & it is required to plot the no. of defectives (np) in samples instead of fraction defectives (p).

np-chartnp-chart-: This chart is constructed for controlling

ExampleExample-:
Sample No. 1 2 3 4 5 6 7 8 9 10 Size of sample (n) 100 100 100 100 100 100 100 100 100 100 No. of defectives (d) 5 3 3 6 5 6 8 10 10 4 Fraction defectives (d/n) 0.05 0.03 0.03 0.06 0.05 0.06 0.08 0.1 0.1 0.04

K = 10

d = 60

= Total no. of defectives/Total no. of units = 60/ 60/1000 = 0.06 q = 1- = 1- 0.06 = 0.94 = 0.06 (central line) UCL = + 3 . q/n = 0.06 + 30.06x0.94/100 06x 94/ = 0.1311 LCL = - 3 . q/n = 0.06 - 3 0.06x0.94/100 06x 94/ = -0.0111 = 0

ExampleExample-:
An inspection of 10 samples of size 400 each from 10 lots reveal the following number of defectives: 17, 15, 14, 26, 17, 15, 14, 26, 9, 4, 19, 12, 9, 15 19, 12, Calculate control limits for the no. of defective units. 400, 10, SolutionSolution-: n = 400, k (No. of samples) = 10, defectives) = 140 n = Now, q = 1d/k = 140/10 = 14 140/ = n /n = 14/400 = 0.035, 14/ 035, = 1- 0.035 = 0.965 d (total no. of

n = 14 (central line) UCL= n + 3 n q = 14 + 3400x0.035x0.965 400x 035x = 25.025 25. LCL= n - 3 n q = 14 - 3400x0.035x0.965 400x 035x = 2.975

 C-Chart-: This chart is used Chartfor the control of no. of defects per unit say a piece of cloth/glass/paper/bottle which may contain more than one defect. The inspection unit in this chart will be a single unit of product. The probability of occurrence of each defect tends to remain very small.

USESUSES-:
The following are the field of application of C-Chart-: C-Chart Number of defects of all kinds of aircraft final assembly.  Number of defects counted in a roll of coated paper, sheet of photographic film, bale of cloth etc.

ACCEPTANCE SAMPLING
MeaningMeaning-: Another major area of S.Q.C. is Product Control or Acceptance Sampling. It is concerned with the inspection of manufactured products. The items are inspected to know whether to accept a lot of items conforming to standards of quality or reject a lot as nonnonconforming.

DEFINITIONDEFINITION-:
Acceptance Sampling is concerned with the decision to accept a mass of manufactured items as conforming to standards of quality or to reject the mass as non-conforming to nonquality. The decision is reached through sampling. ByBy-: SIMPSON AND KAFKA

Risks in Acceptance sampling

1.

Producers risk-: Sometimes inspite of good riskquality, the sample taken may show defective units as such the lot will be rejected, such type of risk is known as producers risk. Consumers Risk-: Sometimes the quality of Riskthe lot is not good but the sample results show good quality units as such the consumer has to accept a defective lot, such a risk is known as consumers risk.

2.

Types of Sampling Inspection Plan

Single Sampling Plan-: Under single Plansampling plan, a sample of n items is first chosen at random from a lot of N items. If the sample contains, say, c or few defectives, the lot is accepted, while if it contains more than c defectives, the lot is rejected (c is known as acceptance number).

Single Sampling Plan

Count the no. of defectives, d in the sample of size n

Is d c

If yes, than accept the lot

If no, then reject the lot

Double Sampling Plan-: PlanUnder this sampling plan, a sample of n1 items is first chosen at random from the lot of size N. If the sample contains, say, c1 or few defectives, the lot is accepted; if it contains more than c2 defectives, the lot is rejected. If however, the number of defectives in the sample exceeds c1, but is not more than c2, a second sample of n2 items is take from the same lot. If now, the total no. of defectives in the two samples together does not exceed c2, the lot is accepted; otherwise it is rejected. (c1 is known as acceptance no. for the first sample & c2 is the acceptance no. of both the samples taken together)

Double Sampling Plan-: PlanCount the no. of defectives, d1in the first sample of size n1

Is d1 c1 ?
If yes, accept the lot
If No, then check If c1 d1 c2 ? Draw another sample of size n2
Count the no. of defectives d2 in this sample

Is d1 + d2 c2 If No, reject the lot If yes, then accept the lot.

Multiple Sampling Plan-: PlanUnder this sampling plan, a decision to accept or reject a lot is taken after inspecting more than two samples of small size each. In this plan, units are examined one at a time & after examining each unit decision is taken. However, such plan are very complicated & hence rarely used in practice.

ADVANTAGES OF S.Q.C.-: S.Q.C. Helpful

in controlling quality of a

product  Eliminate Assignable causes of variation  Better quality at lower inspection cost  Useful to both consumers & producers  It makes workers quality conscious  Helps in earn goodwill

LIMITATIONSLIMITATIONS-:
 Does

not serve as a PANACEA for all quality evils.  It cannot be used to all production process.  It involves mathematical & statistical problems in the process of analysis & interpretation of variations in quality.  Provides only an information services.

THE END