Unit 2 Control charts

Introduction Theory of control charts Measurement range Construction and analysis of R chart Process capability study Attributes of control charts Defects Construction and analysis of control charts Variable sample size Construction and analysis of C charts

 A control chart is a statistical technique for controlling the quality of a product being manufactured. It was first devised by Dr. Walter A. shewart after whose name these charts are also called Shewart charts. The main advantage of control chart is that it can predict the rejects when they are likely to occur, which enables corrective action to be taken before a defective product is actually produced.

Theory of control charts Machine environment follows normal distribution curve. It is not possible to manufacture two exactly identical products. So, variability does exists in all repetitive processes. Difference in dimensions or any other quality of the product are bound to happen if 1. Different machine tools are used. 2. Different cutting tools are used. 3. Working conditions are different. 4. Workers of different skills manufacture the products. 5. Improper jigs, tools and fixtures are used.

 The variability is due to chance causes as well as assignable causes. A control chart accepts the normal variation due to chance causes but eliminates entirely the errors due to assignable causes. Chance (usual) variations are normally of a lesser magnitude than assignable variations and occur randomly. Chance variations occurs randomly and can be described by the normal probability distribution curves. So, control limits are defined within which variations are acceptable and beyond which they are unacceptable. A process is said to be in control if it produces items whose attributes or variable fall within the acceptable range and is said to be out of control if it produces items whose attributes or variables are beyond the acceptable range.

What Is a Control Chart? A statistical tool used to distinguish between process variation resulting from common causes and variation resulting from special causes. Popularity of control charts 1. Control charts are a proven technique for improving productivity. 2. Control charts are effective in defect prevention. 3. Control charts prevent unnecessary process adjustment. 4. Control charts provide diagnostic information. 5. Control charts provide information about process capability.

Use of control charts Quality of a product (Process) can be controlled by the analysis of control charts. X range and We can control the process with respect to mean value with the help of R chart and chart. Period of sample checking depend upon two factors.
1. What is the process ? 2. How much time is taken for observation ?

If process is stable for long time, sample for checking is taken at large intervals.

Plotting of points In actual, plotting of points for individual observations does not properly reveal the trend of variations and the chart gets clustered up. In actual control chart applications, measurements are taken on sample comprising of 4 or 5 consecutively processed articles each, drawn from the production run at regular intervals so one point is plotted for each sample which represents the average value in the sample. Measurement range When the quality of a product is dependent upon some measurable physical quantity or variable that is to be controlled, we make control charts called control charts for variables.

 A control chart consists of: 1. A control or central line (CL): It indicates the desired control level of the process. 2. An upper control limit (UCL): It indicates the upper tolerance limit. 3. A lower control limit (LCL): It indicates the lower tolerance limit. As long as the points fall within the control limits, the process is under statistical control and we do not question the quality of the product. But, if a plotted point falls outside the control limits, this alerts the production manager to the possibility that the quality of the product is unacceptable and that the process is not under statistical control. So, he tries to determine whether variation is due to chance causes or some assignable causes.

 If the control chart indicates that the observed variation is due to chance causes alone, the process is said to be in control. If on the other hand, the control chart indicates that the observed variation is not likely due to chance, it can be said that the manufacturing process is out of control. In that event the process is halted and effort is made to seek and correct the possible cause. Two types of control charts are usually used: 1. Control charts for variables: They are used to achieve and maintain an acceptable quality, level for a process whose product can be subjected to quantitative measurement such as diameter of a hole, length of a bolt, thickness of a pipe, specific resistance of a wire.

2. Control charts for attributes: They are used to achieve and maintain an acceptable quality level for a process whose product can be subjected to quantative measurement but can be classified as good or bad, as acceptable or not acceptable. For instance surface finish of a table colour or brightness of an article is either acceptable or not acceptable. Control charts for variables: 1. Control charts for sample means ( X - charts) 2. Control charts for sample ranges (R - charts)

 Construction of charts. Control charts for attributes In inspection by variables, measurement of the dimensions is done. However, this is sometimes difficult as well as uneconomical. Inspection by attributes is just the other way of inspection. In this method actual measurements are not done, instead the number of defective are counted. The products are inspected the same way as by GO and NO GO gauges. For instance, in case of electricity bulb, the most important attribute is whether the bulb glows or not. In such situations, items are inspected to find out whether they possess a particular attribute or not. Control charts prepared under these situations are termed as control charts for attributes. An attribute is a quality characteristic for which a numerical value is not specified.

 Three most commonly used control charts for attributes are:

Control chart for fraction defective (P-Chart) Control chart for number of defectives (np-Chart) Control chart for number of defects (C-Chart)

P-chart is normally used to plot and control fraction defectives when the sample size does not remains uniform. Also it is usually used to know the proportion of defective items. np-chart is used to plot and control the number of defectives when the sample size remains constant. It is normally used to know the number of defective items in a consignment.

 C-chart is used when the production process involves complex assembly of a large number of components, such as in the manufacture of an aircraft, an automobile, a T.V., a computer, cloth, etc.
Knowledge of the number defects per unit is useful in maintaining a satisfactory level of quality.

Defects A quality characteristic that does not meet certain prescribed standards (or specifications) is said to be a nonconformity (or defect). For example, if the length of steel bars is expected to be 40 1.0 cm, a length of 41.5 cm is not acceptable. A product with one or more nonconformities, such that it is unable to meet the intended standards and is unable to function as required, is a nonconforming item (or defective).