ISYE6094 – Quality Engineering

Week 3

Quality in Production
 Quality in Production

SUB TOPIC
 Process Control
 The Control Charts
 Control Chart for Variable
PROCESS CONTROL
 Process Control

Process Control is the most important component of quality

effort during manufacture, and its objective is to proactively
evaluate the condition of a process and control its so as to
prevent the production of defective units.

Environment

• Machinery
Input Output
• Manpower
• Methods (Products)
(Material)
• Measurements

Fig. 1 The scheme of manufacturing process

 Rationale: Product Inspection

RECEIVING INSPECTION

Sampling
100% inspection 5%, 10%, etc
High cost Based on regulation or agreement
Even with 100% inspection, only MIL-STD-1916  required SPC
80% of the defects are found  implementation  reduction cost of
tools and operator limitation sampling and surveillance
THE CONTROL CHARTS
 The Control Charts

Control Chart was proposed by

Dr. Walter Shewhart (1920s).

here are two sources that make the variability in a

product:

1. Stable system of chance causes (Common

cause)
Walter A. Shewart (1891-1967)
Unavoidable variability arising from natural
differences in material, manpower, machines,
etc
2. Assignable causes (Special cause)
Causes that can be assigned to a specific
occurrence such as broken tools, pressure
surge, temperature drop, etc
 The control chart is a graphical display of a quality
characteristic that has been measured or computed from a
sample versus the sample number or time.
 A control chart contains
– A center line (CL)
– An upper control limit (UCL)
– A lower control limit (LCL)

 A point that plots within the

control limits indicates the process
is in control
– No action is necessary
 A point that plots outside the
control limits is evidence that the
process is out of control
– Investigation and corrective Fig 5.2 Typical control chart
action are required to find and
 Thereeliminate assignable
is a close cause(s)
connection between
control charts and hypothesis
testing
 Determination of the Control Limits
To assist in understanding the statistical basis of this control chart,
consider how the control limits were determined. The process mean is
1.5 microns, and the process standard deviation is = 0.15 microns. Now
if samples of size n = 5 are taken, the standard deviation of the sample
average is

as shown on the control chart. These are typically called three-sigma control
limits.2
Photolithography Example
 Important quality characteristic in hard bake is resist
flow width
 Process is monitored by average flow width
– Sample of 5 wafers
– Process mean is 1.5 microns
– Process standard deviation is 0.15 microns
 Note that all plotted points fall inside the control
limits
– Process is considered to be in statistical control
Shewhart Control Chart Model
How the Shewhart Control Chart Works
 Control Chart Development

• Control charts may be used to estimate process parameters,

which are used to determine capability

• Two general types of control charts

– Variables
• Continuous scale of measurement
• Quality characteristic described by central tendency and a
measure of variability

– Attributes
• Conforming/nonconforming
• Counts

• Control chart design encompasses selection of sample size,

control limits, and sampling frequency
 Types of Process Variability

 Stationary and uncorrelated  data vary around a fixed mean in a

stable or predictable manner
 Stationary and auto correlated  successive observations are
dependent with tendency to move in long runs on either side of mean
 No stationary  process drifts without any sense of a stable or fixed
mean
 Reasons for Popularity
of Control Charts

1. Control charts are a proven technique for improving

productivity.

2. Control charts are effective in defect prevention.

3. Control charts prevent unnecessary process adjustment.

4. Control charts provide diagnostic information.

5. Control charts provide information about process capability.

 Choice of Control Limits

 3-Sigma Control Limits

– Probability of type I error is 0.0027
 Probability Limits
– Type I error probability is chosen directly
– For example, 0.001 gives 3.09-sigma control limits
 Warning Limits
– Typically selected as 2-sigma limits
CONTROL CHARTS FOR VARIABLES
 Control Charts for Variables

• Variable - a single quality characteristic that can be measured

on a numerical scale.

• When working with variables, we should monitor both the

mean value of the characteristic and the variability
associated with the characteristic.
 Control Chart for and R

Statistical Basic of
Chart

Therefore, if µ and σ are known, equation 6.1 could be used as upper

and lower control limits on a control chart for sample means
 Subgroup Data with
Unknown  and 

Thus, would be used as the center line on the chart.

To construct the control limits, we need an estimate of the
standard deviation σ.
 Phase I Application of
and R Charts
• Eqns 6.4 and 6.5 are trial control limits
 Determined from m initial samples
 Typically 20-25 subgroups of size n between 3 and 5
 Any out-of-control points should be examined for assignable
causes
 If assignable causes are found, discard points from
calculations and revise the trial control limits
 Continue examination until all points plot in control
 Adopt resulting trial control limits for use
 If no assignable cause is found, there are two options
1. Eliminate point as if an assignable cause were found and
revise limits
2. Retain point and consider limits appropriate for control
 If there are many out-of-control points they should be examined
for patterns that may identify underlying process problems
Example : The Hard Bake Process
 Revision of Control Limits
and Center Lines

 Effective use of control charts:

– Requires periodic review and revision of control limits and
center lines x
 Sometimes users replace the center line on the chart with a
target value R
x out-of-control points are often
 When R chart is out of control,
eliminated to recomputed a revised value of which is used to
determine new limits and center line on R chart and new limits
on chart
 Phase II Operation of Charts

 Use of control chart for monitoring future production, once a

set of reliable limits are established, is called phase II of control
chart usage (Figure 6-4)

 A run chart showing individuals observations in each sample,

called a tolerance chart or tier diagram (Figure 6-5), may reveal
patterns or unusual observations in the data
 Control vs. Specification Limits

 Control limits are

derived from natural
process variability, or the
natural tolerance limits
of a process

 Specification limits are

determined externally,
for example by
customers or designers

 There is no mathematical
or statistical relationship
between the control
limits and the
specification limits
 Rational Subgroups

 xcharts monitor between-sample variability

 R charts measure within-sample variability
 Standard deviation estimate of  used to construct
control limits is calculated from within-sample
variability
 DO NOT use to calculate  !!!
 Guidelines for Control Chart
Design
 Control chart design requires
– Specification of sample size, control limit width, and sampling
frequency
 Exact solution requires detailed information on statistical
characteristics as well as economic factors
 The problem of choosing sample size and sampling frequency is
onexof allocating sampling effort
 For chart, choose a sample size is consistent with magnitude
of process shift one is trying to detect.
– For moderate to large shifts, relatively small samples are
effective
– For small shifts, larger samples are needed.
 For small samples, R chart is relatively insensitive to changes in
process standard deviation (efficiency drops dramatically in
efficiency as n increases)
 For larger samples (n > 10 or 12), s or s2 charts are better choices.
Changing Sample Size on the x and
R Charts.
Charts Base on Standard Values
Interpretationxthe and R
Charts.
 The Effect of Non-
normality
• An assumption in performance properties is that the underlying
distribution of quality characteristic is normal
– If underlying distribution is not normal, sampling
distributions can be derived and exact probability limits
obtained
• Burr (1967) notes the usual normal theory control limits are very
robust to normality assumption
• Schilling and Nelson (1976) indicate that in most cases, samples
of size 4 or 5 are sufficient
x to ensure reasonable robustness to
normality assumption for chart
• Sampling distribution of R is not symmetric, thus symmetric 3-
sigma limits are an approximation and -risk isxnot 0.0027. R
chart is more sensitive to departures from normality than
chart.
• Assumptions of normality and independence are not a primary
concern in phase I
Control Chart for x and S
The x and s Control Charts with
Variable Sample Size
Example :

Solution :

and
The s2 Control Charts
 REFERENCES

• K. S. Krishnamoorthi. (2019). A first course in quality engineering:

integrating statistical and management methods of quality. 03.cRc
press. Boca Raton. ISBN -13: 978-1-4987-6420-9
• Douglas C. Montgomery. (2013). Introduction to Statistical quality
control . 7th Edition John Wiley & Sons, Inc.. ISBN: 9781118146811.
• David L Goetsch (2013). Quality management for organizational
excellence : introduction to total quality. 07. pearson Education.
Boston. ISBN: 9780132870979
Thank You