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Statistics -Quality Control

Alan D. Smith

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UpComing Events
Complete CD-ROM certifications Review Final Examination

CD-ROM Statistical Quality ASSIGNMENT Control

GOALS

TO DISCUSS THE ROLE OF STATISTICAL

QUALITY CONTROL TO DEFINE THE TERMS CHANCE CAUSES, ASSIGNABLE CAUSES, IN CONTROL, & OUT OF CONTROL. TO CONSTRUCT AND DISCUSS VARIABLES CHARTS: MEAN & RANGE.

GOALS (next class)

TO CONSTRUCT AND DISCUSS

ATTRIBUTES CHARTS: PERCENTAGE DEFECTIVE & NUMBER OF DEFECTS. TO DISCUSS ACCEPTANCE SAMPLING. TO CONSTRUCT OPERATING CHARACTERISTIC CURVES FOR VARIOUS SAMPLING PLANS.

CONTROL CHARTS

Statistical Quality Control emphasizes in-process

control with the objective of controlling the quality of a manufacturing process or service operation using sampling techniques. Statistical sampling techniques are used to aid in the manufacturing of a product to specifications rather than attempt to inspect quality into the product after it is manufactured. Control Charts are useful for monitoring a process.

CAUSES OF VARIATION
There is variation in all parts produced by a

manufacturing process. There are two sources of variation: Chance Variation - random in nature. Cannot be entirely eliminated. Assignable Variation - nonrandom in nature. Can be reduced or eliminated.

PURPOSE OF QUALITY CONTROL CHARTS

The purpose of quality-control charts is to

determine and portray graphically just when an assignable cause enters the production system so that it can be identified and be corrected. This is accomplished by periodically selecting a small random sample from the current production.

TYPES OF QUALITY CONTROL CHARTS - VARIABLES

The mean or the x-bar chart is designed to

control variables such as weight, length, inside diameter etc. The upper control limit (UCL) and the lower control limit (LCL) are obtained from equation:
UCL X A R and LCL X A R 2 2 where X is the mean of the sample means A is a factor from Appendix B 2 R is the mean of the sample ranges

FACTORS FOR CONTROL CHARTS

Chart for averages Factors for control limits A2
1.880 1.023 .729 .577 .483 .419 .373 .337 .308 .285 .266 .249 .235 .223

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Chart for ranges Factors for Factors for central line control limits d2
1.128 1.693 2.059 2.326 2.534 2.704 2.847 2.970 3.078 3.173 3.258 3.336 3.407 3.472

Number of items in sample,

n 2 3 4 5 6 7 8 9 10 11 12 13 14 15

D3
0 0 0 0 0 .076 .136 .184 .223 .256 .284 .308 .329 .348

D4
3.267 2.575 2.282 2.115 2.004 1.924 1.864 1.816 1.777 1.744 1.716 1.692 1.671 1.652

TYPES OF QUALITY CONTROL CHARTS - VARIABLES

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The range chart is designed to show whether the

overall range of measurements is in or out of control. The upper control limit (UCL) and the lower control limit (LCL) are obtained from equations:

UCL D R and LCL D R 4 3 where D and D are factors from Appendix B 3 4 R is the mean of the sample ranges

FACTORS FOR CONTROL CHARTS

Chart for averages Factors for control limits A2
1.880 1.023 .729 .577 .483 .419 .373 .337 .308 .285 .266 .249 .235 .223

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Chart for ranges Factors for Factors for central line control limits d2
1.128 1.693 2.059 2.326 2.534 2.704 2.847 2.970 3.078 3.173 3.258 3.336 3.407 3.472

Number of items in sample,

n 2 3 4 5 6 7 8 9 10 11 12 13 14 15

D3
0 0 0 0 0 .076 .136 .184 .223 .256 .284 .308 .329 .348

D4
3.267 2.575 2.282 2.115 2.004 1.924 1.864 1.816 1.777 1.744 1.716 1.692 1.671 1.652

EXAMPLE
A manufacturer of ball bearings wishes to

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determine whether the manufacturing process is out of control. Every 15 minutes for a five hour period a bearing was selected and the diameter measured. The diameters (in mm.) of the bearings are shown in the table below.

EXAMPLE (continued)
Compute the sample means and ranges. The

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table below shows the means and ranges.

EXAMPLE (continued)

Compute the grand mean (X double bar) and the

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average range. Grand mean = (25.25 + 26.75 + ... + 25.25)/5 = 26.35. The average range = (5 + 6 + ... + 3)/5 = 5.8. Determine the UCL and LCL for the average diameter. UCL = 26.35 + 0.729(5.8) = 30.58. LCL = 26.35 - 0.729(5.8) = 22.12.

FACTORS FOR CONTROL CHARTS

Chart for averages Factors for control limits A2
1.880 1.023 .729 .577 .483 .419 .373 .337 .308 .285 .266 .249 .235 .223

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Chart for ranges Factors for Factors for central line control limits d2
1.128 1.693 2.059 2.326 2.534 2.704 2.847 2.970 3.078 3.173 3.258 3.336 3.407 3.472

Number of items in sample,

n 2 3 4 5 6 7 8 9 10 11 12 13 14 15

D3
0 0 0 0 0 .076 .136 .184 .223 .256 .284 .308 .329 .348

D4
3.267 2.575 2.282 2.115 2.004 1.924 1.864 1.816 1.777 1.744 1.716 1.692 1.671 1.652

EXAMPLE (continued)
Determine the UCL and LCL for the range

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diameter. UCL = 2.282(5.8) = 30.58. LCL = 0(5.8) = 0. Is the process out of control? Observe from the next slide that the process is in control. No points are outside the control limits.

FACTORS FOR CONTROL CHARTS

Chart for averages Factors for control limits A2
1.880 1.023 .729 .577 .483 .419 .373 .337 .308 .285 .266 .249 .235 .223

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Chart for ranges Factors for Factors for central line control limits d2
1.128 1.693 2.059 2.326 2.534 2.704 2.847 2.970 3.078 3.173 3.258 3.336 3.407 3.472

Number of items in sample,

n 2 3 4 5 6 7 8 9 10 11 12 13 14 15

D3
0 0 0 0 0 .076 .136 .184 .223 .256 .284 .308 .329 .348

D4
3.267 2.575 2.282 2.115 2.004 1.924 1.864 1.816 1.777 1.744 1.716 1.692 1.671 1.652

EXAMPLE (continued) X-bar and R Chart for the Diameters

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Short Video Clip

Control Charts W. Edwards Deming

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TYPES OF QUALITY CONTROL CHARTS - ATTRIBUTES

The percent defective chart is also called a

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p-chart or the p-bar chart. It graphically shows the proportion of the production that is not acceptable.

The proportion of defectives is found by: Sum of the percent defectives p Number of samples

TYPES OF QUALITY CONTROL CHARTS - ATTRIBUTES the p-chart.

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The equation below gives the UCL and LCL for

The UCL and LCL are computed as the mean percent defective plus or minus 3 times the standard error of the percents: p ( 1 p ) UCL and LCL p 3 n .

EXAMPLE
A manufacturer of jogging shoes wants to

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establish control limits for the percent defective. Ten samples of 400 shoes revealed the mean percent defective was 8.0%. Where should the manufacturer set the control limits?

0 . 08 ( 1 0 . 08 ) 0.08 3 400 0.08 0.041

TYPES OF QUALITY CONTROL CHARTS - ATTRIBUTES

The c-chart of the c-bar chart is designed to

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control the number of defects per unit. The UCL and LCL are found by:

UCL and LCL c 3 c

EXAMPLE
A manufacturer of computer circuit boards

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tested 10 after they were manufactured. The number of defects obtained per circuit board were: 5, 3, 4, 0, 2, 2, 1, 4, 3, and 2. Construct the appropriate control limits.

26 c 2.6. Thus 10 UCL and LCL 2.6 3 2.6 or 2.6 484 . .

ACCEPTANCE SAMPLING

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Acceptance sampling is a method of determining

whether an incoming lot of a product meets specified standards. It is based on random sampling techniques. A random sample of n units is obtained from the entire lot. c is the maximum number of defective units that may be found in the sample for the lot to still be considered acceptable.

OPERATING CHARACTERISTIC CURVE

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An OC curve, or operating characteristic curve, is

developed using the binomial probability distribution, in order to determine the probabilities of accepting lots of various quality levels.

EXAMPLE

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Suppose a manufacturer and a supplier agree on

a sampling plan with n = 10 and acceptance number of 1. What is the probability of accepting a lot with 5% defective? A lot with 10% defective? P(r n = 10, p = 0.05) = 0.599 + 0.315 = 0.914. P(r n = 10, p = 0.1) = 0.349 + 0.387 = 0.736 etc.

n! P (r ) p r q n r r!(n r )!

Statistical Quality Control Homework

Complete CD-ROM exercises

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