Chapter 6 Statistical Quality Control, 7th Edition by Douglas C. Montgomery.

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Chapter 6 Introduction to Statistical Quality Control, 7th Edition by Douglas C. Montgomery. 2
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Subgroup Data with Unknown  and 

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 Phase I Application of x and R Charts
• Eqns 6.4 and 6.5 are trial control limits
– Determined from m initial samples
• Typically 20-25 subgroups of size n between 3 and 5
– Any out-of-control points should be examined for assignable causes
• If assignable causes are found, discard points from calculations and
revise the trial control limits
• Continue examination until all points plot in control
• Adopt resulting trial control limits for use
• If no assignable cause is found, there are two options
1. Eliminate point as if an assignable cause were found and revise limits
2. Retain point and consider limits appropriate for control
– If there are many out-of-control points they should be examined for
patterns that may identify underlying process problems

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 Example 6.1 The Hard Bake Process

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 Revision of Control Limits
and Center Lines
• Effective use of control charts requires periodic
review and revision of control limits and center lines
• Sometimes users replace the center line on the x chart
with a target value
• When R chart is out of control, out-of-control points
are often eliminated to recompute a revised value of R
which is used to determine new limits and center line
on R chart and new limits on x chart

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 Phase II Operation of Charts
• Use of control chart for monitoring future
production, once a set of reliable limits are
established, is called phase II of control chart
usage (Figure 6.4)
• A run chart showing individuals observations
in each sample, called a tolerance chart or
tier diagram (Figure 6.5), may reveal patterns
or unusual observations in the data

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 Control vs. Specification Limits
• Control limits are derived
from natural process
variability, or the natural
tolerance limits of a process

• Specification limits are

determined externally, for
example by customers or
designers

• There is no mathematical or
statistical relationship
between the control limits
and the specification limits

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 Rational Subgroups
• x charts monitor between-sample variability
• R charts measure within-sample variability
• Standard deviation estimate of  used to construct
control limits is calculated from within-sample
variability
• It is not correct to estimate  using

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 Guidelines for Control Chart Design
• Control chart design requires specification of sample size,
control limit width, and sampling frequency
– Exact solution requires detailed information on statistical
characteristics as well as economic factors
– The problem of choosing sample size and sampling frequency is one of
allocating sampling effort
• For x chart, choose as small a sample size is consistent with
magnitude of process shift one is trying to detect. For
moderate to large shifts, relatively small samples are effective.
For small shifts, larger samples are needed.
• For small samples, R chart is relatively insensitive to changes
in process standard deviation. For larger samples (n > 10 or
12), s or s2 charts are better choices.

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 6.2.4 Interpretation of Control Charts

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 6.2.5 The Effect of Non-normality
• An assumption in performance properties is that the
underlying distribution of quality characteristic is normal
– If underlying distribution is not normal, sampling distributions can be
derived and exact probability limits obtained
• Burr (1967) notes the usual normal theory control limits are
very robust to normality assumption
• Schilling and Nelson (1976) indicate that in most cases,
samples of size 4 or 5 are sufficient to ensure reasonable
robustness to normality assumption for chart
• Sampling distribution of R is not symmetric, thus symmetric
3-sigma
x limits are an approximation and -risk is not 0.0027.
R chart is more sensitive to departures from normality than
chart.
• Assumptions of normality xand independence are not a primary
concern in phase I

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 6.2.6 The Operating Characteristic Function

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 If the shift is 1.0σ and the sample
size is n = 5, then β = 0.75.

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 Development of the control limits:

Thius produces the control limits in equation (6.27)

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 This produces the control limits in equation (6.28)

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 Average Run Lengths
• Crowder (1987b) showed that
ARL0 of combined individuals
and moving-range chart with
conventional 3-sigma limits is
generally much less than ARL0
(= 370) of standard Shewhart
control chart

• Ability of individuals chart to

detect small shifts is very poor
– Rather than narrowing the 3-
sigma limits, correct approach to
detecting small shifts is a
cumulative-sum or exponentially
weighted moving-average control
chart (Chapter 9)

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 Normality

• Borror, Montgomery, and Runger (1999) report that the in-control ARL is
dramatically affected by nonnormal data
• One approach for nonnormal data is to determine control limits for individuals
control chart based on percentiles of correct underlying distribution
– Requires at least 100 and preferably 200 observations
– Transformations can also be useful

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