6-Control Chart PDF

CONTROL CHART
Control Charts
Constructed from historical data, the
purpose of control charts is to help
distinguish between natural variations
and variations due to assignable
causes
© 2011 Pearson Education

Process Control
(a) In statistical
control and capable
of producing within
Frequency control limits
Lower control limit Upper control limit

(b) In statistical
control but not
capable of producing
within control limits
(c) Out of control
Size
(weight, length, speed, etc.)
Using the Control Chart During
Production / Process
■ The control charts have to be displayed in a conspicuous
place where they may be readily viewed by those concerned,
■ There should be no delay in plotting all the points on the
control chart after the sample has been taken.
■ When a point falls outside the control limits, the type of the
action to be taken should be predetermined.
■ After the causes of trouble are located and eliminated, the
control limits have to be periodically reviewed and altered
as far as possible, they should not become
wider than the earlier limits
■ Brief notes may be added on the control chart regarding the causes
of trouble found in the manufacturing process or inspection
methods and the corrective action taken.
Control
Chart
Displayed in a
conspicuous place
no delay in plotting
Types of Data
Variables Attributes
 Characteristics that  Defect-related
can take any real characteristics
value  Classify products
 May be in whole or as either good or
in fractional bad or count
numbers defects
 Continuous random  Categorical or
variables discrete random
variables
Comparison of variable &
Attribute Data
Control Charts
• P chart , NP
Attributes Chart
Chart • C Chart / U chart
• X bar Chart
Variable • R Chart
Chart
Copyright 2011 John Wiley & Sons, Inc. 3-8

Selecting Control Chart
Usually
small/manually Monitor
variability
Control Charts for Variables
 For variables that have

continuous dimensions
 Weight, speed, length,
strength, etc.
 x-charts are to control
the central tendency of the process
 R-charts are to control the dispersion of
the process
 These two charts must be used together

Steps In Creating Control Charts
1. Take samples from the population and

compute the appropriate sample statistic
2. Use the sample statistic to calculate control
limits and draw the control chart
3. Plot sample results on the control chart and
determine the state of the process (in or out of
control)
4. Investigate possible assignable causes and
take any indicated actions
5. Continue sampling from the process and reset
the control limits when necessary

Manual and Automated
Control Charts

Rumus-
rumus
control chart
Patterns in Control Charts
Upper control limit
Target
Lower control limit

Normal behavior.
Process is “in control.”
Figure S6.7

Upper control limit
Target
Lower control limit

One plot out above (or
below). Investigate for
cause. Process is “out
of control.”
Figure S6.7

Upper control limit
Target
Lower control limit

Trends in either
direction, 5 plots.
Investigate for cause of
progressive change.
Figure S6.7

Upper control limit
Target
Lower control limit

Two plots very near
lower (or upper)
control. Investigate for
cause.
Figure S6.7

Upper control limit
Target
Lower control limit

Run of 5 above (or
below) central line.
Investigate for cause.
Figure S6.7

Upper control limit
Target
Lower control limit

Erratic behavior.
Investigate.
Figure S6.7

Process Capability
 The natural variation of a process
should be small enough to produce
products that meet the standards
required
 A process in statistical control does not
necessarily meet the design
specifications
 Process capability is a measure of the
relationship between the natural
variation of the process and the design
specifications

Attribute Chart
jumlah sampel
tidak tetap
Attributes
Chart P chart Proporsi
Defective
NP chart Jumlah
U chart
Defect
C chart
jumlah sampel
jumlah sampel
tetap tidak tetap
Attributes Chart
• Control Chart untuk data-data atribut:
Contoh :
- Jumlah unit yang Gagal
Produksi (Reject)
- Jumlah ketidakhadiran
karyawan
- Jumlah Komponen yang
defective
2 nilai atau pilihan
OK atau NG,
Hadir atau Absen,
Komponen Baik atau Komponen Defective.
Control Charts for Attributes
 For variables that are categorical

 Good/bad, yes/no,
acceptable/unacceptable
 Measurement is typically counting
defectives
 Charts may measure
 Percent defective (p-chart)
 Number of defects (c-chart)

Defect
■ Defects adalah cacat, kesalahan serta kekurangan atau
ketidaksempurnaan yang dapat menyebabkan berkurangnya nilai
dari suatu unit produk. Suatu Cacat tunggal (single defect) apakah
dapat menyebabkan defective adalah tergantung pada spesifikasi
produk maupun spesifikasi pelanggan.
Contoh :
■ Terdapat 1 goresan yang sangat kecil di display LCD, tetapi mungkin
tidak menyebabkan unit produk tersebut ditolak oleh pelanggan.
Berarti unit tersebut terdapat 1 Defect.
■ Terdapat 4 solder ball kecil sehingga tidak memenuhi persyaratan
standar pelanggan. 1 unit  4 defect.
■ Terdapat 1 komponen tidak terpasang sehingga unit produk
tersebut tidak dapat berfungsi dengan baik. Berarti unit tersebut
memiliki 1 Defect.
Defective
■ Defective adalah terganggunya nilai atau fungsi dari seluruh unit atau
produk sehingga produk tersebut dinyatakan tidak dapat digunakan lagi
atau tidak memenuhi standar kualitas Produksi. Unit atau Produk yang
Defective minimal memiliki 1 (satu) defect. Dalam 1 unit produk defective
bisa terdiri dari beberapa defects.
Contoh :
■ Terdapat 1 defective yang dikarenakan oleh Kabel putus sehingga produk
tersebut tidak dapat berfungsi dengan baik. Berarti unit tersebut memiliki
1 defect yang mengakibatkan 1 defective.
■ Terdapat 1 defective yang dikarenakan oleh 2 komponen Resistor yang
tidak dipasangkan oleh Operator sehingga unit produk tidak dapat di-ON-
kan. Berarti unit tersebut memiliki 2 defect yang mengakibatkan 1
defective.
■ Terdapat 1 defective yang dikarenakan 2 goresan dan 1 bintik hitam di
display LCD sehingga tidak memenuhi Standar Kualitas. Berarti unit
tersebut memiliki 3 defect yang mengakibatkan 1 defective.
■ Terdapat 10 defective unit produk di lini produksi.
Defectives VS Defect
U Chart
■ Monitoring the number of nonconformities per lot of raw

material received where the lot size varies
■ Monitoring the number of new infections in a hospital per day
■ Monitoring the number of accidents for delivery trucks per
day
C Chart
■ Monitoring the number of voids per inspection unit

in injection molding or casting processes
■ Monitoring the number of discrete components that must be
re-soldered per printed circuit board
Control Limits for p-Charts
Population will be a binomial distribution,
but applying the Central Limit Theorem
allows us to assume a normal distribution
for the sample statistics
UCLp = p + zsp^ p(1 - p)

sp =
^
n
LCLp = p - zsp^
where p = mean fraction defective in the sample
z = number of standard deviations
sp^ = standard deviation of the sampling distribution
n = sample size

Clerks at Mosier Data Systems
key in thousands of insurance
records each day for a variety of
client firms. CEO Donna Mosier
wants to set control limits to
include 99.73% of the random
variation in the data entry
process when it is in control.

p-Chart for Data Entry
Sample Number Fraction Sample Number Fraction
Number of Errors Defective Number of Errors Defective
1 6 .06 11 6 .06
2 5 .05 12 1 .01
3 0 .00 13 8 .08
4 1 .01 14 7 .07
5 4 .04 15 5 .05
6 2 .02 16 4 .04
7 5 .05 17 11 .11
8 3 .03 18 3 .03
9 3 .03 19 0 .00
10 2 .02 20 4 .04
Total = 80
80 (.04)(1 - .04)
p= (100)(20)
= .04 sp^ = = .02
100
UCLp = p + zsp^ = .04 + 3(.02) = .10
LCLp = p - zsp^ = .04 - 3(.02) = 0
.11 –
.10 – UCLp = 0.10
–
Fraction defective
.09
.08 –
.07 –
.06 –
.05 –
.04 – p = 0.04
.03 –
.02 –
.01 – LCLp = 0.00
| | | | | | | | | |
.00 –
2 4 6 8 10 12 14 16 18 20
Sample number
UCLp = p + zsp^ = .04 + 3(.02) = .10
Possible
LCLp = p - zsp^ = .04 - 3(.02) = 0
assignable
causes present
.11 –
.10 – UCLp = 0.10
–
Fraction defective
.09
.08 –
.07 –
.06 –
.05 –
.04 – p = 0.04
.03 –
.02 –
.01 – LCLp = 0.00
| | | | | | | | | |
.00 –
2 4 6 8 10 12 14 16 18 20
Sample number
Control Limits for c-Charts
Population will be a Poisson distribution,
but applying the Central Limit Theorem
allows us to assume a normal distribution
for the sample statistics
UCLc = c + 3 c LCLc = c - 3 c
where c = mean number defective in the sample

Red Top Cab Company receives several
complaints per day about the behavior
of its drivers. Over a 9-day period
(when days are the units of measure),
the owner, Gordon Hoft, received the
following numbers of calls from irate
passengers: 3,0,8,9,6,7,4,9,8 for a
total of 54 complaints. Hoft wants to
compute 99.73% control limits.

c-Chart for Cab Company
c = 54 complaints/9 days = 6 complaints/day
UCLc = c + 3 c 14 – UCLc = 13.35
Number defective
=6+3 6 12 –
= 13.35 10 –
8 –
6 – c= 6
LCLc = c - 3 c 4 –
=6-3 6 2 – LCLc = 0
0 – | | | | | | | | |
=0 1 2 3 4 5 6 7 8 9
Day

C-Chart
Which Control Chart to Use
Variables Data
Using an x-Chart and R-Chart
1. Observations are variables
2. Collect 20 - 25 samples of n = 4, or n = 5, or
more, each from a stable process and compute
the mean for the x-chart and range for the R-
chart
3. Track samples of n observations each.
Table S6.3

Attribute Data
Using the p-Chart
1. Observations are attributes that can be
categorized as good or bad (or pass–fail, or
functional–broken), that is, in two states.
2. We deal with fraction, proportion, or percent
defectives.
3. There are several samples, with many
observations in each. For example, 20 samples
of n = 100 observations in each.
Table S6.3

Attribute Data
Using a c-Chart
1. Observations are attributes whose defects per
unit of output can be counted.
2. We deal with the number counted, which is a
small part of the possible occurrences.
3. Defects may be: number of blemishes on a
desk; complaints in a day; crimes in a year;
broken seats in a stadium; typos in a chapter of
this text; or flaws in a bolt of cloth.
Table S6.3

CHART STRUCTURE : Xbar R
Steps:
Steps:
Steps:
Plot the data:
Control Chart
Interprete R & X bar chart!

Xbar-R
Varying sample
size
x-Charts
Setting Chart Limits
For x-Charts when we know s
Upper control limit (UCL) = x + zsx
Lower control limit (LCL) = x - zsx
where x = mean of the sample means or a target
value set for the process
z = number of normal standard deviations
sx = standard deviation of the sample means
= s/ n
s = population standard deviation
n = sample size
The Weights of boxes of Oat
Flakes within a large production
lot are sampled each hour.
Managers want to set control
limits that include 99.73% of
the sample mean.

Setting Control Limits
Hour 1 Hour Mean Hour Mean
Sample Weight of 1 16.1 7 15.2
Number Oat Flakes 2 16.8 8 16.4
1 17 3 15.5 9 16.3
2 13 4 16.5 10 14.8
3 16 5 16.5 11 14.2
4 18 6 16.4 12 17.3
n=9 5 17
6 16 For 99.73% control limits, z = 3
7 15
8 17 UCLx = x + zsx = 16 + 3(1/3) = 17 ozs
9 16
Mean 16.1 LCLx = x - zsx = 16 - 3(1/3) = 15 ozs
s= 1

Control Chart
for sample of Variation due
Out of to assignable
9 boxes control causes
17 = UCL
Variation due to
16 = Mean natural causes
15 = LCL
Variation due
| | | | | | | | | | | |
to assignable
1 2 3 4 5 6 7 8 9 10 11 12 Out of causes
Sample number control

For x-Charts when we don’t know s
Upper control limit (UCL) = x + A2R

Lower control limit (LCL) = x - A2R
where R = average range of the samples

A2 = control chart factor found in Table S6.1
x = mean of the sample means

Control Chart Factors
Sample Size Mean Factor Upper Range Lower Range
n A2 D4 D3
2 1.880 3.268 0
3 1.023 2.574 0
4 .729 2.282 0
5 .577 2.115 0
6 .483 2.004 0
7 .419 1.924 0.076
8 .373 1.864 0.136
9 .337 1.816 0.184
10 .308 1.777 0.223
12 .266 1.716 0.284
Table S6.1
Super Cola bottles soft drink labeled
“net weight 12 ounces.” Indeed, an
overall process average of 12 ounces
has been found by taking many
samples, in which each sample
contained 5 bottles. The average range
of the process is 0.25 ounce. The OM
team wants to determine the upper
and lower control limits for average in
this process.

Process average x = 12 ounces
Average range R = .25
Sample size n = 5

Sample size n = 5
UCLx = x + A2R
= 12 + (.577)(.25)
= 12 + .144
= 12.144 ounces
From Table
S6.1

Sample size n = 5
UCLx = x + A2R UCL = 12.144

= 12 + (.577)(.25)
= 12 + .144 Mean = 12
= 12.144 ounces
LCLx = x - A2R LCL = 11.857

= 12 - .144
= 11.857 ounces
Restaurant Control Limits
For salmon filets at Darden Restaurants
x Bar Chart
11.5 – UCL = 11.524
Sample Mean
11.0 – x – 10.959
10.5 – LCL – 10.394

| | | | | | | | |
1 3 5 7 9 11 13 15 17
Range Chart
0.8 –
Sample Range
UCL = 0.6943
0.4 –
R = 0.2125
0.0 – | | | | | | | | | LCL = 0
1 3 5 7 9 11 13 15 17

Restaurant Control Limits
Capability Histogram
LSL USL
Specifications
LSL 10
USL 12
Capability
Mean = 10.959
Std.dev = 1.88
Cp = 1.77
Cpk = 1.7

R – Chart
 Type of variables control chart

 Shows sample ranges over time
 Difference between smallest and
largest values in sample, or
 Monitors process variability

 Independent from process mean

For R-Charts
Upper control limit (UCLR) = D4R

Lower control limit (LCLR) = D3R
where
R = average range of the samples
D3 and D4 = control chart factors from Table S6.1

The average range of a product
at Clinton Manufacturing is 5.3
pounds. With a sample size of
5, owner Roy Clinton wants to
determine the upper and lower
control chart limits.

Average range R = 5.3 pounds
Sample size n = 5
From Table S6.1 D4 = 2.115, D3 = 0
UCLR = D4R UCL = 11.2

= (2.115)(5.3)
= 11.2 pounds Mean = 5.3
LCLR = D3R LCL = 0

= (0)(5.3)
= 0 pounds
Mean and Range Charts
(a)
These (Sampling mean is
sampling shifting upward but
distributions range is consistent)
result in the
charts below
UCL
(x-chart detects
x-chart shift in central
tendency)
LCL
UCL
(R-chart does not
R-chart detect change in
mean)
LCL
Figure S6.5
Mean and Range Charts
(b)
These
sampling (Sampling mean
distributions is constant but
result in the dispersion is
charts below increasing)
UCL
(x-chart does not
x-chart detect the increase
in dispersion)
LCL
UCL
(R-chart detects
R-chart increase in
dispersion)
LCL
Figure S6.5
In a GE insurance claims process, X bar = 210.0 minutes, and
S.D = 0.516 minutes. The design specification to meet customer
expectations is 210 +/- 3 minutes. So the Upper Specification is
213 minutes and the lower specification is 207 minutes. The OM
wants to compute the process capability ratio.

Process Capability Ratio
Insurance claims process
Process mean x = 210.0 minutes

Process standard deviation s = .516 minutes
Design specification = 210 ± 3 minutes
Upper Specification - Lower Specification

Cp =
6s

Cp =
6s
 A capable process must have a Cp of at

least 1.0
 Does not look at how well the process
is centered in the specification range
 Often a target value of Cp = 1.33 is used
to allow for off-center processes
 Six Sigma quality requires a Cp = 2.0



Cp =
6s
213 - 207
= = 1.938
6(.516)



Cp =
6s
213 - 207
= = 1.938 Process is
6(.516)
capable

1 = 2.7 Defects in 1000
1.33 = 64 Defects per million = 4 Sigma
2 = 3.4 Defects per million = 6 Sigma

Process Capability Index
Upper Lower
Cpk = minimum of Specification - x , x - Specification
Limit Limit
3s 3s
 A capable process must have a Cpk of at

least 1.0
 A capable process is not necessarily in the
center of the specification, but it falls within
the specification limit at both extremes

You are the process improvement manager and
have developed a new machine to cut insoles for
the company’s top-of-the-line running shoes. You
are excited because the company’s goal is no
more than 3.4 defects per million and this
machine may be the innovation you need. The
insole cannot be more than +/- 0.001 of an inch
from the required thickness of 0.250 inch. You
want to know if you should replace the existing
machine, which has a Cpk of 1. Estimated standard
deviation of new process is 0.0005 inch.

New Cutting Machine
New process mean x = .250 inches
Process standard deviation s = .0005 inches
Upper Specification Limit = .251 inches
Lower Specification Limit = .249 inches

New Cutting Machine
(.251) - .250
Cpk = minimum of ,
(3).0005

New Cutting Machine
(.251) - .250 .250 - (.249)
Cpk = minimum of ,
(3).0005 (3).0005
Both calculations result in

New machine is
.001
Cpk = = 0.67 NOT capable
.0015

Source:
■ Tim Stapenhurst, Mastering Statistical Process Control

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CONTROL CHART

© 2011 Pearson Education

Lower control limit Upper control limit

(c) Out of control

Copyright 2011 John Wiley & Sons, Inc. 3-8

 For variables that have

© 2011 Pearson Education

1. Take samples from the population and

© 2011 Pearson Education

© 2011 Pearson Education

Lower control limit

© 2011 Pearson Education

Lower control limit

© 2011 Pearson Education

Lower control limit

© 2011 Pearson Education

Lower control limit

© 2011 Pearson Education

Lower control limit

© 2011 Pearson Education

Lower control limit

© 2011 Pearson Education

© 2011 Pearson Education

2 nilai atau pilihan

 For variables that are categorical

© 2011 Pearson Education

■ Monitoring the number of nonconformities per lot of raw

■ Monitoring the number of voids per inspection unit

UCLp = p + zsp^ p(1 - p)

© 2011 Pearson Education

© 2011 Pearson Education

where c = mean number defective in the sample

© 2011 Pearson Education

© 2011 Pearson Education

c = 54 complaints/9 days = 6 complaints/day

UCLc = c + 3 c 14 – UCLc = 13.35

© 2011 Pearson Education

© 2011 Pearson Education

© 2011 Pearson Education

© 2011 Pearson Education

Interprete R & X bar chart!

© 2011 Pearson Education

© 2011 Pearson Education

© 2011 Pearson Education

For x-Charts when we don’t know s

Upper control limit (UCL) = x + A2R

where R = average range of the samples

© 2011 Pearson Education

© 2011 Pearson Education

© 2011 Pearson Education

© 2011 Pearson Education

UCLx = x + A2R UCL = 12.144

LCLx = x - A2R LCL = 11.857

10.5 – LCL – 10.394

© 2011 Pearson Education

© 2011 Pearson Education

 Type of variables control chart

 Monitors process variability

© 2011 Pearson Education

Upper control limit (UCLR) = D4R

© 2011 Pearson Education

© 2011 Pearson Education

UCLR = D4R UCL = 11.2