Quality Engineering I

Tutorial 3
Control Charts for Attributes
Tutorial 3.1

Determine the trial central line and control

limits for a p chart using the following data,
which are for the payment of dental insurance
claims. Plot the values on graph paper and
determine if the process is stable. If there are
any out-of-control points, assume an
assignable cause and determine the revised
central line and control limits.
 Data for the p chart
Subgroup n np p Subgroup n np p
1 300 3 0.0100 14 300 6 0.0200
2 300 6 0.0200 15 300 7 0.0233
3 300 4 0.0133 16 300 4 0.0133
4 300 6 0.0200 17 300 5 0.0167
5 300 20 0.0667 18 300 7 0.0233
6 300 2 0.0067 19 300 5 0.0167
7 300 6 0.0200 20 300 0 0.0000
8 300 7 0.0233 21 300 2 0.0067
9 300 3 0.0100 22 300 3 0.0100
10 300 0 0.0000 23 300 6 0.0200
11 300 6 0.0200 24 300 1 0.0033
12 300 9 0.0300 25 300 8 0.0267
13 300 5 0.0167
Solution

Plot the p chart;

Determine the trial UCL, CL, and LCL;
Revised control limits if any out-of-control
point occurs (assume an assignable cause).
Control limits for the p chart

p 1 p
UCL p 3 0.04016
n
CL p 0.01747
p 1 p
LCL p 3 0.0052 0
n
The p chart
Revised control limits
Discard the 5th point, which has a assignable
cause, A new p can be calculated:
p
np np
0.01542
d

n n
new
d

Recalculate the control limits using the new

fraction nonconforming:
p 1 p
UCLnew p 3 0.03676
n
p 1 p
LCLnew p 3 0.0059 0
n
The revised p chart

P Chart of C2
0.04
UCL=0.03676

0.03
Proportion

0.02
_
P=0.01542

0.01

0.00 LCL=0

1 3 5 7 9 11 13 15 17 19 21 23
Sample
Tutorial 3.2

Fifty motor generators are inspected per day

from a stable process. The best estimate of
the fraction nonconforming is 0.076.
Determine the central line and control limits.
On a particular day, 5 nonconforming
generators were discovered. Is this in control
or out of control?
 Solution
The best estimate of p=0.076.
p 1 p 0.0761 0.076
UCL p 3 0.076 3 0.1884
n 50
CL p 0.076
p 1 p
LCL p 3 0.0364 0
n

p= 5/50=0.1, in control.
Tutorial 3.3

Inspection results of video-of-the-month

shipments to customers for 25 consecutive
days are given in the table. What central line
and control limits should be established and
posted if it is assumed that any out-of-control
points have assignable causes? The number
of inspection each day is constant and equals
1750.
Tutorial 3.3
Date Number Nonconforming Date Number Nonconforming
July 6 47 July 23 37
7 42 26 39
8 48 27 51
9 58 28 44
12 32 29 61
13 38 30 48
14 53 Aug. 2 56
15 68 3 48
16 45 4 40
19 37 5 47
20 57 6 25
21 38 9 35
22 53
Solution
Trial control limits:

UCL np 3 np(1 p ) 65.93

CL np 45.88
LCL np 3 np(1 p ) 25.83
Solution

NP Chart of C1
70 1

UCL=65.93

60
Sample Count

50
__
NP=45.88

40

30
LCL=25.83
1
20
1 3 5 7 9 11 13 15 17 19 21 23 25
Sample
Solution
Tutorial 3.4

The performance of the first shift is reflected

in the inspection results of electric carving
knives. Determine the trial central line and
control limits for each subgroup. Assume that
any out-of-control points have assignable
causes and determine the standard value for
the fraction nonconforming for the next
production period.
 Tutorial 3.4
Date Number Number Date Number Number
Inspected Nonconforming Inspected Nonconforming
Sept.6 500 5 Sept.23 525 10
7 550 6 24 650 3
8 700 8 27 675 8
9 625 9 28 450 23
10 700 7 29 500 2
13 550 8 30 375 3
14 450 16 Oct. 1 550 8
15 600 6 4 600 7
16 475 9 5 700 4
17 650 6 6 660 9
20 650 7 7 450 8
21 550 8 8 500 6
22 525 7 11 525 1
Solution
Solution

P Chart of C2
0.030

0.025 UCL

0.020
Proportion

0.015
_
P=0.01124
0.010

0.005

0.000 LCL

1 3 5 7 9 11 13 15 17 19 21 23
Sample
Tests performed with unequal sample sizes
Tutorial 3.5

The count of surface nonconformities in 1000

square meters of 20-kg kraft paper is given in
the table. Determine the trial central line and
control limits and the revised central line and
control limits, assuming that out-of-control
points have assignable causes.
Tutorial 3.5
Lot Count of Lot Count of
Number Nonconformities Number Nonconformities
20 10 36 2
21 8 37 12
22 6 38 0
23 6 39 6
24 2 40 14
25 10 41 10
26 8 42 8
27 10 43 6
28 0 44 2
29 2 45 14
30 8 46 16
31 2 47 10
32 20 48 2
33 10 49 6
34 6 50 3
35 30
Tutorial 3.5

Given the count of surface nonconformities in

1000 square meters of 20-kg kraft paper;
Determine the trial UCL, CL, and LCL;
Revised control limits if any out-of-control
point occurs.
Solution

UCL c 3 c 16.53;
CL c 8.03;
LCL c 3 c 0.470 0.
Solution
Solution
Solution
Tutorial 3.6

Construct a control chart for the data in the

table for empty bottle inspections of a soft-
drink manufacturer. Assume assignable
causes for any points that are out of control.

The subgroup size varies u chart

 Tutorial 3.6
Number of Chips, Foreign Foreign
Bottles Scratches, Material Material Total
Other On Sides On Bottom Nonconformities
40 9 9 27 45
40 10 1 29 40
40 8 0 25 33
40 8 2 33 43
40 10 6 46 62
52 12 16 51 79
52 15 2 43 60
52 13 2 35 50
52 12 2 59 73
52 11 1 42 54
52 15 15 25 55
52 12 5 57 74
52 14 2 27 43
52 12 7 42 61
Tutorial 3.6
Number of Chips, Foreign Foreign
Bottles Scratches, Material Material Total
Other On Sides On Bottom Nonconformities
40 11 2 30 43
40 9 4 19 32
40 5 6 34 45
40 8 11 14 33
40 3 9 38 50
40 9 9 10 28
52 13 8 37 58
52 11 5 30 46
52 14 10 47 71
52 12 3 41 56
52 12 2 28 42
Solution
The control limits of u chart
c
u ,
n

u
c
n
u
UCL u 3 ;
n
CL u ;
u
LCL u 3 .
n
 Solution
Subgroup n c u UCL u-Bar LCL
1 40 45 1.125 1.59 1.09 0.60
2 40 40 1.000 1.59 1.09 0.60
3 40 33 0.825 1.59 1.09 0.60
4 40 43 1.075 1.59 1.09 0.60
5 40 62 1.550 1.59 1.09 0.60
6 52 79 1.519 1.53 1.09 0.66
7 52 60 1.154 1.53 1.09 0.66
8 52 50 0.962 1.53 1.09 0.66
9 52 73 1.404 1.53 1.09 0.66
10 52 54 1.038 1.53 1.09 0.66
11 52 55 1.058 1.53 1.09 0.66
12 52 74 1.423 1.53 1.09 0.66
 Solution
Subgroup n c u UCL u-Bar LCL
13 52 43 0.827 1.53 1.09 0.66
14 52 61 1.173 1.53 1.09 0.66
15 40 43 1.075 1.59 1.09 0.60
16 40 32 0.800 1.59 1.09 0.60
17 40 45 1.125 1.59 1.09 0.60
18 40 33 0.825 1.59 1.09 0.60
19 40 50 1.250 1.59 1.09 0.60
20 40 28 0.700 1.59 1.09 0.60
21 52 58 1.115 1.53 1.09 0.66
22 52 46 0.885 1.53 1.09 0.66
23 52 71 1.365 1.53 1.09 0.66
24 52 56 1.077 1.53 1.09 0.66
25 52 42 0.808 1.53 1.09 0.66
Solution
Appendix: Normal distribution table