Plot the control chart
SPC step 3
Solving Efeso © 2005 rel. 1 2006/06/05
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Plot the control chart
q First, understand the process control limit concepts
q Then:
– Compute X and R values for each subgroup and plot them
– Compute and plot centre line
– Compute and plot control limits
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Understand the process control limit concepts (1/3)
q Control Limits are the statistical boundaries of a process which define
the amount of variation that can be considered as normal or inherent
variation
q Control Limits are calculated so that, if the process is stable, almost all
of the process output will be located within the control limits
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Understand the process control limit concepts (2/3)
q The most commonly used are the 3 sigma control limits
– Upper Control Limit UCL is 3 standard deviations above the average
– Lower Control Limit LCL is 3 standard deviations below the average
q If the process is stable, only about 3 out of 1000 process outputs will fall
outside the control limits (1 - 0.997 = 0.003)
Special Cause Variation
Upper Control Limit
UCL= X +3σ
Common Cause
Average
LCL = X - 3 σ
Lower Control Limit
Special Cause Variation
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Understand the process control limit concepts (3/3)
q Measures inside the control limits are assumed to come from a stable
process
q Measures outside the control limits are unexpected and considered the
result of a special cause
q The control limits are computed directly from the sample data selected
from the process
q The limits and the average are not the choice of management or the
operator: formulas exist!
q The control limits define the range of inherent variation for the process
as it currently exists, not how we would like it to be
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Compute X and R for each subgroup - Log length example (1/2)
Determine X
ΣX Σ values in the subgroup
X= = Day Log Length (feet)
n subgroup size
1 2 3 4
1 16 18 21 23
2 26 20 19 19
3 20 22 18 18
X = (16+18+21+23)/4 = 19.5 4 For the 1st
24 16 22 20
5 17 19 24 17
6
subgroup
17 17 15 18
7 22 12 20 22
8 24 19 19 17
9 18 18 20 14
10 17 23 19 15
Determine R 11
12
20
21
20
17
17
21
21
23
13 22 17 22 17
14 16 19 18 19
15 17 18 15 23
R = (Subgroup Max value - Subgroup Min)
R = 23 – 16 = 7
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Compute X and R for each subgroup (2/2)
Day Log Length (feet)
1 2 3 4 Average = X Range = R
1 16 18 21 23 19.5 7
2 26 20 19 19 21 7
3 20 22 18 18 19.5 4
4 24 16 22 20 20.5 8
5 17 19 24 17 19.25 7
6 17 17 15 18 16.75 3
7 22 12 20 22 19 10
8 24 19 19 17 19.75 7
9 18 18 20 14 17.5 6
10 17 23 19 15 18.5 8
11 20 20 17 21 19.5 4
12 21 17 21 23 20.5 6
13 22 17 22 17 19.5 5
14 16 19 18 19 18 3
15 17 18 15 23 18.25 8
16 19 17 21 1 18.5 4
17 19 19 13 16 16.75 6
18 21 14 17 16 17 7
19 18 17 25 18 19.5 8
20 20 18 20 19 19.25 2
21 23 21 23 21 22 2
22 20 20 20 14 18.5 6
23 18 18 26 15 19.25 11
24 20 22 23 21 21.5 3
25 23 22 21 24 22.5 3
26 22 14 21 19 19 8
27 18 20 18 22 19.5 4
28 19 20 16 14 17.25 6
29 21 19 16 20 19 5
30 22 22 19 21 21 3
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Plot X values
PLOT OF SUBGROUP AVERAGES
50
45
40
SUBGROUP AVERAGES
35
30
25
20
15
10
0
11
13
15
17
19
21
23
25
27
29
1
SUBGROUPS
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Plot R values
PLOT OF R RANGES
18
16
14
12
RANGES
10
0
1
11
13
15
17
19
21
23
25
27
29
SUBGROUPS
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Compute centre line for each chart
Determine X with 2 decimals more than the measured values
Day Log Length (feet)
1 2 3 4 Average = X Range = R
1 16 18 21 23 19.5 7
ΣX Σ mean values 2
3
26
20
20
22
19
18
19
18
21
19.5
7
4
X= = 4 24 16 22 20 20.5 8
K n. groups 5
6
17
17
19
17
24
15
17
18
19.25
16.75
7
3
7 22 12 20 22 19 10
8 24 19 19 17 19.75 7
9 18 18 20 14 17.5 6
10 17 23 19 15 18.5 8
11 20 20 17 21 19.5 4
12 21 17 21 23 20.5 6
13 22 17 22 17 19.5 5
14 16 19 18 19 18 3
15 17 18 15 23 18.25 8
16 19 17 21 1 18.5 4
X = 577.5 / 30= 19.25 17
18
19
21
19
14
13
17
16
16
16.75
17
6
7
19 18 17 25 18 19.5 8
20 20 18 20 19 19.25 2
21 23 21 23 21 22 2
22 20 20 20 14 18.5 6
23 18 18 26 15 19.25 11
24 20 22 23 21 21.5 3
25 23 22 21 24 22.5 3
26 22 14 21 19 19 8
27 18 20 18 22 19.5 4
28 19 20 16 14 17.25 6
29 21 19 16 20 19 5
30 22 22 19 21 21 3
Determine R with 1 decimal more than the measured values
ΣR
R=
K
R = 171 / 30 = 5.7
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Plot centre line on X chart
PLOT OF SUBGROUP AVERAGES
50
45
40
SUBGROUP AVERAGES
35
30
25
20
15 X = 19.25
10
0
11
13
15
17
19
21
23
25
27
29
1
SUBGROUPS
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Plot centre line on R chart
PLOT OF R RANGES
18
16
14
12
RANGES
10
4
R= 5.7
2
0
1
11
13
15
17
19
21
23
25
27
29
SUBGROUPS
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Compute control limits
For the X chart, the two control limits are:
q UCL = X + A2 R
q LCL = X - A2 R
For the R chart
q UCL = D4 R
q LCL = D3 R
Where A2, D4. e D3 are taken from predefined tables
And if s (standard deviation) is desired the following formula should be applied:
_
s =(A2 n /3) R
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Compute control limits – Log length example
Exercise
Day Log Length (feet)
1 2 3 4 Average = X Range = R
1 16 18 21 23 19.5 7
2 26 20 19 19 21 7
3 20 22 18 18 19.5 4
4 24 16 22 20 20.5 8
5 17 19 24 17 19.25 7
6 17 17 15 18 16.75 3
7 22 12 20 22 19 10
8 24 19 19 17 19.75 7
9 18 18 20 14 17.5 6
10 17 23 19 15 18.5 8
11 20 20 17 21 19.5 4
12 21 17 21 23 20.5 6
13 22 17 22 17 19.5 5
14 16 19 18 19 18 3
15 17 18 15 23 18.25 8
16 19 17 21 1 18.5 4
17 19 19 13 16 16.75 6
18 21 14 17 16 17 7
19 18 17 25 18 19.5 8
20 20 18 20 19 19.25 2
21 23 21 23 21 22 2
22 20 20 20 14 18.5 6
23 18 18 26 15 19.25 11
24 20 22 23 21 21.5 3
25 23 22 21 24 22.5 3
26 22 14 21 19 19 8
27 18 20 18 22 19.5 4
28 19 20 16 14 17.25 6
29 21 19 16 20 19 5
30 22 22 19 21 21 3
For the X chart in the example, the two control limits are:
q UCL = X + A2 R = 19.25 + 0.73(5.7) = 23.41
q LCL = X - A2 R = 19.25 – 0.73(5.7) = 15.09
For the R chart
q UCL =D4 R = 2.28(5.7) = 13.00
q LCL = D3 R = 0.00(5.7) = 0.00
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Plot control limits on X chart
PLOT OF SUBGROUP AVERAGES
50
45
40
SUBGROUP AVERAGES
35
30
UCL=23.41
25
20
15
10
LCL=15.09
X = 19.25
5
0
11
13
15
17
19
21
23
25
27
29
1
SUBGROUPS
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Plot control limits on R chart
PLOT OF R RANGES
18
16
14 UCL=13.00
12
RANGES
10
4
R= 5.7
2
LCL=0.00
0
1
11
13
15
17
19
21
23
25
27
29
SUBGROUPS
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How to fill in the control chart - Wrap up
Example Exercise
1. Fill in the header information
2. Collect data
3. Calculate sum, average and range for
each
4. Work out the scale of the graphs so
that the extreme values fit in. Then
plot the averages and ranges.
5. Using the same data, calculate the
control limits.
6. Draw the conclusion
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