Quality Control Charts

What Are Control Charts

A typical 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. Control charts are used to routinely monitor quality.

The Quality Control Charts are used for following purposes :

It is a proven technique for improving productivity. It is effective in defect prevention. It prevents unnecessary process adjustments. It provides diagnostic information. It provides information about process capability.

Main Components of Control Charts

Center Line
A horizontal reference line on a control chart that is the average value of the charted quality characteristic.

If a process is in control, the points will randomly vary around the center line.

Control Limits
Horizontal lines located above and below the center line that are used to judge whether a process is out of control. The upper and lower control limits are based on the expected random variation in the process. Control Limits are different from Specifications Limit, which are based on customer requirements and desired amount of variation a customer wants to see. Control limits display the actual amount of variation based on the sample data.

Basic Formula
Let w be a sample statistic that measures some continuously varying quality characteristic of interest (e.g., thickness) Suppose that the mean of is m, with a standard deviation of s. Upper Control Limit, UCL = m + ks Center Line = m Lower Control Limit, LCL = m - ks

Graphical Representation
Upper Specification Limit

Quality Characteristic

Upper Control Limit

ks
Center Line (m)

ks
Lower Control Limit

Lower Specification Limit

Sample Number(or time)

Types Of Control Chart

Variable Control Charts
Control charts that plot continuous measurement process data, such as length or pressure, in a time-ordered sequence. Variables charts, like all control charts, help you identify causes of variation to investigate, so that you can take action on your process without over-controlling it.

Further divided into following sub-categories: 1. Xbar-Chart Plots the process mean over time for variables data in subgroups. This control chart is widely used to examine the stability of processes in many industries.

2. R-Chart

Plots the process range over time for variables data in subgroups. This control chart is widely used to examine the stability of processes in many industries. 3. S-Chart
Plots the process standard deviation over time for variables data in subgroups. This control chart is widely used to examine the stability of processes in many industries.

 Attribute Control Charts

Attributes control charts are similar in structure to variables control charts, except that they plot statistics from count data rather than measurement data Further divided into following two sub-categories: i. Defect ii. Defective

Defect
i. A defect is any departure from the specifications.

ii. It refers to a quality characteristic of the product.

iii. Defects can be corrected & the product can be used after correction

iv. Defect Control Charts are further classified into two classes as below:

C chart
Plots the number of nonconformities or defects when subgroup sizes are equal. It is possible for a unit to have one or more nonconformities but still be acceptable in function and performance. In general, C charts are used to chart the total number of defects in a sample, when the sample size is constant.

U chart
Plots the number of nonconformities or defects per unit. It is possible for a unit to have one or more nonconformities but still be acceptable in function and performance.

 Defective
i. A defective is when the whole product or service is considered unacceptable
ii. A defective unit will contain 1 or more defects. It refers to the product. iii. Defective product can not be used or corrected.

iv. Defective Control Charts are further classified as below:

P chart
Plots the fraction, percent, or proportion of nonconforming units. The P chart is the most widely used attributes control chart.
While each unit may have many quality characteristics that can be evaluated, the unit itself is always considered as either conforming or nonconforming. It is used to examine whether wait times are less than 5 minutes, flights depart on time, bicycle tires are flat, printed logos are smudged, and so on.

 NP chart
Plots the number of nonconforming units.
While each unit may have many quality characteristics that can be evaluated, it is always considered as either conforming or nonconforming. It can be used to examine the number of times that flights depart late, that bicycle tires are flat, that printed logos are smudged, and so on.

Control Chart Selection

Quality Characteristic

variable
defective n>1? yes n>=10 or no computer? yes x and s x and R no x and MR constant sample size? no p-chart with variable sample size

attribute
defect

yes

p or np

constant sampling unit?

yes c no u

X-BAR Chart
Formula
where

UCL = X + 3

R nd2 R nd 2

i= 1

Ri n

LCL = X - 3

R i = Range of subgroup
=X
max

-X
n

min

X=

SX
i= 1

Observation Sample No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 11 23

1
21 19 22 20 19 21 20 20 20 25 22 22 20 20 20 19 21 20 20 21 22 24 19

2
21 18 20 21 22 19 19 21 19 20 21 19 21 19 19 22 19 20 22 20 23 24 22

3
23 21 23 23 20 20 20 19 20 22 22 20 22 20 19 19 23 24 21 19 20 22 20

DATA
22 23 22 20 19 19 19 22 21 19 19 19 23 19 21 20 20 22 20 19 19 23 19 21 22 20 21 21 23 19 22 20 17 20 20 20 19 20 19 19 19 19 20 20 26 20

Mean
21.6 20.6 21.4 21 20.2 20.4 19.4 20.8 20 20.6 20.8 20 21.2 19.4 19.8 19.8 20.4 21 20.4 19.8 20.8 23.8 20

R=Max-Min
2 5 3 3 3 4 1 3 2 8 3 3 3 1 2 3 4 5 3 2 4 4 3

Remarks

New Vendor

High Temperature Wrong Die

24 25

20 20

19 23

21 19

22 21

19 22

20.2 21

3 4

SUM

514.4

81

X-BAR Chart

X-BAR CHART
25 20
Values

15 10 5 0 1 3 5 7 9 11 13 15 17 19 21 23 25 Observations

UCL LCL CL

R- Chart
Formula
where

UCL = R + 3d3 R = D4R d2 LCL = R - 3d 3 R = D3R d2

Ri = i= 1 n

D4 = 1 + 3 d3 d2

D3 = max 0, 1 - 3 d3
d2 R i = Range of subgroup = x max - x min

The Data is shown below: Here,

D = 2.114 4 D3 = 0 n = 20
Hence, SR = 26.4 R = 1.32
X max X min

The Graph is plotted as below:

R Chart of Length
3.0 2.5 2.0 1.5 1.0 0.5 0.0 1 3 5 7 9 11 Sample 13 15 17 19 LCL=0 _ R=1.341 UCL=2.835

Sample Range

P - Chart
Formula
g x pi i CL = p = = ng i= 1 g i= 1

g ^

UCL = p + 3 * p ( 1 p ) n LCL = p - 3 * p ( 1 p ) n where g = Total no. of subgroup ^ x p= n n = sample size

p = sample avg proportion non conforming

Data for P - Chart

P Chart for the data

P Chart of No. of defects

0.20
1

UCL=0.1817 0.15 Proportion

0.10 _ P=0.072 0.05

0.00 1 3 5 7 9 11 13 15 Sample 17 19 21 23 25

LCL=0

NP - Chart
Formula

xi CL = = np i= 1 g

LCL = np - 3 np ( 1 p ) UCL = np + 3 np ( 1 p )
where g = Total no. of subgroup
n = sample size p = sample avg proportion non conforming

The Data is shown below:

Where n (sample size) = 300

The Graph is plotted as below:

NP Chart of unsatisfied customers
20
1

UCL=18.16 15

Sample Count

10

__ NP=9.2

0 1 3 5 7 9 11 Sample 13 15 17 19

LCL=0.24

C-Chart
Formula

CL= c UCL = c + 3c LCL = c - 3c

where c= mean number of defectives

The Data is shown below:

The Graph is plotted as below:

C Chart of No. of defects/non confirmities

18 16 14
1

UCL=14.62

Sample Count

12 10 8 6 4 2 0 1 3 5 7 9 11 13 15 Sample 17 19 21 23 25 LCL=0 _ C=6.8

Formulae for U Chart

Sc
=
i= 1 i= 1

UCLu = + 3 ( / n i) LCLu = - 3 / n i )

Data for U Chart

U Chart

U Chart of defects in carpet

0.12 0.10
1

Sample Count Per Unit

UCL=0.0934

0.08 0.06 0.04 0.02 0.00 1 3 5 7 9 11 Sample 13 15 17 19 LCL=0.0011

_ U=0.0473

Tests performed with unequal sample sizes

Control Chart Patterns & Corrective Actions

Common causes of variation

Inherent to a system System is in state of statistical control

Special causes of variation

Periodic and persistent disturbances that affect the process intermittently

Thus we need to study patterns in control charts

Natural Pattern

Properties

No identifiable arrangement of plotted points Stable System

60 40

Natural Pattern for an in-control process on an X-chart

UCL=65

Sample Mean

20

_ _ X=20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Sudden Shift in pattern level

Possible Causes

Sample Mean

Changes in process settings like temperature, pressure. New operators or new equipments could also be the cause

Sudden Shift in Pattern level on an X-chart

60 UCL=65

40 _ _ X=20

20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Gradual Shift in pattern level

Possible Causes

Gradual improvement in quality of raw material Maintenance program or style of supervision changed over time
60 40

Gradual Shift in Pattern level on an X-chart

UCL=65

Sample Mean

20

_ _ X=20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Trending Pattern

Possible Causes

Gradual change in temperature Tool wear or die wear

Trending Pattern on an X-chart
60 UCL=65

40
Sample Mean

20

_ _ X=20

-20 1 2 3 4 5 6 7 8 Sample 9 10 11 12 13 14

LCL=-25

Tests performed with unequal sample sizes

Cyclic Pattern

Possible Causes

Rotation of operators Periodic changes in temperature and humidity

Sample Mean

Cyclic Pattern on an X-chart

60 UCL=65

40 _ _ X=20

20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Freak Pattern

It is different from a recording error Possible Causes

Failure of a component Short-lived power failure

Freak Pattern on an X-chart
80
1

60

UCL=65

Sample Mean

40 _ _ X=20

20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Bunching Pattern

Clusters of several observations decidedly different from other points Possible Causes
60

Bunching Pattern on an X-chart

UCL=65

Sample Mean

Use of a new vendor or different machine for a brief time period

40 _ _ X=20

20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Mixture Pattern

Sample Mean

Points fall either too high or too low with an absence of points near the center line Possible Causes

Mixture Pattern on an X-chart

60 UCL=65

40 _ _ X=20

Difference in incoming material from two different vendors

20

-20 1 2 3 4 5 6 7 8 9 Sample 10 11 12 13 14 15

LCL=-25

Some more

Stratification pattern

The output of two different samples is combined (e.g. two shifts) and samples are selected. Majority points close to the center line. Solution is to plot different data on different control charts Level of one variable impacts the level of another variable. Solution is to change the scheme for rational sampling

Interaction pattern

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