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Quality Control
Chapter 10- Acceptance Sampling Systems

PowerPoint presentation to accompany Besterfield Quality Control, 8e
PowerPoints created by Rosida Coowar
Besterfield: Quality Control, 8th ed..
2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved
Outline
Lot-by-lot acceptance sampling plans for
attributes
Acceptance sampling plans for continuous
production
Acceptance sampling plans for variables
Learning Objectives
When you have completed this chapter you should be able to:
Determine the sampling plan using ANSI/ASQ Z1.4. Know the switching rules for ANSI/ASQ Z1.4. Categorize the various sampling plan systems in
terms of lot-by-lot, continuous production, attributes or variables.
Learning Objectives-contd.
Describe the various sampling plan systems and
know their function (advantages, disadvantages, purpose etc.).

Determine the sampling plan using the Dodge Romig
Tables
Construct the OC Curve for a chain sampling plan.
Learning Objectives-contd.
Be able to use the Shainin Lot Plot Method. Determine the sampling plan ANSI/ASQ S1
Determine whether a lot is accepted or rejected
using ANSI/ASQ Z1.9
Lot-by-Lot Acceptance Sampling Plans for Attributes

Devised in 1942 at Bell Labs
Later became MIL-STD-105E

ISO-2859 ANSI/ASQ Z1.4 Wording & terminology changes Additional tables added
ANSI/ASQ Z1.4
This standard is applicable to: End items Components and raw materials Operations
Materials in process
Supplies in storage Maintenance operations Data or records
ANSI/ASQ Z1.4
Intended to be used for a continuing
series of lots, but may be designed for isolated lots.

Standard provides for single, double, and
multiple sampling plans.

Provision is also provided for normal,
tightened, or reduced inspection.

Plan is specified by the AQL, and sample-
size code.
Besterfield: Quality Control, 8th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved
ANSI/ASQ Z1.4
Normal inspection is used at the start of
inspection with changes being a function of recent quality history.

Tightened inspection: Generally used when producers recent
quality history has deteriorated.
ANSI/ASQ Z1.4
Reduced inspection: Used when the producers recent quality
history has been exceptionally good.

Decision concerning what type of plan to use is
left to the responsible authority.

Nonconformities are classified such as critical,
major
ANSI/ASQ Z1.4
Sample Size Code Letters
Comparison of Inspection levels

100 95 = 0.05
80
Percent of Lots Accepted (100Pa)
60 I = 1/2 n II = n III = 2n 40 III 20 II I
100=10
4 6 Percent Nonconforming (100Pa)
10
ANSI/ASQ Z1.4
AQL The AQL is the most important part of the
standard since the AQL and sample size dictate the plan used.
AQL is defined as the maximum percent
nonconforming that can be considered satisfactory as a process average.

Satisfactory = Producers risk, Usually 0.05
ANSI/ASQ Z1.4
AQL AQL is specified by contract or responsible authority. AQL may be determine from historical data, empirical judgment, engineering information, experimentation, producers capability, consumers requirements.
ANSI/ASQ Z1.4
AQL
AQL is specified by contract or responsible
authority.
AQL may be determine from historical data,
empirical judgment, engineering information, experimentation, producers capability, consumers requirements.
17
ANSI/ASQ Z1.4
Sample Size
Determined by lot size and inspection
level
Use of sample-size code Inspection level is determined by the
responsible authority.
17
ANSI/ASQ Z1.4
Sample Size
Different levels of inspection provide
approximately the same protection to the producer, but different protections to the consumer.
Plan provides for special levels to be
used where relatively small sample sizes are necessary and large sampling risks must be tolerated. (S-1, S-2, S-3, S-4)
18
ANSI/ASQ Z1.4
Implementation
Determine lot size

Determine inspection level Find sample-size code letter in table Determine AQL
19
ANSI/ASQ Z1.4
Implementation contd.
Determine type of sampling plan

Find sampling plan in appropriate table Start with normal inspection and change
to tightened or reduced based on switching rules
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AQL
What an AQL means is that as long as a supplier maintains his/her process average (% defective) at the assigned AQL or lower, there is a very high probability that shipments from that supplier, when inspected using ASQ Z1.4 sampling plans, will be accepted.
21
AQL
By the same token, there is a very high probability that shipments, when inspected using ASQ Z1.4 sampling plans, will be rejected if a supplier's process average (% defective) remains higher than the assigned AQL.
22
ANSI/ASQ Z1.4
Single sampling plans
Start by identification of AQL, lot size,
inspection level, and type of sampling plan.

Locate appropriate plan parameters in
tables.
Double and Multiple Sampling
Similar procedures as single sampling

23
ANSI/ASQ Z1.4
Normal, Tightened, and Reduced Inspection Start with normal inspection Switching Procedures Normal to tightened Institute when 2 out of 5 consecutive lots not accepted
on original inspection
Tightened to normal Institute when 5 consecutive lots accepted If not, then discontinue inspection under this plan
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ANSI/ASQ Z1.4
Switching Procedures Normal to reduced Institute when: (all of the following) Preceding 10 lots on normal inspection have
been accepted
Total nonconforming in preceding 10 samples
is less than number identified in Table 10-5.

Production is at a steady rate Reduced inspection is considered desirable by
responsible authority
25
ANSI/ASQ Z1.4
Switching Procedures Reduced to normal Institute when: (any of the following) A lot is not accepted Sampling procedure terminates with neither
acceptance or rejection criteria have been met

Production is irregular or delayed Other conditions
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ANSI/ASQ Z1.4
Standard is designed for use where units of product
are produced in a continuing series of lots or batches.

If a sampling plan is desirable for a lot or batch of an
isolated nature, it should be chosen based on the Limiting Quality (LQ) and consumers risk, b.
These tables are included in the standard, but not
the textbook.
Or use ANSI/ASQ Standard Q3
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ANSI/ASQ Standard Q3
Standard is used for inspection of isolated
lots by attributes.
Provides indexed tables by Limiting
Quality, LQ.
28
Two Schemes:
1. Used for lots that are isolated or mixed or that have an unknown history as far as all parties know.
Lot size and LQ must be known. Nominal values of the LQ are based on
b=0.10
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Two Schemes:
2. Used when a vendor is producing a continuous stream of lots and sends one or a few to a customer who will consider them as isolated lots.
Occurs frequently when purchasing
small quantities of raw materials.

30
Dodge-Romig Tables
A set of inspection tables for lot-by-lot
acceptance sampling by attributes.

Tables are based on Limiting Quality (LQ)
and Average Outgoing Quality Limit (AOQL).

Tables for single and double sampling
Advantage that the plan provides a
minimum amount of inspection for a given inspection procedure.

Desirable for in-house inspection
31
Dodge-Romig Tables
Limiting Quality LQ
Based on the probability that a particular lot, which has percent nonconforming equal to the LQ, will be accepted. Probability is the consumers risk, = 0.10
LQ plans give assurance that individual lots of poor quality will rarely be accepted.
32
Dodge-Romig Tables
Observations about the LQ tables:
As the lot size increases, the relative
sample size decreases.

The tables extend until the process
average is one-half of the LQ.

As the process average increases, a
corresponding increase occurs in the amount inspected.

33
Dodge-Romig Tables
Average Outgoing Quality Limit AOQL
Applicable when the inspected lot is a
convenient subdivision of a flow of product for materials handling purposes (non-homogeneous)

AOQL plan limits the amount of poor
outgoing quality on an average basis, but gives no assurance on individual lots.

34
Dodge-Romig Tables
Process average
Obtained by the same techniques as for
p-charts
First 25 lots the average percent nonconforming
is obtained
Type of nonconformance
Dodge-Romig tables do not provide for different
categories or tightened inspection

Different LQ or AOQL values may be used
35
Chain Sampling Inspection Plan

A special type of lot-by-lot acceptance sampling
plan for attributes designated as Chain Sampling Plan ChSP-1.

Applicable to quality characteristics which involve
destructive or costly tests.

Use of small sample sizes Acceptance number, c=0 Poor shape of OC curve at the producers risk
36

Chain sampling uses the cumulative results of
several samples
Determination of the value of i, the
number of previous samples, is determined by analysis of the OC curves for a given sample size.
37

Procedure:
For each lot, select a sample of size
n and test each for conformance to

specifications.
38

Procedure:
If the sample has 0 nonconforming units,
accept the lot; if the sample has 2 or more nonconforming units, do not accept the lot; and if the sample has 1 nonconforming unit, it may be accepted provided that there are 0 nonconforming units in the previous
i samples of size n.
39
Chain Sampling Diagram

Current Lot i previous lots n=5 c=0 Accept if 0 Nonconforming Units & in n =5 or if 1 Nonconforming Unit Secondto-Last Lot
Last Lot
Zero Nonconforming Units in i Previous Lots
Figure 10-4 Chain Sampling Diagram
40

Conditions for use of the Chain Sampling Plan:
1. The lot should be one of continuing
series of product that is sampled in substantially the order of production

2. The consumer can normally expect
the lots to be essentially the same quality.
41

Conditions for use of the Chain Sampling Plan:
3. The consumer has confidence in the
producer not to occasionally send an unacceptable lot that would have the optimum chance of acceptance.
4. The quality characteristic is one that
involves destructive or costly tests.
42
Sequential Sampling
Used for costly or destructive tests
Subgroup size of 1 item by item plan
Sequential sampling is similar to multiple sampling,
except sequential sampling can, in theory, continue indefinitely.

In practice, the plan is truncated after the number
inspected is equal to three times the number inspected by a corresponding single sampling plan.
Based on the Sequential Probability Ratio Test
43
Sequential Sampling Plan
44
Sequential Sampling Plan
45
Skip Lot Sampling

Designated SkSP-1 and based on AOQL.
A single sampling plan for minimizing
inspection costs when there is a continuing supply of lots of raw materials, component parts, subassemblies, and finished parts from the same source.
Applicable to chemical and physical
characteristics that require laboratory analysis.

46
Procedure for SkSP-1 Plans

Begin by inspecting every lot When i consecutive lots are found to be conforming
Discontinue inspection of every lot Inspect a fraction, f, of the lots In a random manner When an inspected lot is found nonconforming
Figure 10-7 Procedure SkSP-1 plans

47
ANSI/ASQ S1
Provides procedures to reduce the
inspection effort when the suppliers quality is superior.

A skip-lot scheme used in conjunction
with attribute lot-by-lot plans given in ASQ Z1.4
48
ANSI/ASQ S1
Requirements to use ANSI/ASQ S1
1. Have a documented system for controlling
product quality and design changes

2. Have instituted a system that is capable of
detecting and correcting changes that might adversely affect quality.

3. Not have experienced an organizational
change that might adversely affect quality

49
ANSI/ASQ S1
Additional requirements of the product:
Be of stable design
Have been manufactured on a continuous basis
for at least 6 months unless agreed to a longer period.

Have been on normal and reduced inspection
during the qualification period.

Have maintained a quality level at or less than
the AQL for at least 6 months.

50
ANSI/ASQ S1
Other:
The previous 10 or more consecutive lots
have been accepted

The min cumulative sample size for the last
10 or more consecutive lots have been met.

The acceptance numbers for the last 2 lots
have been met
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Sampling for Continuous Production

Acceptance sampling for continuous
production implies that manufacturing operations do not create lots as part of the normal part of the production process.
Parts are produced by a continuous
process on a conveyor or similar system.
51

Plans for continuous production consist of
alternating sequences of sampling inspection and screening (100%) inspection.

Plans begin with 100% inspection and
convert to sampling after a stated number of items are free of nonconformities.

Sampling continues until a stated number of
nonconforming units are found, at which time 100% inspection in reinstated.

53

Applicable to attribute, nondestructive
inspection of moving product.

Inspection should be easy and rapid Process must be capable of
manufacturing homogeneous product
54

Developed by Dodge
CSP-1, CSP-2, CSP-3

Later, MIL-STD-1235B
55

CSP-1
Begins with 100% inspection of the
product in the order of production until a certain number of successive units are free of nonconformities.
56

CSP-1
Sampling inspection is then instituted
Samples are selected in such a
manner as to minimize any bias

If a nonconformity occurs, sampling is
discontinued and 100% inspection begins.

57
CSP-1 and CSP-F Plans

Start
The Screening Crew Inspects 100% of the Units When i Consecutive Units Are Found Free of Nonconformities Concerned,
The Screening Crew is Released from 100% Inspection and the Sampling Inspector Inspects a Fraction, f, of the Units, Where the Sample Units are Selected in a Random Manner. When the Sampling Inspector Finds One of the Nonconformities Concerned,
58
MIL-STD-1235B
Standard is composed of five different
continuous sampling plans.

Designated by code letters
59
MIL-STD-1235B
Inspection is by attributes for nonconforming
units using three classes of severity:

Critical Major Minor
Each of the plans incorporates a provision for
discontinuance of inspection
60
Acceptance Sampling Plans for Variables

Shainin Lot Plot ANSI/ASQ Z1.9-2003
61

Shainin Lot Plot
Random sample of 10 subgroups of 5 each

Find average and range Construct a histogram Calculate Xdouble bar, R bar Calculate ULL and LLL
Compare to lot plots in Figure 10-15
62

ANSI/ASQ Z1.9-2003 Sampling Procedures and Tables for Inspection by Variables for Percent Nonconforming is an acceptance sampling system to be used on a continuing stream of lots for Acceptance Quality Limit (AQL) specified.
63

ANSI/ASQ Z1.9-2003 provides tightened, normal, and reduced plans to be used on measurements which are normally distributed. Variation may be measured by sample standard deviation, sample range, or known standard deviation. It is applicable only when the normality of the measurements is assured.
64

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Quality Control

Chapter 10- Acceptance Sampling Systems

PowerPoints created by Rosida Coowar

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

terms of lot-by-lot, continuous production, attributes or variables.

Besterfield: Quality Control, 8th ed..

know their function (advantages, disadvantages, purpose etc.).

Besterfield: Quality Control, 8th ed..

Determine whether a lot is accepted or rejected

using ANSI/ASQ Z1.9

Besterfield: Quality Control, 8th ed..

Lot-by-Lot Acceptance Sampling Plans for Attributes

Later became MIL-STD-105E

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

series of lots, but may be designed for isolated lots.

multiple sampling plans.

tightened, or reduced inspection.

inspection with changes being a function of recent quality history.

quality history has deteriorated.

Besterfield: Quality Control, 8th ed..

history has been exceptionally good.

left to the responsible authority.

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Sample Size Code Letters

Besterfield: Quality Control, 8th ed..

Comparison of Inspection levels

Percent of Lots Accepted (100Pa)

60 I = 1/2 n II = n III = 2n 40 III 20 II I

4 6 Percent Nonconforming (100Pa)

Besterfield: Quality Control, 8th ed..

nonconforming that can be considered satisfactory as a process average.

empirical judgment, engineering information, experimentation, producers capability, consumers requirements.

Determined by lot size and inspection

Different levels of inspection provide

Determine lot size

Determine type of sampling plan

to tightened or reduced based on switching rules

Start by identification of AQL, lot size,

inspection level, and type of sampling plan.

Similar procedures as single sampling

is less than number identified in Table 10-5.

acceptance or rejection criteria have been met

are produced in a continuing series of lots or batches.

small quantities of raw materials.

acceptance sampling by attributes.

and Average Outgoing Quality Limit (AOQL).

minimum amount of inspection for a given inspection procedure.

As the lot size increases, the relative

sample size decreases.

average is one-half of the LQ.

corresponding increase occurs in the amount inspected.

Applicable when the inspected lot is a

convenient subdivision of a flow of product for materials handling purposes (non-homogeneous)

outgoing quality on an average basis, but gives no assurance on individual lots.

First 25 lots the average percent nonconforming

categories or tightened inspection

Chain Sampling Inspection Plan

plan for attributes designated as Chain Sampling Plan ChSP-1.

destructive or costly tests.

Chain Sampling Inspection Plan