The above formula is used to calculate the control limits when all samples are

relatively the same size. If any individual subgroup sample size is more than 25%
above or below the average sample size, the precise control limits for that sample
must be calculated and plotted. The formula is the same as for the other
calculations except that the value of n for that sample is used instead of the
average value of n. The use of variable control limits is cumbersome and
potentially confusing. It is much better whenever possible to avoid this situation
by using constant subgroup sample sizes. SUMMARY The objective of the
control chart for variables is to identify evidence that the process is no longer
operating at the same level - that it is out of control - and to signal when to
take appropriate corrective action. It needs to be emphasized here that a process
may be in satatistical control and yet not be satisfactory. The process could be in
statistical control and be producing an unacceptable amount of nonconforming
product. It is assumed here that the average amount of nonconforming product is
acceptable. Evidence of Noncontrol 1. Points Beyond the Control Limits
- The presence of one or more points beyond either control limit is
evidence of instability at that point. Since points beyond the
control limits would be very rare if the process were stable and only
common-cause variation were present, we presume that special cause has
accounted for the extreme value. The special cause may be either
unfavorable or favorable; either bears immediate investigation. This
is the primary decision rule for any control chart. Points outside the
control limits should be marked for identification and action.
A point above the UCL is generally an indication that: a. The
control limit or plot point may be in error b.
The process performance has deteriorated c. The measuring system
has changed (e.g., inspector, gage). A point below
the LCL is generally a sign that: a. The control limit or plot is
in error b. The process has improved (study to determine
what is being done "right") c. The measuring system has changed
Patterns or Trends Within the Control Limits - The presence of unusual patterns or
trends, even when all points are within the control limits, can be evidence of
noncontrol or change in level of performance during the period of which, if left
uncorrected, could cause averages beyond the control limits. NOTE: When the average
number of nonconforming items per subgroup (np) is moderately large (9 or more),
the distribution of the subgroup p's is nearly normal and trend analysis similar to
that used for charts can be used. When np becomes small (5 or fewer), the
following rules are directly applicable. 2. Distance of points from the process
average - In a process under statistical control, with only common-
cause variation present and np moderately large, about 2/3 of the data
points will be within the middle third of the region between the control
limits; about 1/3 of the points will be in the outer two-thirds of the
region; about 1/20 will lie relatively close to the control limits (in the
outer third of the region). If substantially more than 2/3 of the points lie
close to the process average, this could mean: a. The control limits
or plot points have been miscalculated or misplotted b. The
process or the sampling method is stratified (e.g., the mixed output of
two parallel production lines) c. The data have been edited
(values that would have deviated much more from the average have been
altered or removed). If substantially fewer than 2/3 of the points lie close
to the process average, this could mean: a. Calculation or plotting errors
have been made b. The process or sampling method causes successive
subgroups to contain measurements from two or more process streams that
have very different average performance (e.g., performance between
shifts). If several process streams are present, they should be
identified and tracked separately. 3. Runs - In a process under control, with
np moderately large, approximately equal numbers of points should fall
on either side of the average. Either of the following could be a sign that
a process shift or trend has begun: 7 points in a row on one side of
the average, or 7 points in a row that are consistently increasing
(equal or greater than the preceding points) or consistently
decreasing. In these cases, the point that signals the decision
should be marked (e.g., the eighth point above or below the average); it may
be helpful to extend a reference line back to the beginning of the run. The
analysis should consider the approximate time at which it appears
that the trend or shift first began. Runs above the process average, or runs
up, generally signify that: a. The process performance has worsened -
and may still be worsening b. The measuring system has changed.
Runs below the process average, or runs down, generally signify that:
a. The process performance has improved (the causes should be studied for
permanent incorporation) b. The measuring system has changed. NOTE:
When np is small (e.g., below 5), the likelihood of runs below the average
increases. Therefore, a run length of 8 or more might be necessary to signal
a decrease in the proportion of nonconforming. Data from control charts
for attributes are of considerable value in determining process capability with
respect to the quality level of the finished product.