1

TOPIC 9 & 10
TOOLS TO IMPROVE
QUALITY AND QUALITY
DIAGNOSIS PROCEDURE :
STATISTICAL QUALITY
CONTROL

Topic 9.0 : Statistical Process

Control For Variables Data
1. Statistical Fundamentals
2. Process Control Charts / SPC
3. Some Control Chart Concepts for
Variables
4. Process Capability for Variables
5. Other Statistical Techniques in Quality
Management
BJMQ3013-Quality Management: Dr Che Azlan Taib

Topic 10.0 : Statistical Process

Control For Attributes Data
1. What is an Attribute
2. Generic Process for developing structure
Charts
3. Understanding Attributes Control Charts
4. Choosing the Right Attributes Chart

BJMQ3013-Quality Management: Dr Che Azlan Taib

Data are required to obtain the

average dimensions and the degree of
dispersion (in process) so that we can
determine .. Whether the production
process used for manufacturing the lot
was suitable, of if some action must be
taken. In other words, action can be
taken on a process on the basis of
data gained from the samples.

KAORU ISHIKAWA

STATISTICAL
FUNDAMENTALS
1. What Is Statistical Thinking
Is a decision-making skill demonstrated by
the ability to draw conclusions based on data.
Statistical thinking is based on three
concepts:

All work occurs in a system of

interconnected processes.
All processes have variation (the amount
of variation tends to be underestimated).
Understanding variation and reducing
variation are important keys to success.

2. Why Do Statistics Sometimes

Fall in the Workplace?
Lack of knowledge about the tools.

General disdain for all things mathematical

creates a natural barrier to the use of
statistics.

3. What Do We Mean by the Term

Statistical Quality Control?

4. Understanding Process Variation

Processes involve variation. Some variation
can be managed and some cannot.
If too much variation, the process not fit
correctly., product not function properly
and firms will, get bad reputation/image.
TWO types of variation commonly occur:

1. Random variation
2. Non-random
variation

Random Variation

Is uncontrollable
In centered around a mean and occurs
with a somewhat consistent amount of
dispersion.
The amount of random variation in a
process may be either large or small

Non-Random Variation

10

The event may be shift

in a process mean or
some unexpected
occurrence.

Process Stability

11

Means that the variation we observe in

the process is random variation
(common csuse) and not nonrandom
variation.
To determine process stability, we use
process chart.
Process charts are graphs designed to
signal process workers when
nonrandom variation is occurring in a
process.

PROCESS CONTROL CHARTS /

STATISTICAL PROCESS CONTROL
A methodology for monitoring a
(SPC)

process to identify special causes of

variation and signal the need to take
corrective action when appropriate

12

SPC relies on control charts

HISTOGRAMS VS. CONTROL

CHARTS

Histograms do not take into account changes over

time.
Control charts can tell us when a process changes

CONTROL CHART APPLICATIONS

Establish state of statistical control
Monitor a process and signal when
it goes out of control

14

Determine process capability

Process capability calculations make

little sense if the process is not in
statistical control because the data
are confounded by special causes
that do not represent the inherent
capability of the process.

QUALITY CONTROL
APPROACHES
Statistical process control (SPC)
Monitors the production process to prevent

poor quality

Acceptance sampling

16

Inspects a random sample of the product

to determine if a lot is acceptable

STATISTICAL PROCESS
CONTROL
Take periodic samples from a process
Plot the sample points on a control chart
Determine if the process is within limits

17

Correct the process before defects occur

SPC APPLIED TO SERVICES

Nature of defect is different in services
Service defect is a failure to meet customer requirements
Monitor times, customer satisfaction
Service Quality Examples

Hospitals
timeliness, responsiveness, accuracy
Grocery Stores
Check-out time, stocking, cleanliness
Airlines
luggage handling, waiting times, courtesy
Fast food restaurants
waiting times, food quality, cleanliness

PROCESS CONTROL
CHART
Upper
control
limit

Process
average

Lower
control
limit
2

Sample number

10

19

CONSTRUCTING A CONTROL
CHART
Decide what to measure or count
Collect the sample data
Plot the samples on a control chart
Calculate and plot the control limits on the control chart
Determine if the data is in-control
If non-random variation is present, discard the data (fix the
problem) and recalculate the control limits
A Process Is In Control If

No sample points are outside control limits

Most points are near the process average
About an equal # points are above & below the centerline
Points appear randomly distributed

20

THE NORMAL
DISTRIBUTION

95 %
99.74 %
-3

-2

-1

= 0 1 2 3

Area under the curve = 1.0

1998 by Prentice-Hall Inc
Russell/Taylor Oper Mgt 2/e

Ch 4 - 14

CONTROL CHART Z
VALUES
Smaller Z values make more
sensitive charts
Z = 3.00 is standard
Compromise between sensitivity
and errors

CONTROL CHARTS AND THE

NORMAL DISTRIBUTION
UCL

+3
Mean

-3

23

LCL

TYPES OF DATA
Attribute data (p-charts, c-charts)
Product characteristics evaluated with a
discrete choice (Good/bad, yes/no, count)

Variable data (X-bar and R charts)

24

Product characteristics that can be

measured (Length, size, weight, height, time, velocity)

CONTROL CHARTS
FOR ATTRIBUTES
p Charts
Calculate percent defectives in a sample;
an item is either good or bad
c Charts

25

Count number of defects in an item

P - CHARTS
Based on the binomial distribution

p = number defective / sample size, n

p=

total no. of defectives

total no. of sample observations

UCLp =

LCLp =

P-CHART CALCULATIONS
Proportion
Sample Defect Defective
1
2
3

6
0
4

.06
.00
.04

.
20

18
.18
200
1.00
100 jeans in each sample
total defectives
p =
total sample observations

200 =
20 (100) 0.10

UCL = p + 3 p(1-p) /n

= 0.10 + 3 0.10 (1-0.10) /10

= 0.190
LCL = p - 3 p(1-p) /n

= 0.10 + 3 0.10 (1-0.10) /10

= 0.010

0.2
0.18
0.14
0.12
0.1
0.08
0.06
0.04
0.02
20

18

16

14

12

..

10

Sample number

28

0
0

Proportion defective

0.16

C - CHART
CALCULATIONS
Count # of defects per roll in 15 rolls of denim fabric

c = 190/15 = 12.67
UCL = c + z c
.
= 12.67 + 3 12.67
= 23.35
LCL = c - z c
= 12.67 - 3 12.67
= 1.99

30

Sample Defects
1
12
2
8
3
16
.
.
.
15
15
190

EXAMPLE C - CHART
24

18
15
12
9
6
3

14

12

10

Sample number

31

Number of defects

21

CONTROL CHARTS
FOR VARIABLES
Mean chart (X-Bar Chart)
Measures central tendency of a sample
Range chart (R-Chart)
Measures amount of dispersion in a sample

32

Each chart measures the process differently. Both

the process average and process variability must
be in control for the process to be in control.

EXAMPLE: CONTROL CHARTS

FOR VARIABLE DATA
Slip Ring Diameter (cm)
Sample
0.08
0.12
0.08
0.14
0.13
0.10
0.14
0.11
0.15
10

5.02

5.01

4.94

4.99

4.96

4.98

5.01

5.03

5.07

4.95

4.96

5.00

4.99

5.00

4.93

4.92

4.99

4.97

5.03

4.91

5.01

4.98

4.89

4.96

4.95

4.92

5.03

5.05

5.01

4.99

4.97

5.06

5.06

4.96

5.03

5.01

5.05

5.01

5.10

4.96

4.99

5.02

5.09

5.10

5.00

4.99

5.08

5.05

5.14

5.10

4.99

5.08

5.09

5.08

5.01

4.98

5.08

5.07

4.99

50.09

1.15

5.03

0.10

34

CONSTRUCTING A MEAN CHART

EXAMPLE X-BAR
CHART
5.10

UCL

5.08
5.06
e
g 5.04
a
r
e
v 5.02
a
e
l 5.00
p
m
a 4.98
S
4.96

4.94
4.92
1

Sample number

10

LCL

CONSTRUCTING AN
RANGE CHART
UCLR = D4 R = (2.11) (.115) = 2.43
LCLR = D3 R = (0) (.115) = 0

where R =

R / k = 1.15 / 10 = .115

k = number of samples = 10

36

R = range = (largest - smallest)

3 CONTROL CHART
FACTORS
D4
3.27
2.57
2.28
2.11
2.00
1.92
1.86

X-chart

R-chart

A2

D3

1.88

1.02

0.73

0.58

0.48

0.42

0.08

0.37

0.14

37

Sample size

EXAMPLE R-CHART
UCL

0.3
0.25
0.2
e
g
n 0.15
a
R

0.1
0.05
0
1

Sample number

10

LCL

CONTROL CHART
PATTERNS
UCL

UCL

LCL

LCL

Sample observations
consistently below the
center line

1998 by Prentice-Hall Inc

Russell/Taylor Oper Mgt 2/e

Sample observations
consistently above the
center line

Ch 4 - 34

CONTROL CHART
PATTERNS
UCL

UCL

LCL

LCL

Sample observations
consistently increasing

1998 by Prentice-Hall Inc

Russell/Taylor Oper Mgt 2/e

Sample observations
consistently decreasing

Ch 4 - 35

CONTROL CHART
PATTERNS
UCL

UCL

LCL

LCL

Sample observations
consistently below the
center line
1998 by Prentice-Hall Inc
Russell/Taylor Oper Mgt 2/e

Sample observations
consistently above the
center line
Ch 4 - 36

CONTROL CHART
PATTERNS
1.

8 consecutive points on one side of the

center line

2.

8 consecutive points up or down

across zones

3.

14 points alternating up or down

4.

2 out of 3 consecutive points in Zone A

but still inside the control limits
4 out of 5 consecutive points in Zone A or B
42

5.

ZONES FOR PATTERN

TESTS
Values for example 4.4

LCL

5.08

Zone A

x + 3 sigma

Zone B

x + 2 sigma

Zone C

x + 1 sigma

Zone C

x - 1 sigma

Zone B

x - 2 sigma

Zone A

x - 3 sigma

5.05
5.03
5.01
4.98
4.965
4.94

43

UCL

SAMPLE SIZE
DETERMINATION
Attribute control charts
50 to 100 parts in a sample
Variable control charts
2 to 10 parts in a sample

1998 by Prentice-Hall Inc

Russell/Taylor Oper Mgt 2/e

Ch 4 - 41