09 Lot-By-lot Acceptance Sampling For Attributes

Quality Control
Chapter 9- Lot-by-Lot
Acceptance Sampling
By Attributes
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Besterfield: Quality Control, 8th ed.. © 2009 Pearson Education, Upper Saddle River, NJ 07458.
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Outline
 Fundamental Aspects
 Statistical Aspects
 Sampling Plan Design
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Learning Objectives
When you have completed this chapter you should be able
to:
 Know the advantages and disadvantages of sampling; the
types of sampling plans and selection factors; criteria for
formation of lots; criteria for sampling selection; and
decisions regarding rejected lots.
 Determine the OC Curve for a single sampling plan.
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Learning Objectives-cont’d.
When you have completed this chapter you
should be able to:
 Determine the equations needed to graph the
OC Curve for a double sampling plan.
 Know the properties of OC Curves.
 Know the consumer-producer relationships of
risk, AQL, and LQ.
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Learning Objectives-cont’d.
When you have completed this chapter you
should be able to:
 Determine the AOQ curve and the AOQL for a
single sampling plan.
 Determine single sampling plans for stipulated
producers risk and for stipulated consumers
risk.
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Fundamental Aspects
Acceptance Sampling is a form of

inspection applied to lots or
batches of items before or after a
process to judge conformance to
predetermined standards.
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Acceptance Sampling
Acceptance Sampling is very useful when:
 Large numbers of items must be
processed in a short amount of time.
 The cost of “passing defectives” is low.
 Fatigue/boredom is caused by inspecting
large numbers of items.
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Acceptance Sampling
Acceptance Sampling is very useful when:
Destructive testing is required
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Acceptance Sampling
 Three important aspects of sampling:
 Involves random sampling of the
entire lot
 Accept and Reject Lots (does not
improve the quality) “Lot
Sentencing”
 Audit Tool
 Three approaches to “lot sentencing”:
 Accept with no inspection
 100% inspection
 Acceptance Sampling
Besterfield: Quality Control, 8 ed..
th
© 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Acceptance Sampling
 Advantages
 Less expensive
 Reduced damage
 Reduces the amount of inspection
error
 Disadvantages
 Risk of accepting “bad” lots and
rejecting “good” lots
 Less information generated
 Requires planning and
documentation
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Sampling Plans
Sampling Plans specify the lot size, sample
size, number of samples and
acceptance/rejection criteria.
Sampling plans involve:
 Single sampling
 Double sampling
 Multiple sampling
Random
Lot
sample
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Sampling Plans
Single Sampling Plan
N = lot size
n = sample size
C=acceptance number
If c or less non-conforming units are found
in the sample, the lot is accepted, else it is
rejected.
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Single Sampling Plan
A single sampling plan is one where:
 A representative sample of n items is
drawn from a lot size of N items
Each item in the sample is examined
and classified as good/defective
If the number of defective exceeds a
specified rejection number (c) the whole lot
is rejected; otherwise the whole lot is
accepted
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Double Sampling Plan
A Double Sampling Plan allows to take a

second sample if the results of the original
sample are inconclusive.
 Specifies the lot size, size of the initial sample,
the accept/reject/inconclusive criteria for the
initial sample (N, n1, c1 (Ac), r1(Re))
 Specifies the size of the second sample and the
acceptance rejection criteria based on the total
number of defective observed in both the first
and second sample (n2,c2,r2)
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Lot First Random
sample
First sample
Accept Reject
inconclusive, take
Lot Lot
second sample
C1 r1
Compare number of defective found in the first
random sample to C1 and r1 and make appropriate
decision.
Besterfield: Quality Control, 8 ed..
th
© 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Lot First Random
sample
Second Random
sample
Accept Lot Reject

Lot
C2
Compare the total number of defective in both
lots to C2 and make the appropriate decision
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A Multiple Sampling Plan is similar to the
double sampling plan in that successive
trials are made, each of which has
acceptance, rejection and inconclusive
options.
Which Plan you choose depends on:

Cost and time
Number of samples needed and
number of items in each sample
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Lot Formation
Considerations before inspection:
 Lots should be homogeneous
 Larger lots are more preferable than
smaller lots
 Lots should be conformable to the
materials-handling systems used in
both the vendor and consumer
facilities
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Random Sampling
 Units selected for inspection should

be chosen at random
 If random samples are not used, bias
can be introduced
 If judgment methods are used to
select the sample, the statistical
basis of the acceptance-sampling
procedure is lost
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Statistical Aspects
The Operating Characteristic
Curve:
 Measures the performance of an
acceptance sampling plan
 Plots the probability of accepting the
lot versus the lot fraction defective
 Shows the probability that a lot
submitted with a certain fraction
defective will be either accepted or
rejected
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Acceptable Quality Level
(AQL)
The AQL is a percent defective that is
the base line requirement for the
quality of the producer's product.
The producer would like to design a
sampling plan such that there is a
high probability of accepting a lot
that has a defect level less than or
equal to the AQL.
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Lot Tolerance Percent
Defective
The Lot Tolerance Percent Defective
LTPD or LQ is a designated high
defect level that would be
unacceptable to the consumer. The
consumer would like the sampling
plan to have a low probability of
accepting a lot with a defect level as
high as the LTPD.
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Type I Error (Producer’s Risk)
This is the probability, for a given
(n,c) sampling plan, of rejecting a lot
that has a defect level equal to the
AQL. The producer suffers when this
occurs, because a lot with acceptable
quality was rejected. The symbol α is
commonly used for the Type I error
and typical values for range from 0.2
to 0.01.
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Type II Error (Consumer’s
Risk)
This is the probability, for a given
(n,c) sampling plan, of accepting a
lot with a defect level equal to the
LTPD. The consumer suffers when
this occurs, because a lot with
unacceptable quality was accepted.
The symbol β is commonly used for
the Type II error and typical values
range from 0.2 to 0.01.
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Operating Characteristic
Curve
This curve plots the probability of
accepting the lot (Y-axis) versus the
lot fraction or percent defectives (X-
axis). The OC curve is the primary
tool for displaying and investigating
the properties of a Lot Acceptance
Sampling Plan.
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OC Curves
There are two types of OC curves:
 Type A
Gives the probability of
acceptance of an individual lot
coming from finite production
 Type B
Gives the probability of
acceptance for lots coming
from a continuous production
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OCCs for Single Sampling Plans
An Operating Characteristic Curve (OCC) is a
probability curve for a sampling plan that shows the
probabilities of accepting lots with various lot
Probability of accepting lot
quality
1 levels (% defectives).
0.9 Under this sampling plan, if the lot
has 3% defective
0.8
. the probability
0.7 of accepting the lot is 90% .
0.6 the probability of rejecting the lot
0.5 If is
the10%
lot has 20% defective
0.4 . it has a small
0.3 probability (5%) of being accepted .
0.2 the probability of rejecting the lot is 95%
0.1
0
0 .05 .10 .15 Lot
.20 quality (% defective)
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OCC, AQL and Producer’s Risk
1
0.9 Producer’s Risk = probability

0.8
acceptable lot is rejected
0.7
0.6
0.5 AQL - percentage level of
0.4 defects at which a
0.3 customer is willing to
0.2 accept
0.1
0
0 .05 .10 .15 Lot
“Acceptable Lot”
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OCC, LTPD and Consumer’s Risk
1
0.9
0.8
0.7
LTPD - upper limit on the
0.6 percentage of defectives
0.5 that a customer is willing
0.4 to accept.
0.3
0.2
0.1 Consumer’s Risk = probability
0 unacceptable is accepted
0 .05 .10 .15 Lot
“Unacceptabl
e Lot”
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OCC for Double Sampling Plan
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Inspect a sample
of 150 from lot
of 2400
If 1 or less If 4 or more
Nonconforming Nonconforming units
units accept lots andIf 2 or 3 nonconforming the lot is not accepted
stop units, inspect a second and stop
sample of 200
If 5 or less If 6 or more
Nonconforming units Nonconforming units
On both samples, On both samples
Accept the lot The lot is not accepted
Figure 9-5 Graphical description of the double sampling plan: N=2400,n1=150,c
r1=4, n2=200, c2=5, and r2=6
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OCC for a Multiple Sampling Plan
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Average Outgoing Quality
(AOQ)
A common procedure, when
sampling and testing is non-
destructive, is to 100% inspect
rejected lots and replace all
defectives with good units. In this
case, all rejected lots are made
perfect and the only defects left are
those in lots that were accepted.
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Average Outgoing Quality
The Average Outgoing Quality (AOQ) is the

average of rejected lots (100% inspection)
and accepted lots ( a sample of items
inspected)
N -n
AOQ= P ac * p( ) where
N
Pac = Probability of accepting a lot
p = Fraction defective
n = sample size
N = Lot size
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AOQ and Acceptance Sampling
15 lots 11 lots
2% nonconforming N=3000 2% nonconforming
Producer n=89 Consumer
c=2
4 lots
2% nonconforming
4 lots
0% nonconforming
Figure 9-15 How acceptance Sampling works
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AOQ and Acceptance
Sampling
Total Number Number
Nonconformin
g
11 lots- 11(3000)=33,000 33,000(0.02)=660
2%
Nonconforming
4 lots- 4(3000) 0
0% (0.98)=11,760
Nonconforming
44,760 660
Percent Nonconforming (AOQ) =

660/44,760 X 100 =1.47%
Figure 9-15 cont’d.

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Average Quality of Inspected Lots
Typically the term (N-n)/N is very close to 1;
therefore, the equation most often used is:
AOQ = Pac * p where

Pac = Probabili ty of acce pting a lo t
p = Fraction defective
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Average Outgoing Quality Level
• A plot of the AOQ (Y-axis) versus

the incoming lot p (X-axis) will start
at 0 for p = 0, and return to 0 for p
= 1 (where every lot is 100%
inspected and rectified). In
between, it will rise to a maximum.
This maximum, which is the worst
possible long term AOQ, is called
the Average Outgoing Quality Level
AOQL.
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Average Total Inspection
(ATI)
When rejected lots are 100%
inspected, it is easy to calculate the
ATI if lots come consistently with a
defect level of p. For a LASP (n,c)
with a probability pa of accepting a
lot with defect level p, we have:
ATI = n + (1 - pa) (N - n)
where N is the lot size.
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Average Sample Number
(ASN)
For a single sampling (n,c) we know each
and every lot has a sample of size n
taken and inspected or tested. For
double, multiple and sequential plans,
the amount of sampling varies
depending on the number of defects
observed.
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Average Sample Number
(ASN)
For any given double, multiple
or sequential plan, a long term
ASN can be calculated
assuming all lots come in with a
defect level of p. A plot of the
ASN, versus the incoming
defect level p, describes the
sampling efficiency of a given
plan scheme.
ASN = n1 + n2 (1 – P1) for a double
sampling plan.
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Sampling Plan Design
Suppose α is known and the AQL is also
known then :
 Sampling plan with stipulated producer’s risk
 Sampling plan with stipulated consumer’s risk
 Sampling plan with stipulated producer’s and

consumer’s risk
can be designed.
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 Stipulated Producer’s Risk
α
= 0.05 AQL = 1.2%
 Pa=0.95 P0.95= 0.012
 Assume values for C, find np0.95 for
this c value, calculate n
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 Stipulated Consumer’s Risk
β
= 0.10 LQ = 6.0%
 Pa=0.10 P0.10= 0.060
 Assume values for C, find np0.95 for
this c value, calculate n
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 Stipulated Producer’s and
Consumer’s risk
 α = 0.10 β = 0.10
 AQL=0.9 LQ= 7.8
 Find the ratio of P0.10/P0.95. From
table 9-4 C is between 1 and 2. Find
n for c =1 and n for c =2 .
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 Have 4 plans.
 Select plan based on:
 Lowest sampling size
 Greatest sampling size
 Plan exactly meets consumer’s
stipulation and is as close as
possible to producer’s stipulation
 Plan exactly meets producer’s
stipulation and is as close as
possible to consumer’s stipulation
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Quality Control

PowerPoints created by Rosida

Acceptance Sampling is a form of

A Double Sampling Plan allows to take a

Accept Lot Reject

Which Plan you choose depends on:

 Units selected for inspection should

0.9 Producer’s Risk = probability

The Average Outgoing Quality (AOQ) is the

Figure 9-15 How acceptance Sampling works

Percent Nonconforming (AOQ) =

Figure 9-15 cont’d.

AOQ = Pac * p where

• A plot of the AOQ (Y-axis) versus

 Sampling plan with stipulated producer’s and

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