Statistical Quality
Control
Dr. Nasrullah Khan
Introduction
Statistical Process Control
Collection of tools for problem Solving
Bases upon
Principles and significant impact and can be applied to any process
The Magnificent Seven
Chance and Assignable Causes of Variation
• This natural variability or “background noise” is the cumulative effect of many small, essentially
unavoidable causes.
• A process that is operating with only chance causes of variation
present is said to be in statistical control
Assignable Causes of Variation
Other Variability has 3 Sources
• 1. Improperly adjusted or controlled machines,
• 2. Operator errors
• 3. Defective raw material
A process that is operating in the presence of assignable causes is said to be an out-of-control process.
Chance and Assignable Causes of Variation
Check Sheet
Pareto Chart
Cause and Effect Diagram
Defect Concentrated Diagram
Scatter Diagram
Introduction
Several Quality characteristics that can be expressed numerically
• Diameter of bearing
• Temperature of machine
• Dimension
• Weight
• Volume
Introduction
To Deal with Such type of Characteristics variable control chart are used in
term of
Mean
Variance (S or Range)
X-bar and R or S Control Charts
• 3-sigma control limits:
• The grand mean: (20 to 25 preliminary samples of 4,5 or 6 )
15-3: X-bar and R or S Control Charts
The average range:
An unbiased estimator of :
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15-3: X-bar and R or S Control Charts
x Control Chart (from R):
R Chart:
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15-3: X-bar and R or S Control Charts
3-sigma control limits for S:
An unbiased estimator of :
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15-3: X-bar and R or S Control Charts
S Chart:
x Control Chart (from S ):
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15-3: X-bar and R or S Control Charts
Example 15-1
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15-3: X-bar and R or S Control Charts
Example 15-1
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15-3: X-bar and R or S Control Charts
Example 15-1
Figure 15-8 X and R control
charts for vane opening.
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15-3: X-bar and R or S Control Charts
Example 15-1
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15-3: X-bar and R or S Control Charts
Example 15-1
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15-3: X-bar and R or S Control Charts
Example 15-1
Figure 15-9 The S control chart for vane opening.
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15-3: X-bar and R or S Control Charts
Example 15-1
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15-3: X-bar and R or S Control Charts
Example 15-1
Figure 15-10
The X-bar
and R control charts
for vane opening.
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Revision of Control limits and Centre Lines
Periodic Revision
• Weakly
• Monthly
25,30 or 50 samples
Some authorities suggests it as 200-300
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Interpretation of control chart
• If there is Non random pattern in Both Xbar and R chart
search for the assignable causes R chart.
• Cyclic pattern usually occurs due to temp, operator
fatigue, regular rotation and voltage issue.
•
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Interpretation of control chart
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Interpretation of control chart
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Guideline for the design of control chart
• We must specify
• Sample size
Small samples for Moderate to large shift
Large samples for smaller shift
For n>10 or 12 S or S^2 chart should be used
• Control limit width
• Frequency of sampling
Small frequent samples
Large sample less frequent
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15-4: Control Charts for Individual Measurements
• What if you could not get a sample size greater than 1
(n =1)? Examples include
– Automated inspection and measurement technology
is used, and every unit manufactured is analyzed.
– The production rate is very slow, and it is
inconvenient to allow samples sizes of N > 1 to
accumulate before analysis
– Repeat measurements on the process differ only
because of laboratory or analysis error, as in many
chemical processes.
• The individual control charts are useful for samples of 32
sizes n = 1.
15-4: Control Charts for Individual Measurements
• The moving range (MR) is defined as the
absolute difference between two successive
observations:
MRi = |xi - xi-1|
which will indicate possible shifts or
changes in the process from one observation
to the next.
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15-4: Control Charts for Individual Measurements
Individuals Control Chart
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15-4: Control Charts for Individual Measurements
Interpretation of the Charts
• X Charts can be interpreted similar to X-bar charts. MR charts cannot be
interpreted the same as X-bar or R charts.
• Since the MR chart plots data that are “correlated” with one another, then
looking for patterns on the chart does not make sense.
• MR chart cannot really supply useful information about process variability.
• More emphasis should be placed on interpretation of the X chart.
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15-5: Process Capability
• Process capability refers to the performance of
the process when it is operating in control.
• Two graphical tools are helpful in assessing
process capability:
• Tolerance chart (or tier chart)
• Histogram
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15-5: Process Capability
Tolerance Chart
Figure 16-12 Tolerance diagram of
vane openings.
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15-5: Process Capability
Histogram
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Figure 15-13 Histogram for vane openings.
15-5: Process Capability
Process Capability Ratio
PCRk
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15-5: Process Capability
Figure 15-14 Process Fallout and
the process capability ratio
(PCR).
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15-5: Process Capability
Example 15-3
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15-5: Process Capability
Figure 15-15 Mean of a six-sigma process shifts by 1.5 standard deviations.
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15-6: Attribute Control Charts
15-6.1 P Chart (Control Chart for Proportions)
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15-6: Attribute Control Charts
Example 15-4
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15-6: Attribute Control Charts
Example 15-4
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Figure 15-16 P chart for a ceramic substrate.
15-6: Attribute Control Charts
Example 15-4
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15-6: Attribute Control Charts
15-6.2 U Chart (Control Chart for Defects per Unit)
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15-6: Attribute Control Charts
Example 15-5
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15-6: Attribute Control Charts
Example 15-5
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15-6: Attribute Control Charts
Example 15-5
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Figure 15-17 U chart of defects per unit on printed circuit boards.
15-7: Control Chart Performance
Average Run Length
• The average run length (ARL) is a very important
way of determining the appropriate sample size
and sampling frequency.
• Let p = probability that any point exceeds the
control limits. Then,
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15-7: Control Chart Performance
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THANKS
