Control Charts

Control Charts
• Control charts are used to routinely monitor

quality
•A control chart is one of many process
improvement techniques
•A control chart is used to monitor a process
variable over time.
• The variable can be in any type of company
or organization, service, manufacturing, non-
profit and healthcare.
• The control chart is a graph used to study how
a process changes over time.
• A control chart always has a central line for
the average, an upper line for the upper control
limit, and a lower line for the lower control
limit.
• These lines are determined from historical
data.
WHEN TO USE A CONTROL CHART
• When controlling ongoing processes by finding and

correcting problems as they occur
• When predicting the expected range of outcomes from a
process
• When determining whether a process is stable in statistical
control
• When analyzing patterns of process variation from special
causes (non-routine events) or common causes (built into
the process)
• When determining whether your quality improvement
project should aim to prevent specific problems or to make
fundamental changes to the process
Types of Control Chart
Variable Control Chart
Range Control Chart
Standard Deviation Control Chart
Attribute Control Charts
Variable Control Chart
•This type of chart graphs the means (or averages) of a set of samples,
plotted in order to monitor the mean of a variable, for example the
length of steel rods, the intensity of laser beams, etc.
•In constructing this chart, samples of process outputs are taken at
regular intervals, the means of each set of samples are calculated and
graphed onto the X bar control chart.
•This chart can then be utilized to determine the actual process mean,
versus a nominal process mean and will demonstrate if the mean
output of the process is changing over time.
Range Control Chart
• This type of chart demonstrates the variability
within a process.
• Sets of sample data are recorded from a process
for the particular quality characteristic being
monitored.
• For each set of date the difference between the
smallest and largest readings are recorded.
• This is the range “R” of the set of data.
• The ranges are now recorded onto a control chart.
The center line is the averages of all the ranges.
Standard Deviation Control Chart
• The “S” chart can be applied when monitoring
variable data.
• It is suited to situations where there are large
numbers of samples being recorded.
• The “S” relates to the standard deviation within the
sample sets and is a better indication of variation
within a large set versus the range calculation.
• An advantage of using the standard deviation is
that all data within a set are utilized to determine
the variation, rather than just the minimum and
maximum values.
Standard Deviation Chart
Attribute Control Charts
• Attribute control charts are utilized when
monitoring count data
• These charts are used to achieve and maintain an
acceptable quality level for a process whose
output products are not subjected to dimensional
or quantitative measurement
• It can be classified as good or bad or acceptable
and non-acceptable
• For example surface finish of a product brightness
of an item is either acceptable or not acceptable
Commonly used control charts for attributes
• Control charts from fraction defectives
• Control charts for number Defectives
• Control charts for percent defectives chart
• Control charts for number of defects per unit
Process Capability
• It is the ability of a process to meet specifications
• A process has been defined as a sequence of
interdependent procedures, operations or steps
that consume resources and convert the inputs
into outputs.
• In every process, there exists a certain amount of
variation.
• Variation in a process cannot be eliminated, but it
can be measured, monitored, reduced and
controlled.
• Process Capability is a statistical measurement
of a processes ability to produce parts within
specified limits on a consistent basis.
To determine how our process is operating, we
can calculate
• Cp (Process Capability)
• Cpk (Process Capability Index)
• Pp (Preliminary Process Capability)
• Ppk (Preliminary Process Capability Index)
• Process capability indices Cp and Cpk
evaluate the output of a process in comparison
to the specification limits determined by the
target value and the tolerance range.
• Cp tells you if your process is capable of
making parts within specifications
• Cpk tells you if your process is centered
between the specification limits.
• The Cp index is a fundamental indication of
process capability.
• The Cp value is calculated using the
specification limits and the standard deviation
of the process.
Reason to measure Process Capability
• Reduction of waste and providing a quality product
• Waste exists in many forms in a process
• It involves collecting and analyzing data to

understand the statistical performance of the process
and identifying the causes of variation
• Monitoring process capability allows the
manufacturing process performance to be evaluated
and adjusted as needed to assure products meet the
design or customer’s requirements.

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Control Charts

• Control charts are used to routinely monitor

• When controlling ongoing processes by finding and

• Waste exists in many forms in a process

• It involves collecting and analyzing data to

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