Introduction to Control Charts

Dr. Shahul Hamid Khan

 Introduction to Control chart

Symbols

Ѳ – parameter
Ѳ
ˆ - estimator
α - probability of type I error
β - probability of type II error
σ - process standard deviation
σ―x - standard deviation of sample mean

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 A control chart is a graphical tool for
monitoring the activity of an ongoing
process.
Sometimes referred as Shewhart’s
control chart

Control charts for variables

Control charts for Attributes

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 Benefits of Control chart

1. When to take corrective actions

2. Type of remedial action necessary
3. To find Process capability
4. Possible means of quality improvement

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 Causes of variation
Special Causes Common causes

Special causes or Assignable

Methods
causes
People
15% of all problems are due to Equipments
Special cause. Materials
§ Wrong tool Policies

§ Improper raw materials

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 Common causes

Inherent to a process
Inherent part of process design

Cannot be totally eliminated

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 Type I Error
o Inferring that a process is out of control
when it is actually in control
o The probability of this error is denoted by
α
o For 3s

Type II Error

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Tolerance Limits vs. Process Capability

Specification Width

Actual Process Width

Specification Width

Actual Process Width

Control chart makes it very easy
for you to identify visually
points and processes that are out
of control without using complicated
statistical tests.
 Analysis of patterns in Control Charts

Rule 1

A process is assumed to be out of control

if a single point plots outside the

control limits.

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 Warning limits

Construct two lines at two sigma

deviations above and below center line

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 Rule 2

A process is assumed to be out of control if two

out of three consecutive points falls outside

the two sigma warning limits on the same side of

the center line.

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 Rule 3

A process is assumed to be out of control if

four out of five consecutive points falls beyond

1 sigma limit on the same side of the center

line.

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 Rule 4

A process is assumed to be out of control

if nine or more consecutive points fall

to one side of the center line.

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 Rule 5

A process is assumed to be out of control if

there is a run of six or more consecutive points

steadily increasing or decreasing .

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Control Charts for Variables

§ Control Charts for Mean and Range (Constant

Sample size)
X – bar chart
R – chart
Control Charts for Mean and Range

Average

Range

g – No of Samples
x Chart Control Limits
UCL = x + 3 s X

LCL = x - 3 s X
x Chart Control Limits
UCL = x + 3 s X

LCL = x - 3 s X

x Chart Control Limits

UCL = x + A 2 R where
LCL = x - A 2 R
R Chart Control Limits
UCL = D 4 R
LCL = D 3 R Trial Control
Limits
Example
Revised Control Limits
x Chart Control Limits
UCL = x + A 2 R
LCL = x - A 2 R
X- bar chart
= 0
 Control Charts for Mean and Std Deviation

S- Chart

S chart is preferable when the sample size is greater than 10

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 (1)

(
2)

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 S- Chart (With no Given
Standard)

By Eqn (1)

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