Chapter 08

Statistical Quality Control

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Statistical quality Control (SQC)

Is the application of statistical techniques to accept or reject products already produced, or to control the process & therefore product quality is attained. The latter one is called process control & former is called acceptance sampling.
THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Statistical Process Control (SPC)

A methodology for monitoring a process to identify special causes of variation and signal the need to take corrective action when appropriate

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Causes of variation
These are because of four reasons variation because of Equipment variation because of Material variation because of Environment variation because of Operator Causes of variation are of two forms
Chance causes Assignable causes
THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Causes of Variation
Chance causes These are inherent & cannot be controlled or prevented Any effort to eliminate them is uneconomical & may be counter productive too & so ignored. When only chance causes are present in a process, the process is considered to be in a state of statistical control. It is stable and predictable.

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Assignable causes
Variations for which we can detect the cause & rectify it i.e. possible to stop when an assignable cause of variation is present, the variation will be excessive, and the process is classified as out of control or beyond the expected natural variation.

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

 A process that is operating with only chance causes of variation present is said to be in statistical control.
A process that is operating in the presence of assignable causes is said to be out of control. The eventual goal of SPC is reduction or elimination of variability in the process by identification of assignable causes.

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Control Charts
A statistical tool used to distinguish between process variation resulting from common causes and variation resulting from special causes Monitor process variation over time Differentiate between special cause and common cause variation Assess effectiveness of changes Communicate process performance

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Common Causes

assignable Causes

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

Types the control chart

Variables Control Charts These are quality characteristics that can be measured on a continuous scale Variables answer the question how much? E.G. elapsed time, temperature, height, weight

Control charts for variables are

1)Range chart ( R-Chart ) Uses amount of dispersion in a sample 2)Mean chart ( x bar Chart ) Uses process average of a sample
THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

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Types the control chart

Attributes Control Charts There are numerous occasions on which firms use a 2 way classification of products/services while assessing quality like good or bad, defective or non defective. Attribute charts are applied for data that follow a discrete distribution. Attributes answer the question how many? Control charts for attributes are NP chart(no of defectives charts for constant sample) P chart (for varying sample size) C chart ( no of defects chart for constant sample size) U chart (no of defects per unit chart for varying 11 THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson Learning sample size)
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Control charts for variables

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X-bar R chart
Calculate mean & range for each subgroup Then calculate central line for mean & range
X X n R R n

Compute upper control limit & lower limit for both mean

UCL X X A 2 R LCL X X A 2 R UCL R D 4 R LCL R D3R

For Range

Plot the graph & see whether it is statistical stable

THE MANAGEMENT AND CONTROL OF QUALITY, 5e, 2002 South-Western/Thomson LearningTM

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Control chart for Attributes

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NP chart or Fraction defective chart

Used when sample size is constant for all subgroups C Compute Avg fraction defective P K*n p Calculate Central line = n

Upper control limit = Uc ln p n p 3 n p(1 p )

Lower control limit = Lc ln p n p 3 n p(1 p) Where C= no of defectives per sub group n = sample size k= no of sub groups 16

P chart
Used when sample size is not constant for all subgroups c Compute Avg fraction defective = p Calculate Central line =

p p
k

p(1 p ) Upper control limit = Ucl p p 3 n Lower control limit = Lcl p p 3 p(1 p ) n
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C chart
Used when it is possible to count number of defects in a single unit Used when sample size is not constant for all subgroups

Calculate Central line =

c c
k

Upper control limit = Ucl c c 3 c Lower control limit = Lcl c c 3 c

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U chart
Used when it is possible to count number of defects in a single unit & when sample size is not constant for all subgroups

c Compute Avg fraction defective =u n

u Calculate Central line = u

k

u Upper control limit = Ucl u u n u Lower control limit = Lcl u u n

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Operator role in Quality Assurance

No one knows a work place better than the worker. Quality goals cannot be achieved unless we use the hands & heads of the workforce. The roles of workforce are
Nominating quality problems for solution Serving as a members of various types of quality teams identifying elements of their own jobs that do not meet the 3 criteria of self control
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Operator role in Quality Assurance

3 criteria of self control are
Knowledge of what they are supposed to do Knowledge of their performance Means of regulating performance if they fail to meet the goals

Becoming knowledgeable as to the needs of their customers.

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