12 Sampling Tech 4
12 Sampling Tech 4
System
by
Attributes
Topic Outcome:
At the end of this topic, students will be able to:
Use sampling system for lot-by-lot
sampling (ANSI/ASQ Z1.4 1993 & Dodge-
Romig sampling Tables)
Use sampling system for isolated lot sampling
(ANSI/ASQ Standard Q3 – 1998)
Topic Outline:
• Lot-by-lot Acceptance Sampling Plans:
1)AQL Sampling Plans (ANSI/ASQ Z1.4 1993)
- An Introduction.
- Inspection Level
- Types of Sampling Plans.
- Switching Procedures
- AOQL factors
- LQ
- ASN
2) Dodge-Romig Sampling Tables
Topic Outline:
Estimation of
Good Fair Fair
Quality
How to use this Standard for Single Sampling
Plans?
The steps are:
1) Decide on AQL.
2) Decide on the inspection level.
3) Decide on the type sampling plan to be used
SINGLE
4) Decide whether normal, tightened, or reduced
inspection is to be used.
5) Determine Lot size (N).
6) Use Table 1 to find the sample size code letter.
7) Use the appropriate table to obtain the plan (Table
II.A to II.C).
8) Look at OC curve.
Q&A
NORMAL TIGHTENED
REDUCED
AQL=1.0%
Ac Re
First 1 4
Second 4 5
Q&A
* Some of these plans continue to the ‘bitter end’, i.e., the taking of
samples continues if necessary until the lot is fully inspected, unless
the plan has meanwhile ‘made up its mind’.
The steps are:
1) Decide on AQL.
2) Decide on the inspection level.
3) Decide on the type sampling plan to be used
MULTIPLE
4) Decide whether normal, tightened, or reduced
inspection is to be used.
5) Determine Lot size (N).
6) Use Table 1 to find the sample size code letter.
7) Use the appropriate table to obtain the plan (Table
IV.A to IV.C).
8) Look at OC curve.
Q&A
First 32 32 # 3
Second 32 64 0 3
Third 32 128 1 4
Fourth 32 160 2 5
product would be 10
accepted). 0
0 1 2 3 4 5 6 7 8
Percent Nonconforming (100p 0)
Plans classified on this basis are called LQ (or LTPD)
plans because their point of similarity is the quality level or
percent of nonconforming which can just be tolerated in a
small percentage of the product.
LQ is defined as “ an allowable percentage nonconforming”
a number which may be considered as the borderline of
distinction between a satisfactory lot and in unsatisfactory
one.
To engineers, this means the percent nonconforming
which will regularly be rejected by inspection, that is, the
percentage nonconforming for which the probability of
acceptance is very low.
When an engineer chooses a “2% LQ Sampling Plan”,
he/she is choosing a plan which would regularly reject 2%
nonconforming product. The fact that the plan is classified
as “2% LQ” does not tell the characteristic of the remainder
of the OC curve that is what quality of product will regularly
be accepted.
Customers sometime specify a certain value of LQ for a
particular product. In such case, the manufacturer of the
product will try to select a sampling plan which has a low
probability of acceptance at the specified LQ.
Sampling Plans on this basis have been published by
Dodge and Romig (1920s). These tables provide a useful
classification of sampling plans wherever we wish to make
sure that product of a particular quality will have a low
probability of acceptance.
How to use the table?
Determine the usual lot size.
Determine the process average (percent nonconforming at
which the products runs).
Determine sample size, n
Under the applicable process average, determine the
number c.
Q&A
N=1500, process average=0.25%, required single
sampling plan for LQ=1.0%
100
• Consider a sampling
90
plan for n=18, c=0.
• When product is 8% 30
…etc. 0
0 1 2 3 4 5 6 7 8
Percent Nonconforming (100p 0)
Suppose we make the following rules:
All rejected lots by this sampling plan must be 100%
inspected.
All nonconforming unit found by this inspection must
be replaced with good units, and
The rejected lots which have had all nonconforming
removed must then be considered together with the
accepted lots in such a way as to make one total
quality of product.
It is possible to calculate the percentage of nonconforming
which will be left in the mass of product if this procedure is
followed.
AOQ Curve This curve shows that
when the incoming
2.5
Average Outgoing Quality-%
product is 10%
2.0 AOQL~2% nonconforming, the
outgoing product will
1.5 be only 1.6%
nonconforming;
1.0
provided the
0.5 requirements of the
sampling plan,
0.0 including 100%
0 5 10 15
Percent Nonconforming
inspection for
rejected products,
have been faithfully
carried out.
Note that the AOQ curve rises until it reaches a certain
maximum point, after which it falls off again as a result of
more and more product being “100% inspected”.
The AOQL is the maximum point which is reached by the
AOQ curve.
The AOQL of a sampling plan is therefore defined as
follows: This limit is the worst average quality that can
exist, in the long run, in the outgoing product, after the
rejected lots have been 100% inspected and all the
nonconformities have been replaced by good units.
How to calculate AOQL?
Three ways:
1) From a series of AOQ values, a graph is plotted and
AOQL is determined from the maximum point of the
graph.
2) From Table V-A and V-B (MS 567)
3) From an equation.
y y
AOQL
n N
c 0 1 2
y 0.368 0.841 1.372
c 3 4 5
y 1.946 2.544 3.172
c 6 7 8
y 3.810 4.465 5.150
c 9 10 11
y 5.836 6.535 7.234
y=0.368
10
0
0 1 2 3 4 5 6 7 8
Percent Nonconforming (100p 0)
When an engineer chooses a “2% AOQL sampling plan”,
he/she is choosing a plan which will limit the outgoing
product, in the long run, to a 2% average or less.
The outgoing quality may be, and frequently is, limited to
some point much lower than the stated AOQL.
For example, the above curve is shown that if the
submitted product were 20% nonconforming, this particular
plan would force the shop to do sufficient screening to cut it
down (theoretically) to 0.5%. The plan imposes, under
these circumstances, a much tighter standard of quality
than the stated 2%.
The fact that a sampling plan is classified as “2% AOQL”
does not tell the engineer anything about any part of the
OC curve.
He/she is not able to tell what quality of product will be
regularly accepted, or rejected. (same as LQ and AQL)
When an AOQL is specified for a particular product, we try
to select a sampling plan whose AOQL is equal to the
specified value.
To make it easier to select plans on this basis, Dodge and
Romig have developed tables of sampling plans classified
according to their AOQLs. The values of AOQL range from
0.1% to 10% nonconforming.
The plans in these tables are arranged in such a way that,
if the engineer selects a plan under the correct “process
average”, he/she will minimize the total number of pieces
which must be looked at, including both sampling and
100% inspection.
LQ values also included as supplementary information.
These tables are useful wherever we are interested in
setting a fixed maximum limit on outgoing quality and are
willing to achieve this by a combination of sampling and
100% inspection.
Table 10-9
Precautions to be taken in using AOQL
Sampling Plan
Since this plans involve a combination of sampling and
100% inspection, they are often subjected to
misinterpretation and misuse.
Engineers should guard against the following errors:
(1) We sometime hear of “AOQL sampling plans”
being used in connection with destructive test or in
Receiving Inspection where the rejected lots are
junked, returned to the supplier or accepted on an
outside limit basis, but where there is no intention
whatever of doing 100% inspection on the lots which
fail to meet the acceptance number of the plans.
[IMPORTANT: Unless 100% inspection is done, we
will not get the protection promised by an AOQL
sampling plan]
(2) If the product contains nonconforming to begin
with, an AOQL sampling plan will depend on the
presence of the rejected lots, which have been
made prefect by screening, to dilute the percentage
of the nonconformities which may still be present in
the lots accepted.
What the Operating organization should know
about AOQL Sampling Plans?
Operating people often assume that a “2% AOQL
sampling Plan” will accept product which is 2%
nonconforming.
That is, if inspection is using a 2% AOQL plan, and if
Operating submits product which is actually 2%
nonconforming, they feel that all or most of the submitted
product should pass the inspection plan.
Engineers also frequently make this assumption in
discussing suitable quality levels for sampling or in
agreeing to the use of some specific proposed plan.
However, unless the AOQL sampling plan is deliberately
chosen with this in mind, a 2% plan may reject large
portions of 2% nonconforming product.
The following example will show why it is necessary to
restrict the choice of plan.
Suppose a sampling plan were to be chose solely for its
AOQL. The following plans will have an AOQL of 2% when
used for lots of approx. 1000.
(a) n=18, c=0
(b) n=40,c=1
(c) n=65,c=2
(d) n=90,c=3
While all of these plans have a 2% AOQL, they will reject
very different amounts of 2% nonconforming product.
Approximate Percentage of
Product Rejected
2% AOQL Sampling Plan
(if product is running at 2%
nonconforming)
Table 10-7
The last 5 columns can be used to plot the OC curves.
Q & A:
Q: Lot size = 295, inspection level II, LQ=3.15%, where
the isolated lot is from a vendor with a continuous
stream of product, determine the sampling plan.
A: n=125, Ac=1
End