TKI 329 Quality Control

Control Charts for Attributes

Ronald Sukwadi, Ph.D.
Department of Industrial Engineering

Introduction

Data that can be classified into one of several

categories or classifications is known as attribute
data.
Classifications such as conforming and
nonconforming are commonly used in quality
control.
Another example of attributes data is the count of
defects.

Ronald Sukwadi

TKI 329 Quality Control

Control Charts for Fraction

Nonconforming

Fraction nonconforming is the ratio of the

number of nonconforming items in a
population to the total number of items in that
population.
Control charts for fraction nonconforming are
based on the binomial distribution.

Ronald Sukwadi

TKI 329 Quality Control

Control Charts for Fraction

Nonconforming
Recall: A quality characteristic follows a binomial
distribution if:
1. All trials are independent.
2. Each outcome is either a success or failure.
3. The probability of success on any trial is given as
p. The probability of a failure is 1-p.
4. The probability of a success is constant.

Ronald Sukwadi

TKI 329 Quality Control

Control Charts for Fraction

Nonconforming

The binomial distribution with parameters n

0 and 0 < p < 1, is given by

n x
nx
p( x) p (1 p)
x
The mean and variance of the binomial
distribution are
np

Ronald Sukwadi

2 np(1 p)
TKI 329 Quality Control

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Design of Fraction Nonconforming

Chart
Three parameters must be specified

The sample size

The frequency of sampling
The width of the control limits

1.
2.
3.

Common to base chart on 100% inspection of

all process output over a period of time
Rational subgroups may also play role in
determining sampling frequency

Ronald Sukwadi

TKI 329 Quality Control

Sample size

If p is very small, we should choose n sufficiently

large to find at least one nonconforming unit

Otherwise the presence of only one non-conforming

in the sample would indicate out-of-control
condition (example)

To avoid this, choose n such that the probability of

finding at least one nonconforming per sample is at
least (example)

Ronald Sukwadi

TKI 329 Quality Control

Example

p = 0.01 and n = 8

p (1 p )
0.01(1 0.01)
UCL p 3
0.01 3
0.1155
n
8

If there is one nonconforming in the sample, then

p =1/8=0.125
and we conclude that the process is out of control

Ronald Sukwadi

TKI 329 Quality Control

Sample size

The sample size can be determined so that the

probability of finding at least one nonconforming
unit per sample is at least
Example p = 0.01 and = 0.95
Find n such that P(D 1) 0.95
Using Poisson approximation of the binomial with
=np
From cumulative Poisson table must exceed 3.00
np 3 n 300

Ronald Sukwadi

TKI 329 Quality Control

Sample size

The sample size can be determined so that a shift of some

specified amount, can be detected with a stated level of
probability (50% chance of detection).
UCL = pout

If is the magnitude of a process shift, then n must satisfy:

p(1 p)
L
n
Therefore,

Ronald Sukwadi

L
n p(1 p)

TKI 329 Quality Control

Positive Lower Control Limit

The sample size n, can be chosen so that the

lower control limit would be nonzero:
p(1 p)
LCL p L
0
n

and
(1 p)
n
L2
p
Ronald Sukwadi

TKI 329 Quality Control

Interpretation of Points on the Control

Chart for Fraction Nonconforming

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Variable Sample Size

Variable-Width Control Limits

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Variable Sample Size

Control Limits Based on an Average Sample Size

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Variable Sample Size

The Standardized Control Chart

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The Opening Characteristic Function

and Average Run Length Calculations

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Control Charts for Nonconformities

(Defects)
Procedures with Constant Sample Size

Ronald Sukwadi

TKI 329 Quality Control

There are many instances where an item will

contain nonconformities but the item itself is
not classified as nonconforming.

It is often important to construct control charts

for the total number of nonconformities or the
average number of nonconformities for a
given area of opportunity. The inspection
unit must be the same for each unit.

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Control Charts for Nonconformities

(Defects)
Procedures with Variable Sample Size

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