06-Mar-15

Outline

Lot-by-lot acceptance sampling plans for

attributes
Acceptance sampling plans for continuous
production
Acceptance sampling plans for variables

Photo by Janitors - Creative Commons Attribution License https://www.flickr.com/photos/65265630@N03 Created with Haiku Deck

Learning Objectives Lot-by-Lot Acceptance Sampling Plans

for Attributes
Devised in 1942 at Bell Labs
Categorize the various sampling plan systems in
Later became MIL-STD-105E
terms of lot-by-lot, continuous production,
attributes or variables. ISO-2859

Describe the various sampling plan systems and ANSI/ASQ Z1.4

know their function (advantages, disadvantages, Wording & terminology changes
purpose etc.). Additional tables added
Construct the OC Curve for a chain sampling plan

ANSI/ASQ Z1.4
This standard is applicable to:
Intended to be used for a continuing series of
End items lots, but may be designed for isolated lots.
Components and raw materials Standard provides for single, double, and
Operations multiple sampling plans.
Materials in process Provision is also provided for normal,
Supplies in storage tightened, or reduced inspection.
Maintenance operations Plan is specified by the AQL, and sample-size

Data or records code.

1
 06-Mar-15

Normal inspection is used at the start of inspection

Reduced inspection:
with changes being a function of recent quality
history. Used when the producers recent quality history

Tightened inspection:
has been exceptionally good.
Decision concerning what type of plan to use is left
Generally used when producers recent quality
history has deteriorated. to the responsible authority.
Nonconformities are classified such as critical,
major

Sample Size Code Letters

Comparison of Inspection levels

AQL
100 = 0.05
95

80 The AQL is the most important part of the standard

Percent of Lots Accepted (100Pa)

since the AQL and sample size dictate the plan

60
I = 1/2 n
II = n
used.
III = 2n

40 AQL is defined as the maximum percent

III II I nonconforming that can be considered satisfactory
20
as a process average.
100=10

Satisfactory = Producers risk,

0 2 4 6 8 10
Percent Nonconforming (100Pa)
Usually 0.05

2

AQL
AQL is specified by contract or responsible
authority.
AQL may be determine from historical
data, empirical judgment, engineering
information, experimentation,
producers capability, consumers
requirements.
Sample Size
Determined by lot size and inspection level
Use of sample-size code
Inspection level is determined by the
responsible authority.
17
AQL
Implementation contd.
Determine type of sampling plan
Find sampling plan in appropriate table
Start with normal inspection and change to
tightened or reduced based on switching
rules
20
06-Mar-15
AQL is specified by contract or responsible authority.
AQL may be determine from historical data,
empirical judgment, engineering information,
experimentation, producers capability, consumers
requirements.
17
Sample Size
Different levels of inspection provide
approximately the same protection to the
producer, but different protections to the
consumer.
Plan provides for special levels to be used
where relatively small sample sizes are
necessary and large sampling risks must be
tolerated. (S-1, S-2, S-3, S-4)
18
What an AQL means is that as long as a
supplier maintains his/her process average
(% defective) at the assigned AQL or lower,
there is a very high probability that
shipments from that supplier, when
inspected using ASQ Z1.4 sampling plans,
will be accepted.
21
3
 06-Mar-15

AQL
By the same token, there is a very high
probability that shipments, when inspected
using ASQ Z1.4 sampling plans, will be
rejected if a supplier's process average (%
defective) remains higher than the assigned
AQL.
Single sampling plans
Start by identification of AQL, lot size,
inspection level, and type of sampling plan.
Locate appropriate plan parameters in
tables.
Double and Multiple Sampling
Similar procedures as single sampling

22 23

Normal, Tightened, and Reduced Inspection Switching Procedures

Start with normal inspection Normal to reduced

Switching Procedures Institute when: (all of the following)

Preceding 10 lots on normal inspection have been
Normal to tightened
accepted
Institute when 2 out of 5 consecutive lots not accepted on
Total nonconforming in preceding 10 samples is
original inspection
less than number identified in Table 10-5.
Tightened to normal Production is at a steady rate
Institute when 5 consecutive lots accepted Reduced inspection is considered desirable by
If not, then discontinue inspection under this plan responsible authority

24 25

Switching Procedures Standard is designed for use where units of product are
Reduced to normal produced in a continuing series of lots or batches.
Institute when: (any of the following) If a sampling plan is desirable for a lot or batch of an
A lot is not accepted
isolated nature, it should be chosen based on the Limiting
Quality (LQ) and consumers risk, b.
Sampling procedure terminates with neither acceptance
These tables are included in the standard, but not the
or rejection criteria have been met
textbook.
Production is irregular or delayed
Or use ANSI/ASQ Standard Q3
Other conditions

26 27

4

Standard is used for inspection of
isolated lots by attributes.
Provides indexed tables by Limiting
Quality, LQ.
28
Two Schemes:
2. Used when a vendor is producing a
continuous stream of lots and sends one or a
few to a customer who will consider them as
isolated lots.
Occurs frequently when purchasing
small quantities of raw materials.
30
Limiting Quality LQ
Based on the probability that a particular lot, which
has percent nonconforming equal to the LQ, will be
accepted.
Probability is the consumers risk, = 0.10
LQ plans give assurance that individual lots of poor quality
will rarely be accepted.
32
06-Mar-15
Two Schemes:
1. Used for lots that are isolated or mixed or that
have an unknown history as far as all parties
know.
Lot size and LQ must be known.
Nominal values of the LQ are based on
b=0.10
29
Dodge-Romig Tables
A set of inspection tables for lot-by-lot
acceptance sampling by attributes.
Tables are based on Limiting Quality (LQ)
and Average Outgoing Quality Limit
(AOQL).
Tables for single and double sampling
Advantage that the plan provides a
minimum amount of inspection for a given
inspection procedure.
Desirable for in-house inspection
31
Observations about the LQ tables:
As the lot size increases, the relative
sample size decreases.
The tables extend until the process
average is one-half of the LQ.
As the process average increases, a
corresponding increase occurs in the
amount inspected.
33
5

Average Outgoing Quality Limit AOQL
Applicable when the inspected lot is a
convenient subdivision of a flow of product for
materials handling purposes (non-
homogeneous)
AOQL plan limits the amount of poor outgoing
quality on an average basis, but gives no
assurance on individual lots.
34
Chain Sampling Inspection Plan
A special type of lot-by-lot acceptance sampling
plan for attributes designated as Chain
Sampling Plan ChSP-1.
Applicable to quality characteristics which
involve destructive or costly tests.
Use of small sample sizes
Acceptance number, c=0
Poor shape of OC curve at the producers risk
36
Chain Sampling Inspection Plan
Procedure:
For each lot, select a sample of size n
and test each for conformance to
specifications.
38
06-Mar-15
Dodge-Romig Tables
Process average
Obtained by the same techniques as for p-charts
First 25 lots the average percent nonconforming is
obtained
Type of nonconformance
Dodge-Romig tables do not provide for different
categories or tightened inspection
Different LQ or AOQL values may be used
35
Chain Sampling Inspection Plan
Chain sampling uses the cumulative results of
several samples
Determination of the value of i, the number
of previous samples, is determined by
analysis of the OC curves for a given sample
size.
37
Chain Sampling Inspection Plan
Procedure:
If the sample has 0 nonconforming units,
accept the lot; if the sample has 2 or more
nonconforming units, do not accept the lot;
and if the sample has 1 nonconforming unit, it
may be accepted provided that there are 0
nonconforming units in the previous
i samples of size n.
39
6
 06-Mar-15

Chain Sampling Diagram Chain Sampling Inspection Plan

Current Lot Conditions for use of the Chain Sampling
i previous lots
Plan:
Second-
n=5
Last Lot to-Last
1. The lot should be one of continuing
c=0
Lot series of product that is sampled in
Accept if 0 Nonconforming Units & Zero Nonconforming Units in i
substantially the order of production
in n =5 or if 1 Nonconforming Unit Previous Lots
2. The consumer can normally expect the
Figure 10-4 Chain Sampling Diagram
lots to be essentially the same quality.

40 41

Chain Sampling Inspection Plan Sequential Sampling

Conditions for use of the Chain Sampling Used for costly or destructive tests
Subgroup size of 1 item by item plan
Plan:
3. The consumer has confidence in the
Sequential sampling is similar to multiple
producer not to occasionally send an sampling, except sequential sampling can, in
unacceptable lot that would have the theory, continue indefinitely.
In practice, the plan is truncated after the number inspected is
optimum chance of acceptance.
equal to three times the number inspected by a corresponding
4. The quality characteristic is one that single sampling plan.
involves destructive or costly tests. Based on the Sequential Probability Ratio Test

42 43

Sequential Sampling Plan Sequential Sampling Plan

44 45

7

Skip Lot Sampling Procedure for SkSP-1 Plans
Designated SkSP-1 and based on AOQL.
A single sampling plan for minimizing
inspection costs when there is a continuing
supply of lots of raw materials, component
parts, subassemblies, and finished parts
from the same source.
Applicable to chemical and physical
characteristics that require laboratory
analysis.
46
ANSI/ASQ S1 ANSI/ASQ S1
Provides procedures to reduce the
inspection effort when the suppliers
quality is superior.
A skip-lot scheme used in conjunction
with attribute lot-by-lot plans given in
ASQ Z1.4
48
ANSI/ASQ S1 ANSI/ASQ S1
Additional requirements of the product:
Be of stable design
Have been manufactured on a continuous basis for
at least 6 months unless agreed to a longer period.
Have been on normal and reduced inspection
during the qualification period.
Have maintained a quality level at or less than the
AQL for at least 6 months.
50
06-Mar-15
Begin by inspecting every lot
When i consecutive lots are
found to be conforming
Discontinue inspection of every lot
Inspect a fraction, f, of the lots
In a random manner
When an inspected lot is found
nonconforming
Figure 10-7 Procedure SkSP-1 plans 47
Requirements to use ANSI/ASQ S1
1. Have a documented system for controlling
product quality and design changes
2. Have instituted a system that is capable of
detecting and correcting changes that might
adversely affect quality.
3. Not have experienced an organizational change
that might adversely affect quality
49
Other:
The previous 10 or more consecutive lots have been
accepted
The min cumulative sample size for the last 10 or more
consecutive lots have been met.
The acceptance numbers for the last 2 lots have been met
51
8

Sampling for Continuous Production
Acceptance sampling for continuous
production implies that manufacturing
operations do not create lots as part of
the normal part of the production
process.
Parts are produced by a continuous
process on a conveyor or similar system.
51
Sampling for Continuous Production
Applicable to attribute, nondestructive
inspection of moving product.
Inspection should be easy and rapid
Process must be capable of
manufacturing homogeneous product
54
Sampling for Continuous Production
CSP-1
Begins with 100% inspection of the product
in the order of production until a certain
number of successive units are free of
nonconformities.
56
06-Mar-15
Sampling for Continuous Production
Plans for continuous production consist of
alternating sequences of sampling
inspection and screening (100%) inspection.
Plans begin with 100% inspection and convert
to sampling after a stated number of items are
free of nonconformities.
Sampling continues until a stated number of
nonconforming units are found, at which time
100% inspection in reinstated.
53
Sampling for Continuous Production
Developed by Dodge
CSP-1, CSP-2, CSP-3
Later, MIL-STD-1235B
55
Sampling for Continuous Production
CSP-1
Sampling inspection is then instituted
Samples are selected in such a manner
as to minimize any bias
If a nonconformity occurs, sampling is
discontinued and 100% inspection begins.
57
9
 06-Mar-15

CSP-1 and CSP-F Plans MIL-STD-1235B

Start
Standard is composed of five different
The Screening Crew Inspects 100% of the Units continuous sampling plans.
When i Consecutive Units Are Found Free of
Nonconformities Concerned, Designated by code letters

The Screening Crew is Released from 100% Inspection

and the Sampling Inspector Inspects a Fraction, f, of
the Units, Where the Sample Units are Selected in a
Random Manner.

When the Sampling Inspector Finds One of the

Nonconformities Concerned,

58 59

MIL-STD-1235B Acceptance Sampling Plans for Variables

Inspection is by attributes for
nonconforming units using three classes of Shainin Lot Plot
severity: ANSI/ASQ Z1.9-2003
Critical
Major
Minor
Each of the plans incorporates a provision
for discontinuance of inspection

60 61

Acceptance Sampling Plans for Variables Acceptance Sampling Plans for Variables
Shainin Lot Plot
ANSI/ASQ Z1.9-2003 Sampling
Random sample of 10 subgroups of 5 each
Procedures and Tables for Inspection
Find average and range
by Variables for Percent
Construct a histogram
Nonconforming is an acceptance
Calculate Xdouble bar, R bar
sampling system to be used on a
Calculate ULL and LLL
continuing stream of lots for
Compare to lot plots in Figure 10-15 Acceptance Quality Limit (AQL)
specified.

62 63

10
 06-Mar-15

Acceptance Sampling Plans for Variables

ANSI/ASQ Z1.9-2003 provides
tightened, normal, and reduced plans
to be used on measurements which are
normally distributed. Variation may be
measured by sample standard
deviation, sample range, or known
standard deviation. It is applicable only
when the normality of the
measurements is assured.

64

11