Control Charts for

Variables

EBB 341 Quality Control

Variation

 There is no two natural items in any

category are the same.
 Variation may be quite large or very
small.
 If variation very small, it may appear
that items are identical, but precision
instruments will show differences.
3 Categories of variation

 Within-piece variation
 One portion of surface is rougher than another
portion.
 Apiece-to-piece variation
 Variation among pieces produced at the same
time.
 Time-to-time variation
 Service given early would be different from that
given later in the day.
Source of variation

 Equipment
 Tool wear, machine vibration, …
 Material
 Raw material quality
 Environment
 Temperature, pressure, humadity
 Operator
 Operator performs- physical & emotional
Control Chart Viewpoint

 Variation due to
 Common or chance causes
 Assignable causes

 Control chart may be used to discover

“assignable causes”
Some Terms

 Run chart - without any upper/lower

limits
 Specification/tolerance limits - not
statistical
 Control limits - statistical
Control chart functions

 Control charts are powerful aids to

understanding the performance of a process
over time.

Input Output

PROCESS

What’s causing variability?

Control charts identify
variation
 Chance causes - “common cause”
 inherent to the process or random and not
controllable
 if only common cause present, the process is
considered stable or “in control”
 Assignable causes - “special cause”
 variation due to outside influences
 if present, the process is “out of control”
Control charts help us learn
more about processes
 Separate common and special causes of
variation
 Determine whether a process is in a state of
statistical control or out-of-control
 Estimate the process parameters (mean,
variation) and assess the performance of a
process or its capability
Control charts to monitor
processes
 To monitor output, we use a control chart
 we check things like the mean, range, standard
deviation
 To monitor a process, we typically use two
control charts
 mean (or some other central tendency measure)
 variation (typically using range or standard
deviation)
Types of Data
 Variable data
 Product characteristic that can be measured
 Length, size, weight, height, time, velocity

 Attribute data
 Product characteristic evaluated with a discrete
choice
• Good/bad, yes/no
Control chart for variables

 Variables are the measurable

characteristics of a product or
service.
 Measurement data is taken and

arrayed on charts.
Control charts for variables
 X-bar chart
 In this chart the sample means are plotted in order to
control the mean value of a variable (e.g., size of
piston rings, strength of materials, etc.).
 R chart
 In this chart, the sample ranges are plotted in order to
control the variability of a variable.
 S chart
 In this chart, the sample standard deviations are
plotted in order to control the variability of a variable.
 S2 chart
 In this chart, the sample variances are plotted in order
to control the variability of a variable.
X-bar and R charts

 The X- bar chart is developed from the

average of each subgroup data.
 used to detect changes in the mean between
subgroups.
 The R- chart is developed from the ranges of
each subgroup data
 used to detect changes in variation within
subgroups
Control chart components

 Centerline
 shows where the process average is centered or
the central tendency of the data
 Upper control limit (UCL) and Lower control
limit (LCL)
 describes the process spread
The Control Chart Method
X bar Control Chart:
UCL = XDmean + A2 x Rmean
LCL = XDmean - A2 x Rmean
CL = XDmean 
R Control Chart:
UCL = D4 x Rmean
LCL = D3 x Rmean
CL = Rmean 
Capability Study:
PCR = (USL - LSL)/(6s); where s = Rmean /d2
Control Chart Examples

UCL
Variations

Nominal
LCL

Sample number
How to develop a control
chart?
Define the problem

 Use other quality tools to help determine the

general problem that’s occurring and the
process that’s suspected of causing it.

Select a quality characteristic to

be measured
 Identify a characteristic to study - for
example, part length or any other variable
affecting performance.
Choose a subgroup size to be
sampled
 Choose homogeneous subgroups
 Homogeneous subgroups are produced under the
same conditions, by the same machine, the same
operator, the same mold, at approximately the
same time.
 Try to maximize chance to detect differences
between subgroups, while minimizing chance
for difference with a group.
Collect the data

 Generally, collect 20-25 subgroups (100 total

samples) before calculating the control limits.
 Each time a subgroup of sample size n is
taken, an average is calculated for the
subgroup and plotted on the control chart.
Determine trial centerline

 The centerline should be the population

mean, µ
 Since it is unknown, we use X Double bar, or
the grand average of the subgroup averages.
m

∑X i

X = i =1
m
Determine trial control limits -
Xbar chart
 The normal curve displays the distribution of
the sample averages.
 A control chart is a time-dependent pictorial
representation of a normal curve.
 Processes that are considered under control
will have 99.73% of their graphed averages
fall within 6σ .
UCL & LCL calculation

UCL = X + 3σ
LCL = X − 3σ
σ = standard deviation
Determining an alternative
value for the standard
deviation R
m

∑ i
R = i=
1

UCL =X+A2 R

LCL =X−A2 R
Determine trial control limits - R
chart
 The range chart shows the spread or
dispersion of the individual samples within
the subgroup.
 If the product shows a wide spread, then the
individuals within the subgroup are not similar to
each other.
 Equal averages can be deceiving.
 Calculated similar to x-bar charts;
 Use D3 and D4 (appendix 2)
 Example: Control Charts for Variable Data
Slip Ring Diameter (cm)
Sample 1 2 3 4 5 X R
1 5.02 5.01 4.94 4.99 4.96 4.98 0.08
2 5.01 5.03 5.07 4.95 4.96 5.00 0.12
3 4.99 5.00 4.93 4.92 4.99 4.97 0.08
4 5.03 4.91 5.01 4.98 4.89 4.96 0.14
5 4.95 4.92 5.03 5.05 5.01 4.99 0.13
6 4.97 5.06 5.06 4.96 5.03 5.01 0.10
7 5.05 5.01 5.10 4.96 4.99 5.02 0.14
8 5.09 5.10 5.00 4.99 5.08 5.05 0.11
9 5.14 5.10 4.99 5.08 5.09 5.08 0.15
10 5.01 4.98 5.08 5.07 4.99 5.03 0.10
50.09 1.15
Calculation
From Table above:
 Sigma X-bar = 50.09

 Sigma R = 1.15

 m = 10

Thus;
 X-Double bar = 50.09/10 = 5.009 cm

 R-bar = 1.15/10 = 0.115 cm

Note: The control limits are only preliminary with 10 samples.

It is desirable to have at least 25 samples.
Trial control limit
 UCLx-bar = X-D bar + A2 R-bar = 5.009 +
(0.577)(0.115) = 5.075 cm
 LCLx-bar = X-D bar - A2 R-bar = 5.009 -
(0.577)(0.115) = 4.943 cm

 UCLR = D4R-bar = (2.114)(0.115) =

0.243 cm
 LCLR = D3R-bar = (0)(0.115) = 0 cm
n=5
For A2, D3, D4: see Table B, Appendix
3-Sigma Control Chart Factors

Sample size X-chart R-chart

n A2 D3 D4
2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
X-bar Chart

5.10
UCL
5.08
5.06
5.04
X bar

5.02
5.00 CL
4.98
4.96 LCL
4.94
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
R Chart

0.25 UCL

0.20

0.15
Range

CL

0.10

0.05
LCL
0.00
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
Run Chart
6.70
6.65
6.60

Mean, X-bar
6.55
6.50
6.45
6.40
6.35
6.30
0 5 10 15 20 25
Subgroup number
0.35
0.3
0.25
Range, R

0.2
0.15
0.1
0.05
0
0 5 10 15 20 25
Subgroup number
Another Example
of X-bar & R chart
Subgroup X1 X2 X3 X4
Given
X-bar
Data (Table
UCL- X-Dbar LCL- R UCL-R R-bar LCL-R
X-bar X-bar

5.2)
1 6.35 6.4 6.32 6.37 6.36 6.47 6.41 6.35 0.08 0.20 0.0876 0
2 6.46 6.37 6.36 6.41 6.4 6.47 6.41 6.35 0.1 0.20 0.0876 0
3 6.34 6.4 6.34 6.36 6.36 6.47 6.41 6.35 0.06 0.20 0.0876 0
4 6.69 6.64 6.68 6.59 6.65 6.47 6.41 6.35 0.1 0.20 0.0876 0
5 6.38 6.34 6.44 6.4 6.39 6.47 6.41 6.35 0.1 0.20 0.0876 0
6 6.42 6.41 6.43 6.34 6.4 6.47 6.41 6.35 0.09 0.20 0.0876 0
7 6.44 6.41 6.41 6.46 6.43 6.47 6.41 6.35 0.05 0.20 0.0876 0
8 6.33 6.41 6.38 6.36 6.37 6.47 6.41 6.35 0.08 0.20 0.0876 0
9 6.48 6.44 6.47 6.45 6.46 6.47 6.41 6.35 0.04 0.20 0.0876 0
10 6.47 6.43 6.36 6.42 6.42 6.47 6.41 6.35 0.11 0.20 0.0876 0
11 6.38 6.41 6.39 6.38 6.39 6.47 6.41 6.35 0.03 0.20 0.0876 0
12 6.37 6.37 6.41 6.37 6.38 6.47 6.41 6.35 0.04 0.20 0.0876 0
13 6.4 6.38 6.47 6.35 6.4 6.47 6.41 6.35 0.12 0.20 0.0876 0
14 6.38 6.39 6.45 6.42 6.41 6.47 6.41 6.35 0.07 0.20 0.0876 0
15 6.5 6.42 6.43 6.45 6.45 6.47 6.41 6.35 0.08 0.20 0.0876 0
16 6.33 6.35 6.29 6.39 6.34 6.47 6.41 6.35 0.1 0.20 0.0876 0
17 6.41 6.4 6.29 6.34 6.36 6.47 6.41 6.35 0.12 0.20 0.0876 0
18 6.38 6.44 6.28 6.58 6.42 6.47 6.41 6.35 0.3 0.20 0.0876 0
19 6.35 6.41 6.37 6.38 6.38 6.47 6.41 6.35 0.06 0.20 0.0876 0
20 6.56 6.55 6.45 6.48 6.51 6.47 6.41 6.35 0.11 0.20 0.0876 0
21 6.38 6.4 6.45 6.37 6.4 6.47 6.41 6.35 0.08 0.20 0.0876 0
22 6.39 6.42 6.35 6.4 6.39 6.47 6.41 6.35 0.07 0.20 0.0876 0
23 6.42 6.39 6.39 6.36 6.39 6.47 6.41 6.35 0.06 0.20 0.0876 0
24 6.43 6.36 6.35 6.38 6.38 6.47 6.41 6.35 0.08 0.20 0.0876 0
25 6.39 6.38 6.43 6.44 6.41 6.47 6.41 6.35 0.06 0.20 0.0876 0
Calculation
From Table 5.2:
 Sigma X-bar = 160.25

 Sigma R = 2.19

 m = 25

Thus;
 X-double bar = 160.25/29 = 6.41 mm

 R-bar = 2.19/25 = 0.0876 mm

Trial control limit
 UCLx-bar = X-double bar + A2R-bar = 6.41
+ (0.729)(0.0876) = 6.47 mm
 LCLx-bar = X-double bar - A2R-bar = 6.41 –
(0.729)(0.0876) = 6.35 mm
 UCLR = D4R-bar = (2.282)(0.0876) =
0.20 mm
 LCLR = D3R-bar = (0)(0.0876) = 0 mm

For A2, D3, D4: see Table B Appendix, n = 4.

X-bar Chart
R Chart
 Revised CL & Control
Limits
 Calculation based on discarding subgroup 4 &
20 (X-bar chart) and subgroup 18 for R chart:


X new =
∑ X −X d = (160.25 - 6.65 - 6.51)/(25-2)
m − md = 6.40 mm


Rnew = ∑ R−R d = (2.19 - 0.30)/25 - 1
m − md = 0.079 = 0.08 mm
New Control Limits

New value:
RO
X o = X new , Ro = Rnew , σ o =
d2
 Using standard value, CL & 3σ control limit
obtained using formula:

UCLX = X o + Aσ o , LCLX = X o − Aσ o
UCLR = D2σ o , LCLR = D1σ o
From Table B:
 A = 1.500 for a subgroup size of 4,

 d = 2.059, D = 0, and D = 4.698

2 1 2

Calculation results:
Ro 0.079
X o = X new = 6.40mm Ro = Rnew = 0.079, σo = =
d 2 2.059
= 0.038mm

UCL X = X o + Aσ o = 6.40 + (1.500)(0.038) = 6.46 mm

LCL X = X o − Aσ o = 6.40 − (1.500)(0.038) = 6.34 mm
UCLR = D2σ o = (4.698)(0.038) = 0.18 mm
LCL R = D1σ o = (0)(0.038) = 0 mm
Trial Control Limits & Revised Control Limit
6.65

6.60 Revised control limits

6.55
Mean, X-bar

6.50
UCL = 6.46
6.45

6.40
CL = 6.40
6.35

6.30 LCL = 6.34

0 2 4 6 8
Subgroup

0.20 UCL = 0.18

0.15
Range, R

0.10 CL = 0.08
0.05

0.00
0 2 4 6 8
LCL = 0
Subgroup
Revise the charts

 In certain cases, control limits are revised

because:
 out-of-control points were included in the

calculation of the control limits.

 the process is in-control but the within

subgroup variation significantly

improves.
Revising the charts

 Interpret the original charts

 Isolate the causes
 Take corrective action
 Revise the chart
 Only remove points for which you can determine an
assignable cause
Process in Control

 When a process is in control, there occurs a

natural pattern of variation.
 Natural pattern has:
 About 34% of the plotted point in an imaginary
band between 1σ on both side CL.
 About 13.5% in an imaginary band between 1σ
and 2σ on both side CL.
 About 2.5% of the plotted point in an imaginary
band between 2σ and 3σ on both side CL.
 The Normal
Distribution
σ = Standard deviation

Mean
-3σ -2σ -1σ +1σ +2σ +3
68.26%
95.44%
LSL USL 99.74%

-3σ +3σ
CL
 34.13% of data lie between µ and 1σ above the mean (µ ).
 34.13% between µ and 1σ below the mean.
 Approximately two-thirds (68.28 %) within 1σ of the mean.
 13.59% of the data lie between one and two standard deviations
 Finally, almost all of the data (99.74%) are within 3σ of the
mean.
Normal Distribution Review
 Define the 3-sigma limits for sample means as follows:
3σ 3(0.05)
Upper Limit = µ + = 5.01 + = 5.077
n 5
3σ 3(0.05)
Lower Limit = µ − = 5.01 − = 4.943
n 5
 What is the probability that the sample means will lie
outside 3-sigma limits?
 Note that the 3-sigma limits for sample means are
different from natural tolerances which are at
µ ± 3σ
Common Causes
Process Out of Control

 The term out of control is a change in the

process due to an assignable cause.
 When a point (subgroup value) falls outside
its control limits, the process is out of control.
Assignable Causes
Average (a) Mean

Grams
Assignable Causes
Average
(b) Spread

Grams
Assignable Causes
Average
(c) Shape

Grams
Control Charts Assignable
causes
likely

UCL

Nominal

LCL

1 2 3
Samples
Control Chart Examples

UCL
Variations

Nominal
LCL

Sample number
Control Limits and
Errors
Type I error:
(a) Three-sigma limits
Probability of searching for
a cause when none exists

UCL

Process
average

LCL
Control Limits and
Errors
Type I error:
(b) Two-sigma limits
Probability of searching for
a cause when none exists

UCL

Process
average

LCL
Control Limits and
Errors
Type II error:
Probability of concluding
(a) Three-sigma limits that nothing has changed

UCL

Shift in process
average Process
average

LCL
Control Limits and
Errors
Type II error:
(b) Two-sigma limits Probability of concluding
that nothing has changed

UCL

Shift in process
average Process
average

LCL
Achieve the purpose

 Our goal is to decrease the variation inherent

in a process over time.
 As we improve the process, the spread of the
data will continue to decrease.
 Quality improves!!
Improvement
Examine the process

 A process is considered to be stable and

in a state of control, or under control,
when the performance of the process
falls within the statistically calculated
control limits and exhibits only chance, or
common causes.
Consequences of
misinterpreting the process
 Blaming people for problems that they cannot
control
 Spending time and money looking for problems that
do not exist
 Spending time and money on unnecessary process
adjustments
 Taking action where no action is warranted
 Asking for worker-related improvements when
process improvements are needed first
Process variation
 When a system is subject to only
chance causes of variation, 99.74% of
the measurements will fall within 6
standard deviations
 If 1000 subgroups are measured,

997 will fall within the six sigma

limits.
Mean
-3σ -2σ -1σ +1σ +2σ +3σ
68.26%
95.44%
99.74%
Chart zones
 Based on our knowledge of the normal curve, a
control chart exhibits a state of control when:
♥ Two thirds of all points are near the center

value.
♥ The points appear to float back and forth

across the centerline.

♥ The points are balanced on both sides of the

centerline.
♥ No points beyond the control limits.

♥ No patterns or trends.