WHEN TO USE X-R CHARTS

X-R charts should be used when you have taken data frequently. How often you plot
points on the charts depends on your subgroup size. For example, if your subgroup
size is four, it will take four samples before you calculate the average and range and
plot the points. If you only take one sample per day, it will be four days before you
can plot the points. If the point is out of control, the reason for it could have
occurred four days ago. This often makes it difficult to find out what happened.

X-R charts should be used if you can rationally subgroup the data and are interested
in detecting differences between subgroups over time. This means there should be
some logical basis for the way the subgroups are formed. They should be formed to
examine the variation of interest to you. You might be interested in the variation
from day to day. In this case, samples from one day would be used to form a
subgroup. The X chart would examine the variation from day to day, while the R
chart would examine the variation within a day.

The R chart is a measure of the short-term variation in the process. Subgroups

should be formed to minimize the amount of variation within a subgroup. This
causes the X chart to do the work in detecting process changes.

STEPS IN CONSTRUCTING AN X-R CHART

The steps in constructing an X-R chart are given below.

1. Gather the data.

a. Select the subgroup size (n). Typical subgroup sizes are 4 to 5. The concept of
rational subgrouping should be considered. The objective is to minimize the amount
of variation within a subgroup. This helps us "see" the variation in the averages
chart more easily.

b. Select the frequency with which the data will be collected. Data should be
collected in the order in which it is generated (in most cases).
c. Select the number of subgroups (k) to be collected before control limits are
calculated. You can start with initial control limits after ten subgroups, but
recalculate the limits each time until you get to twenty subgroups.
d. For each subgroup, record the individual, independent sample results.
e. For each subgroup, calculate the subgroup average:
subgroup average calculation

where n is the subgroup size.

f. For each subgroup, calculate the subgroup range:
R = Xmax - Xmin

where Xmax is the maximum individual sample result in the subgroup and Xmin is
the minimum individual sample result in the subgroup.
2. Plot the data.

a. Select the scales for the x and y axes for both the X and R charts.
b. Plot the subgroup ranges on the R chart and connect consecutive points with a
straight line.
c. Plot the subgroup averages on the X chart and connect consecutive points with a
straight line.
3. Calculate the overall process averages and control limits.

a. Calculate the average range (Rbar):

subgroup range calculation

where k is the number of subgroups.

b. Plot Rbar on the range chart as a solid line and label.

c. Calculate the overall process average (Xdbar):

overall average calculation

d. Plot X on the X chart as a solid line and label.

e. Calculate the control limits for the R chart. The upper control limit is given by
UCLr. The lower control limit is given by LCLr.

r control chart limits

where D4, D3, are control chart constants that depend on subgroup size (see the
table below).
f. Plot the control limits on the R chart as dashed lines and label.
g. Calculate the control limits for the X chart. The upper control limit is given by
UCLx. The lower control limit is given by LCLx.

xbar control limits

where A2 is a control chart constant that depends on subgroup size (see the table
below). h. Plot the control limits on the X chart as dashed lines and label.
4. Interpret both charts for statistical control.

a. Always consider variation first. If the R chart is out of control, the control limits on
the X chart are not valid since you do not have a good estimate of . All tests for
statistical control apply to the X chart. Points beyond the limits, number of runs and
length of runs tests apply to the R chart.
5. Calculate the process standard deviation, if appropriate.

a. If the R chart is in statistical control, the process standard deviation, s, can be

calculated as:
sigma calcuation

where d2 is a control chart constant that depends on subgroup size (see the table
below).

To calculate control limits and to estimate the process standard deviation, you must
use the control chart constants D4, D3, A2, and d2. These control chart constants
depend on the subgroup size (n). These control chart constants are summarized in
the table below. For example, if your subgroup is 4, then D4 = 2.282, A2 = 0.729,
and d2 = 2.059. There is no value for D3. This simply means that the R chart has no
lower control limit when the subgroup size is 4.
Subgroup

Size (n)

A2

D3

D4

d2

1.880

3.267

1.128

1.023

2.574

1.693

0.729

2.282

2.059

0.577

2.114

2.326

0.483

2.004

2.534

0.419

0.076

1.924

2.704

0.373

0.136

1.864

2.847

0.337

0.184

1.816

2.970

10

0.308

0.223

1.777

3.078

11

0.285

0.256

1.774

3.173

12

0.266

0.284

1.716

3.258

13

0.249

0.308

1.692

3.336

14

0.235

0.329

1.671

3.407

15

0.223

0.348

1.652

3.472

16

0.212

0.364

1.636

3.532

17

0.203

0.379

1.621

3.588

18

0.194

0.392

1.608

3.640

19

0.187

0.404

1.596

3.689

20

0.180

0.414

1.586

3.735

21

0.173

0.425

1.575

3.778

22

0.167

0.434

1.566

3.819

23

0.162

0.443

1.557

3.858

24

0.157

0.452

1.548

3.895

25

0.153

0.459

1.541

3.931

SUMMARY

This publication has introduced the X-R chart. When you should use an X-R chart
was covered as well as the steps in constructing the chart.