6.

ProcessorProductMonitoringandControl
6.2.TestProductforAcceptability:LotAcceptanceSampling
6.2.3.HowdoyouChooseaSingleSamplingPlan?

6.2.3.2. ChoosingaSamplingPlanwithagivenOC
Curve
Sample
OC
curve

WestartbylookingatatypicalOCcurve.TheOCcurvefora(52,3)
samplingplanisshownbelow.

Numberof
defectivesis
approximately
binomial

Itisinstructivetoshowhowthepointsonthiscurveare
obtained,oncewehaveasamplingplan(n, c )laterwe
willdemonstratehowasamplingplan(n, c )isobtained.
WeassumethatthelotsizeN isverylarge,ascomparedto
thesamplesizen ,sothatremovingthesampledoesn't
significantlychangetheremainderofthelot,nomatterhow
manydefectsareinthesample.Thenthedistributionofthe
numberofdefectives,d ,inarandomsampleofn itemsis
approximatelybinomialwithparametersn andp ,wherep
isthefractionofdefectivesperlot.
Theprobabilityofobservingexactlyd defectivesisgiven
by

Thebinomial
distribution

n!
P d = f (d) =

nd

p (1 p)
d!(n d)!

Theprobabilityofacceptanceistheprobabilitythatd ,the
numberofdefectives,islessthanorequaltoc ,theaccept
number.Thismeansthat
c

n!

P a = P (d c) =
d=0

Sampletable
forP ,P
usingthe
binomial
distribution
a

Usingthisformulawithn
p = 0.01, 0.02, ,

nd

p (1 p)

d!(n d)!

,c = 3 ,and
0.12 ,wefind:
= 52

Pa

Pd

0.998
0.980
0.930
0.845
0.739
0.620
0.502
0.394
0.300
0.223
0.162
0.115

0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12

Solvingfor(n,c)
Equationsfor
calculatinga
samplingplan
withagiven
OCcurve

InordertodesignasamplingplanwithaspecifiedOC
curveoneneedstwodesignatedpoints.Letusdesigna
samplingplansuchthattheprobabilityofacceptanceis
1 forlotswithfractiondefectivep andtheprobability
ofacceptanceis forlotswithfractiondefectivep .
Typicalchoicesforthesepointsare:p istheAQL,p is
theLTPDand, aretheProducer'sRisk(TypeIerror)
andConsumer'sRisk(TypeIIerror),respectively.
1

Ifwearewillingtoassumethatbinomialsamplingisvalid,
thenthesamplesizen ,andtheacceptancenumberc arethe
solutionto
c

d=0
c

n!

=
d!(n d)!
n!

=
d=0

nd

p (1 p1 )
1

nd

p (1 p2 )
d!(n d)!

Thesetwosimultaneousequationsarenonlinearsothereis
nosimple,directsolution.Therearehoweveranumberof
iterativetechniquesavailablethatgiveapproximate

solutionssothatcompositionofacomputerprogramposes
fewproblems.

AverageOutgoingQuality(AOQ)
Calculating
AOQs

WecanalsocalculatetheAOQfora(n, c )samplingplan,
providedrejectedlotsare100%inspectedanddefectives
arereplacedwithgoodparts.
Assumealllotscomeinwithexactlyap proportionof
defectives.Afterscreeningarejectedlot,thefinalfraction
defectiveswillbezeroforthatlot.However,acceptedlots
havefractiondefectivep .Therefore,theoutgoinglots
fromtheinspectionstationsareamixtureoflotswith
fractionsdefectivep and0.AssumingthelotsizeisN ,we
have.
0

P a p(N n)
AOQ =

.
N

Forexample,letN = 10000 ,n = 52 ,c = 3 ,andp ,the

qualityofincominglots,equals0.03.Nowatp = 0.03 ,we
gleanfromtheOCcurvetablethatp = 0.930 and
a

(0.930)(0.03)(10000 52)
AOQ =

= 0.02775 .
10000

Sampletable
ofAOQ
versusp

Settingp = 0.01,
followingtable.

0.02, , 0.12

AOQ
0.0010
0.0196
0.0278
0.0338
0.0369
0.0372
0.0351
0.0315
0.0270
0.0223
0.0178
0.0138
Sampleplotof
AOQversusp

,wecangeneratethe

0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12

AplotoftheAOQversusp isgivenbelow.

Interpretation
ofAOQplot

Fromexaminingthiscurveweobservethatwhenthe
incomingqualityisverygood(verysmallfractionof
defectivescomingin),thentheoutgoingqualityisalsovery
good(verysmallfractionofdefectivesgoingout).When
theincominglotqualityisverybad,mostofthelotsare
rejectedandtheninspected.The"duds"areeliminatedor
replacedbygoodones,sothatthequalityoftheoutgoing
lots,theAOQ,becomesverygood.Inbetweenthese
extremes,theAOQrises,reachesamaximum,andthen
drops.
ThemaximumordinateontheAOQcurverepresentsthe
worstpossiblequalitythatresultsfromtherectifying
inspectionprogram.Itiscalledtheaverageoutgoing
qualitylimit,(AOQL).
FromthetableweseethattheAOQL
fortheaboveexample.
Onefinalremark:ifN

= 0.372

,thentheAOQ

atp

Pa p

= 0.06

TheAverageTotalInspection(ATI)
Calculating
theAverage
Total
Inspection

Whatisthetotalamountofinspectionwhenrejectedlots
arescreened?
Ifalllotscontainzerodefectives,nolotwillberejected.
Ifallitemsaredefective,alllotswillbeinspected,andthe
amounttobeinspectedisN .
Finally,ifthelotqualityis0 < p < 1,theaverageamount
ofinspectionperlotwillvarybetweenthesamplesizen ,
andthelotsizeN .
Letthequalityofthelotbep andtheprobabilityoflot
acceptancebeP ,thentheATIperlotis
a

ATI = n + (1 P )(N n) .

ATI = n + (1 P a )(N n) .

Forexample,letN = 10000 ,n = 52 ,c = 3 ,and

p = 0.03 .WeknowfromtheOCtablethatP
= 0.93 .
ThenATI = 52 + (1 0.930)(10000 52) = 753 .
(Notethatwhile0.930wasroundedtothreedecimalplaces,
753wasobtainedusingmoredecimalplaces.)
a

Sampletable
ofATIversus
p

PlotofATI
versusp

Settingp
table.

= 0.01, 0.02, , 0.14

ATI
70
253
753
1584
2655
3836
5007
6083
7012
7779
8388
8854
9201
9453

generatesthefollowing

0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12
0.13
0.14

AplotofATIversusp ,theIncomingLotQuality(ILQ)is
givenbelow.