Statistical Process Control

 Basics of Statistical Process Control

 Control Charts
 Control Charts for Attributes
 Control Charts for Variables
 Control Chart Patterns

4-1
 Basics of Statistical
Process Control
 Statistical Process Control
(SPC)
 monitoring production process
to detect and prevent poor
quality
 Sample
 subset of items produced to
use for inspection
 Control Charts
 process is within statistical
control limits

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 Variability

 Random  Non-Random
 common causes  special causes
 inherent in a process  due to identifiable
 can be eliminated factors
only through  can be modified
improvements in the through operator or
system management action

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 SPC in TQM

 SPC
 tool for identifying problems and
make improvements
 contributes to the TQM goal of
continuous improvements

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 Quality Measures

 Attribute
 a product characteristic that can be
evaluated with a discrete response
 good – bad; yes - no
 Variable
 a product characteristic that is continuous
and can be measured
 weight - length

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 Where to Use Control Charts

 Process has a tendency to go out of control

 Process is particularly harmful and costly if it goes
out of control
 Examples
 at the beginning of a process because it is a waste of time
and money to begin production process with bad supplies
 before a costly or irreversible point, after which product is
difficult to rework or correct
 before and after assembly or painting operations that
might cover defects
 before the outgoing final product or service is delivered

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 Control Charts

 A graph that establishes  Types of charts

control limits of a
process  Attributes
 Control limits  p-chart
 upper and lower bands of  c-chart
a control chart
 Variables
 range (R-chart)
 mean (x bar – chart)

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 Process Control
Chart
Out of control
Upper
control
limit

Process
average

Lower
control
limit

1 2 3 4 5 6 7 8 9 10
Sample number
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Normal Distribution

4-9
 A Process Is in
Control If …

1. … no sample points outside limits

2. … most points near process average
3. … about equal number of points above
and below centerline
4. … points appear randomly distributed

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 Control Charts for
Attributes

 p-charts
 uses portion defective in a sample
 c-charts
 uses number of defects in an item

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P Chart:

The Western Jeans Company produces denim jeans. The company wants to establish a p-chart
to monitor the production process and maintain high quality. Western believes that approximately
99.74% of the variability in the production process (corresponding to 3-sigma limits, or z 3.00) is random
and thus should be within control limits, whereas 0.26% of the process variability is not random and suggests
that the process is out of control.
The company has taken 20 samples (one per day for 20 days), each containing 100 pairs of jeans (n 100),
and inspected them for defects, the results of which are as follows.
The company wants to construct a p-chart to determine when the production process might be out of control.

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p-Chart

UCL = p + zp
LCL = p - zp
z = number of standard
deviations from process average
p = sample proportion
defective; an estimate of process average
p = standard deviation of sample
proportion
p(1 - p)
p =
n
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p-Chart Example

NUMBER OF PROPORTION
SAMPLE DEFECTIVES DEFECTIVE
1 6 .06
2 0 .00
3 4 .04
: : :
: : :
20 18 .18
200

20 samples of 100 pairs of jeans

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p-Chart Example (cont.)

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 0.20

0.18 UCL = 0.190

0.16

0.14

p-Chart
Proportion defective
0.12

Example 0.10
p = 0.10

(cont.) 0.08

0.06

0.04

0.02 LCL = 0.010

2 4 6 8 10 12 14 16 18 20
Sample number

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C Chart:

The Ritz Hotel has 240 rooms. The hotel’s housekeeping department is responsible for
maintaining the quality of the rooms’ appearance and cleanliness. Each individual
housekeeper is responsible for an area encompassing 20 rooms. Every room in use is
thoroughly cleaned and its supplies, toiletries, and so on are restocked each day. Any
defects that the housekeeping staff notice that are not part of the normal housekeeping
service are supposed to be reported to hotel maintenance. Every room is briefly inspected
each day by a housekeeping supervisor. However, hotel management also conducts
inspection tours at random for a detailed, thorough inspection for quality-control purposes.
The management inspectors not only check for normal housekeeping service defects like
clean sheets, dust, room supplies, room literature, or towels, but also for defects like an
inoperative or missing TV remote, poor TV picture quality or reception, defective lamps, a
malfunctioning clock, tears or stains in the bedcovers or curtains, or a malfunctioning
curtain pull. An inspection sample includes 12 rooms, that is, one room selected at random
from each of the twelve 20-room blocks serviced by a housekeeper. Following are the
results from 15 inspection samples conducted at random during a one-month period:

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The hotel believes that approximately 99% of the defects (corresponding to 3-sigma limits)
are caused by natural, random variations in the housekeeping and room maintenance
service, with 1% caused by nonrandom variability. They want to construct a c-chart to
monitor the housekeeping service.

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c-Chart

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c-Chart (cont.)

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 24
UCL = 23.35
21

18

Number of defects
c = 12.67

c-Chart 15

(cont.)
12

3 LCL = 1.99

2 4 6 8 10 12 14 16
Sample number

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 Control Charts for
Variables
 Mean chart ( x -Chart )
 uses average of a sample
 Range chart ( R-Chart )
 uses amount of dispersion in a
sample

4-22
X-bar Chart:

The Goliath Tool Company produces slip-ring bearings, which look like flat doughnuts or
washers. They fit around shafts or rods, such as drive shafts in machinery or motors. At an early
stage in the production process for a particular slip-ring bearing, the outside diameter of the
bearing is measured. Employees have taken 10 samples (during a 10-day period) of 5 slip ring
bearings and measured the diameter of the bearings. The individual observations from each
sample (or subgroup) are shown as follows:
From past historical data it is known that the process standard deviation is .08. The company
wants to develop a control chart with 3-sigma limits to monitor this process in the future.

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x-bar Chart

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 x-bar Chart Example
OBSERVATIONS (SLIP- RING DIAMETER, CM)
SAMPLE k 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
Example 15.4
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x- bar Chart
Example (cont.)

Retrieve Factor Value A2

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 5.10 –

5.08 –
UCL = 5.08
5.06 –

5.04 –

5.02 – x= = 5.01
Mean

5.00 –

4.98 –
x- bar
Chart 4.96 –

Example 4.94 –
LCL = 4.94

(cont.) 4.92 –
| | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number

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R- Chart

UCL = D4R LCL = D3R

R
R=
k
where
R = range of each sample
k = number of samples

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 R-Chart Example

Example 15.3
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 R-Chart Example (cont.)

Retrieve Factor Values D3 and D4

Example 15.3
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R-Chart Example (cont.)
0.28 –
0.24 – UCL = 0.243
0.20 –
Range

0.16 – R = 0.115
0.12 –
0.08 –
0.04 – LCL = 0
| | | | | | | | | |
0–
1 2 3 4 5 6 7 8 9 10
Sample number

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 Using x- bar and R-Charts
Together

 Process average and process variability must be

in control.
 It is possible for samples to have very narrow
ranges, but their averages is beyond control
limits.
 It is possible for sample averages to be in
control, but ranges might be very large.

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 Control Chart Patterns
UCL

UCL

LCL

Sample observations
consistently below the LCL
center line
Sample observations
consistently above the
center line
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 Control Chart Patterns (cont.)
UCL

UCL

LCL

Sample observations
consistently increasing LCL

Sample observations
consistently decreasing

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 Control Chart Patterns

 8 consecutive points on one side of the center line

 8 consecutive points up or down across zones
 14 points alternating up or down
 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

4-35
 Sample Size

 Attribute charts require larger sample sizes

 50 to 100 parts in a sample
 Variable charts require smaller samples
 2 to 10 parts in a sample

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