CSP Mathematics
CSP Mathematics
\
AEC RESEARCH AND DEVELOPMENT REPORT
MASTER Y-1585
Engineeri ng and
Equipment
R. H. Hull
operated for the ATOMIC ENERGY COMMISSION unrler U. S. GOVERNMENT Contract W-7405 eng 26
•
OAK RIDGE Y-12 PLANT
P . O.Bo x Y
OAK RIDGE , TENNESSEE 37830
LEGAL NOTICE - - - - - - - - - - - - - - - -
This report was prepared as an account of Government sponsored work. Neither the United States,
nor the Commission, nor any person acting on behalf of the Commission:
A, Makes any warranty or representation, expressed or imp I ied, with respect to the occuracy,
completeness, or usefulness of the information contained in this report, or that the use of
any information, apparatus, method, or process disclosed in this report may not infringe
privately owned rights; or
B. Assumes any I iobil ities with respect to the use of, or for damages resulting from the use of
any information, apparatus, method, or process disclosed in this report .
As used in the above, "person acting on behalf of the Commission" includes any employee or
contractor of the Commission, or employee of such contractor, to the extent that such employee
or contractor of the Commission, or employee of such contractor prepares, disseminates, or
provides access to, any information pursuant to his employment or contract with the Commission,
or his employment with such contractor.
Date Issued: July 7, 1967 Document Y-1585
~----------
RC:: $ 3 .C'Jc>; MN
----
UNION CARBIDE CORPORATION
Nuclear Division
Y-12 PLANT
Contract W-7405-eng-26
With the US Atomic.Energy Commission
R. H. Hull, Jr
Document _ Y-1585
__.;;___;,...;;....;;...;;_.. __
Engineering and Equipment
TID-4500
Distribution:
ABSTRACT
proof of the AOQ formula for CSP-3, and (2) to apply this formula in deriving
Before AOQ and AFI values were generated, it was necessary to verify
[
qi (1-q k+4 + q4)(1-f) J
This above formula is different from the formula given in error by
Dodge and Torrey in the March, 1951 issue of Industrial Quality Control.
Because of the complexity of the AOQ formula and time consuming cal-
for the IBM 7090 computer in order to determine AOQ and AFI values. For
each set of values generated, the per cent defective, p, ranged from 0.5 per
cent to 50.0 per cent at increments of 0.5 per cent. The values of i used in this
study ranged from 5 to 200 units, and the sampling rate, f, began with 5 per
cent and terminated with 50 per cent at increments of 5 per cent. An assumption
which was made throughout this stl.~dy is that i = k. The computer program was
written in such a manner that AOQ and AFI values could be generated for a
iv
given i value at various levels of f and p with only one data card. Therefore,
AOQ and AFI values other than those appearing in this study may be generated
an examination revealed that the i values for CSP-3 were reduced by about
4 units when AOQL is 2 per cent; at 3 per cent AO QL, the CSP-3 i values were
about 3 units less than the CSP-2 values; and for AOQL values greater than 3
per cent, the i values for CSP-3 were about 2 units less than the CSP-2 values.
v
TABLE OF CONTENTS
CHAPTER PAGE
I. INTRODUCTION •• . . .. . .. . .. .. .. . .. ..
The Prob Iem • .. . . .. ..... ... 3
CHAPTER PAGE
Choice of i, f, and p • • • • • • • • • • • • • • • • • • ~ •. • • • • 35
AO Q Results • • • • • • • • • • • • • • • • • • • • , • • • • • • • 38
AFI Results .. .. . . .. . . .. . . . . . . . . . . .. . . .. 41
Value of AOQL . . . . . . . . . . . . . . . . . .. . . . . . . . . 44
Summary • . . . . . . • . . . . . . • . . . • • . . • . • . . . . . . 47
APPENDIX A • • • • • • . • • • . • • • . • . . • • . • • • • • • • . • . • 55
APPENDIX B. • • • • • • • • • • • • . • • • • • • • • . • • • • • • • . • 56
vii
LIST OF TABLES
·TABLE PAGE
f=0.100andi=5 ••••••••••• • • • • • 0 • ~ • • • 57
f = O. 150 and i = 5 • • • • • • . . . . . . . . . .. . . . . . . 58
...
f = 0.300 and i = 5 • • • • • • • • • • • • • ....... 61
f = 0.400 and i =5 • • • • • • •. • • • ~ . . . . . . . . . . •. 63
f = 0.450 and i = 5 . . . . · · · .· · · • • · · • · • · · • • · 64
. '.?
viii
TABLE PAGE
f = O. 150 and i = l 0 • • • • • • • . .. . . . . . . . . . . . . . . 68
ix
TABLE PAGE
f == 0.450 and i == 10 • • • • • • • • ~ -. •• 74
TABLE PAGE
f = 0.500 and i = 20 • • • • • • • 85
f = 0.250 and i = 30 • • • • • • • • • 90
TABLE PAGE
TABLE PAGE
TABLE PAGE
TABLE PAGE
TABLE PAGE
TABLE PAGE
TABLE PAGE
TABLE. PAGE
LIST OF FIGURES
FIGURE PAGE
6. AF I Curves, f Varying, i = 20 • • • • • • 0 • • • • 0 • 43
of AO QL • • • , • • • • • • • • • • • • • • • • • • • • • • ...... -45
CHAPTER I
INTRODUCTION
be applied continuously as the items are completed and presented for acceptance.
it according to: (l) previous inspection results, and (2) a random selection
1
procedure that gives the proper probability of selecting each item. One
of the basic and most important advantages of continuous sampling plans over
especially vital when producing costly items because: (1) defective items
wil I be. spotted sooner after they occur than if the items were accumulated
1
inspection and Quality Control Handbook (interim) H-106, Multi-Level
Continuous Sampling Procedures and Tables for Inspection by Attributes,
A Report Prepared by the Department of the Navy (Washington: Office of the
Assistant Secretary of Defense, 1958), p. l.
2
plans upon which CSP-3 is based. Dodge's initial continuous sampling plan
3
is referred to as CSP-1. At the beginning of inspection, 100 per cent of
the product is examined. When i consecutive· units are free of defects, 100
While sampling, if a defective unit is found, reversion to 100 per cent in-
to 100 per cent inspection after only one defect was too severe a restriction,
4
Dodge and Torrey devised CSP-2. The only additional stipulation under
per cent inspection will occur when two defective items are found within
2
Harold F. Dodge and Mary N. Torrey, "Additional Continuous Sampling
Inspection Plans," Industrial Quality Control, 7:7-12, March, 1951.
3
Harold F. Dodge, "A Sampling Inspection Plan for Continuous Pro-
duction," The Annals of Mathemat'ical Statistics, 14:264-79, September, 1943.
4
Dodge and Torrey, loc. cit.
3
to CSP-2. This new plan is referred to as CSP-3. When applying CSP-3 under
sampling inspection, after a defective item has been found, the next four
items are inspected. If a defect is found within the four items, 100 per cent
I. THE PROBLEM
sampling plan is called the. Average Outgoing Quality,. or AOQ. The curve
and final outgoing quality. Final outgoing quality includes those items accepted
on the basis of the sampling plan and excludes other defective items which
Were rejected on the basis of the sampling plan. In other words, if the frac-
accepted and therefore, the outgoing quality will have a low fraction defective.
items), 100 per cent inspection would. be invoked resulting in a low fraction
as per cent defective which, in the long run, will not be exceeded, regardless
5
of the quality submitted to the inspector.
The average fraction of total items inspected is o. direc;:t function of the in-
of the AOQ formula for CSP-3, (2) to apply this formula in deriving AOQ
curves for CSP-3, (3) to generate AF I curves for CS P-3, and (4) to offer
and Torrey stated that AOQ values for CSP-2 may be used to approximate
6
the CSP-3 AOQ values. In some instances, however, it would be advantageous
to use exact AOQ vo.lues for CSP-3 instead of CSP-2 approximations. One
5
Dodge, op. cit., p. 264.
6
Dodge and Torrey, op. cit., p. 10.
- --
5
plan which is based upon CSP-3 is in use at the Y-12 Plant. Since very little
hav~ n-1ore exact AOQ values for CSP-3 in lieu of CSP-2 approximations.
The information contained in this study can supply the Y-12 Plant with these
The Average Outgoing Quality Limit (AOQL) describes the worst quality
the AOQL is the maximum AOQ value for any given plan. Therefore, with
the use of the AOQ curves derived in this study, AOQL values for CSP-3 may
be determined approximately.
Another use for the AOQ curves presented in this study may be for
AFI =l - AOQ,
p
The AO Q and AF I values for CSP-3 were derived with the use of the
this study is that i = k. Therefore, with the exception of the general proof
of the AOQ formula appearing in Chapter 111, i will be used to refer to both
AOQ and AFI values. For each curve generated, the per cent defective, p,
ranged from 0.5 to 50.0 per cent in increments of 0.5 per cent. A large number
of AOQ and AFI values were then derived for various levels off and i.
sampling procedures.
7
1bid., p. 11.
7
Chapter 111 contains a full discussion and diagram for CSP-3 and gives
Chapter IV describes the manner in which the AOQ and AFI curves
CHAPTER II
I. DODGE-TYPE PLANS
tribution to other plans, the procedures for Dodge's first plan, CSP-1, shall
i consecutive units must be found free of defects before beginning the sampling
1
H. F. Dodge and M. N. Torrey, "Additional Continuous Sampling In-
spection Plans," Industrial Quality Control, 7:7-12, March, 1951.
2
1bid., pp. 9-12.
3
c. Derman, M. V. Johns, Jr.,and G. J. Lieberman, "Continuous Sampling
Procedures Without Control," The Annals of Mathematical Statistics, 30:
1175-1191, December, 1959.
9
4 5 6 7 8 9
CSP-5, H-106, MLP, MLP-r x 1, MLP-T, and MLP-r x s.
Single-Level Plans
In 1951, Dodge and Torrey expanded CSP-1 into two additional con-
tinuous sampling plans, CSP-2 and CSP-3. Under these three continuous
sampling plans, Dodge and Torrey assumed that the process was in a state
ness of all the other items produced. In the original sampling plans, Dodge
and Torrey guaranteed an AOQL with the assumption that the process was
5
1nspection and Quality Control Handbook (interim) H- l06, Multi-Level
Continuous Sampling Procedures and Tables for Inspection by Attributes, a
Report Prepared by the Department of the Navy (Washington: Office of the
Assistant Secretary of Defense, 1958) pp. 1-16.
6
Gerald J. Lieberman and Herbert Solomon, "Multi-Level Continuous
Sampling Plans," The Annals of Mathematical Statistics, 26:686-704, December,
1955.
7
C. Derman, S. Littauer, and H. Solomon, "Tightened Multi-Level Con-
tinuous Sampling Plans," The Annals of Mathematical Statistics, 28:395-404,
March, 1957.
8
1bid.
9
,,, 1bid.
10
procedures for CSP-4 and CSP-5, changes from the original Dodge plan were
made in the rule of action when a defective item was found while sampling
was in effect. Following are the steps outlining the procedures for CSP-4:
per cent inspection, and inspect only a fraction 1/k of the units,
of size k.
per cent inspection with the next item following the eliminated
10
Gerald J. Lieberman, "A Note on Dodge's Continuous Inspection
Plan," The Annals of Mathematical Statistics, 24:480--84, September, 1953.
11
The second continuous sampling plan, CSP-5, which was derived without
CSP-4 except for Step 3. Under Step 3, the procedure for CSP-5 is as follows:
If, while sampling, a defective unit is found, screen the remaining k-1 items
in the segment. After screening, begin 100 per cent inspection with the next
item produced. Continue 100 per cent inspection until i successive defect-free
units are found. These i units do not include the k-1 screened units. It is
significant to note that for a given k and i, the AOQL values for CSP-4 and
Multi-Level Plans
. too abrupt a change between 100 per cent inspection and sampling inspection,
100 per cent inspection and sampling inspection, the authors contended that
MLP required 100 per cent inspection only when the quality was very poor
and required a minimum amount of inspection.when quality was good. The MLP
sampling levels subject to the provision that transitions can only occur between
If the next i units are free of defects, proceed to the next level.
to sampling at rate f.
sampling at rater.
13
The above procedure may continue until a sampling rate off is reached.
with good items. It is significant to observe that for the special case where
plans, based upon MLP, were originated. These plans are referred to as
units . ore found while sampling at the j-th level, proceed to sample at the
revert immediately to the (j - r)-th level, if j > r, or to 100 per cent inspection
plan.
when i successive units are found free of defects while sampling at the j-th
level, sampling begins at level (j + s). If a defect is found, the some action
tightened plan, with respect to the MLP plan, only cases where r > s should
be considered.
except upon finding a defective item a reversion to 100 per cent inspection
the most strict in the sense that a reversion to 100 per cent inspection is
level of this plan very closely resembles CSP-3. The only difference between
Level of the H-106 plan and CSP-3 is that after inspecting the four units
following a sampling defect, and no defects are found within these four units,
the H-106 plan requires sampling to continue until the next i - 4 units are
to continue until i acceptable units are inspected. As in the MLP plans, the
H-106 plan provides for a reduction of the sampling rate when the process
exhibits a quality level much better than the AOQL. The H-106 plan calls
for three sampling levels with the rate of change of sampling from level to
3
level being in a geometric progression, f, f, and f • Figure 1 shows a flow
100% Level
lnspect-100%
of the units in
the order
i...11---------------------------------------.....,
produced.
'
Sampling Rate
~evel No. 1
Inspect at rate
f = 1/2 -State 1°
Resume in-
spection at
rate f-1/2
If a defective is lound while
sampling at rate f = 1/2, shift
to State lR~.-----------------iunits following
- - - - - - - If the 4 inspected units are Found
to be free of defectives, shift to
State R
1
Inspect next 4
the defe~tive
found.
State 1° . - - - - - - - - - - - - " '
- - - - - - - - - - I f a defective is found
If i inspected units ofter resuming inspection If a defective is
If i-4 inspected units at rate f= 1/2, shift to
are found to be free found among the
are found to be free 100% inspection-.---"'
of defectives, shift 4 inspected units,
of defectives, shift
to Level No. 2. shift to State 1R.
to Level No. 2.
Sampling Rate
I
State 3R
Level No. 3 1---------- If a d~fective is (ound whi.le
Inspect next 4
Inspect atrate sampling at rate rJ= 1/8, shift
units following
f3 = 1/8 State 3 o to State 3R. the defective
i-::.=_::_::....._-f"I_________ If the 4 inspected units are
Resume in-
found.
found to be free of defectives,
spection at shift to State 3° . - - - - - - - - - - - - " '
ral~ r3~ ljs 1------ - - - - - - - I f a defective is found
If i-4 inspected units are ofter resuming inspection
found to be free of defec- at rate f3= 1/8, shift to
tive" shift tn LP.vel No, 3. State 2R . - - - - - - - - - - - - - - - - - - "
FIGURE
control. In 1966, White provided several AOQL values for the H-106 plan
11
under the assumption that the process was not in a stQte of statistical control.
Thus, the UAO QL may be defined as the long-run per cent of defective items
against the worst possible quality sequence of produced items. The author
points out that in some instances the UAOQL has been found to be as much as
four times greater than the corresponding AOQL calculated under. the as-
.. .
17
more than a fixed number of defective items are found while sampling. Whenever
this fixed number of defective units is exceeded, 100 per cent inspection is
defective of the inspected units is equal to or less than the prescribed limit.
The authors state that SPA will guarantee a given AOQL whether or not the
The authors reported that although the SPA plan will guarantee the
The authors emphasize that the use of the SPC plan does not increase the
AOQL over the corresponding SPA values. However, the amount of inspection
13
1bid., pp. 43-46.
18
ments.
1/1< units and continues at this rate until a predetermined number of defective
units, m, have been observed. At this time, if the cumulative sample size, n,
if the cumulative sample size is greater than or equal to N, the plan requires
100 per cent inspection of (N - n) k units before beginning the cycle anew.
The values of m and N are mainly dependent upon the desired AOQL. As in
the plans of Wald and Wolfowitz, the big advantage of the Girshick plan is
that it holds the AOQL whether or not the process is in a state of statistical
control.
In summary, the basic difference between the Dodge-type plans and the
Wald and Wolfowitz-type plans is the concept of sampling versus initial 100
per cent inspection. Al I Dodge-type plans begin with 100 per cent inspection
quality level. The Wald and Wolfowitz-type plans initially call for sampling
14
M. A. Girshick, Technical Report No. 16, Applied Mathematics and
Statistics Laboratory, Stanford University, July, 1954.
19
inspection, with 100 per cent inspection being required only when the production
.•
20
CHAPTER Ill
VERIFICATION OF AOQ
units. If a defect is found in the four units, revert to 100 per cent
1
Harold F. Dodge and Mary N. Torrey, "Additional Continuous Sampling
Inspection Plans," Industrial Quality Control, 7:9-10, March, 1951.
21
100 per cent inspection and follow the procedure outlined in·
continue sampling until the next defect is found. When the next
mathematically, the AOQ formula for CSP-3. The formulae to follow, with
.the exception of 7 and 8, were presented in earlier CSP-1 and CSP-2 works
2
of Dodge and Torrey. The proofs and derivations of some of these formulae,
2
1bid., pp. 10-11; and H. F. Dodge, "A Sampling Inspection Plan for
Continuous Production," The Annals of Mathematical Statistics, 14:264-79,
September, 1943.
22
FIGURE 2
to CSP-3, the proofs of these formulae were not duplicated in this study.
Following are the definitions and formulae for 100 per cent inspection:
2 3 i-1 l i i
(l + q + q + q + ••• + q ) p = -1 (l-q ) p = 1-q •
-q
i
2. Since the probability of getting a failure sequence is 1-q , the probe-
3
C. C. Thigpen, "Extension of the Dodge CSP-2 Continuous Sampling
Plan to the Case i Not Equal to k" (unpublished Master's thesis, The University
of Tennessee, Knoxville, 1957), pp. 11-17.
24
i
1. .!.9_i-- h 1 •
p
1-q
a:n
defined to be ~ + i = g1•
7. The probability of a failure sequence of less than four units occurring
4
is 1-q , and is denoted by R.
8. From Definition 7, it follows that the probability of getting at least
4
four good units is q , and is denoted by R.
as follows:
25
within these four units, and then a reversion to 100 per cent
units).
10. The probability of finding k or more good sample units before finding
AF I = u + d + fv •
u+d+v
of 100 per cent inspection until it is reverted to again. The expected value
of the total number of units inspected for any given plan may be found by
considering the number of units that would be inspected in all possible cycles.
Q1R Q1R(g1+4)
Q1RP2 + Q1RP2(gl+h2+4)
Q1RQ2R + Q1RQ2R(gl+g2+2·4)
Q1RQ2RP2 + Q1RQ2RP2(gl+g2+h2+2•4)
+ ••• +
pl Ql RP2 + PlQlRP2(hl+gl+h2+4)
pl Ql RQ2RQ2RP2 + P a Ra Ra RP (h +g 2g +h +3·4)
1 1 2 2 2 1 1 2 2
+ ••• +
2 - 2 -
pl Ql R p 1 Q1R(2hl +gl +4)
2 2
pl Ql RP2 + p 1 Q lRP 2(2h tg1 +h2 +4)
2 - 2 -
pl Ql RQ2R + p 1 Q lRQ2R(2hl +gl +92 +2·4)
2 2
pl Q1RQ2RP2 +pl QlRQ2RP2(2hl+gl+g2+h2+2•4)
2 - 2 -
pl QlRQ2RQ2R + Pl Q l RQ Ra R(2h l +g l +2g +3·4)
2 2 2
2 2 .
pl Ql RQ2RQ2RP 2 +Pl Q Ra Ra RP (2h +g +2g +h +3·4)
1 2 2 2 1 1 2 2
2 - 2 -
pl QlRQ2RQ2RQ2R +Pl Ql RQ Ra RQ R(2h +g +3g +4•4)
2 2 2 1 1 2
+ ••• +
+ ••• +
28
+ ••• +
- 2 3 2 3
= Q1R9 1(1 + p1 + p1 + p 1 + •") + Q1Rp 29 1 ( l + p 1 + p 1 + p 1 + ••• ) +
- 2 3
Q1 RQ2 R9 1 ( l + p 1 + p 1 + p 1 + •'•) + ••. •
Since,
2 3 1
l + p 1 + p 1 + p 1 + ... = 1-P = Q'
1 1
therefore,
a1'R91
+ + •••
a,
=R91 + RP291 + RQ2R91 + RQ2RP29l + •••
2 2
= (R + R p 2 )9 1 + RQ2 (R + Rp 2 )9 1 + R Q2 (R + Rp 2 )9 1 + •••
2 2
=CR+ RP2)(9l + RQ291 + R Q2 91 + ••• )
= g Ra R+ g Ra RP + 2g2RQ Ra R+ 2g Ra Ra RP + •••
2 2 2 2 2 2 2 2 2 2 2
,. - 2 2 2- 3 2
=g (RQ R+R a P +2R a R+2R a P + ••• )
2 2 2 2 2 2 2
- - 2
= g RQ~(R + RP +2RQ R + 2R a P + ••• )
2 2 2 2 2
- 2 2 -
= g Ra (R + RP ) + 2g R a (R + RP ) + •••
2 2 2 2 2 2
- 2 2
= (R + RP )(g RQ + 292 R a + ••• )
2 2 2 2
. = (R + RP 2) ( RQ2 2\ 92
\Cl-RQ ) ~;
2
- 2
RRQ R P a
2 2 2
- g + g
- (1-RQ )2 2 (1-RQ )2 2
2 2
= g (RQ2 (1-RQ2))
2 (1-RQ2)2 .
+ ••.
:-
2 2
= h2QlRP2(l +pl+ pl + ••• ) + h2QlRQ2RP2(l +pl+ pl
2
+ ••• ) + h2QlRQ2RQ2RP2(l +pl+ pl + ••. ) + •••
= h2 c~=~J.
Sum of all terms containing four consecutive inspections:
+ •.•
- 2 2
= 4Q lR(l + pl + pl + ••• ) + 4Q lRP 2(1 + pl+ pl + ••• )
- . ·2
+ {4)(2)Q R.a R(l + Pl + P + ."..) + •.•
1 2 1
- . . - 2 2 2-
= 4R + 4RP 2 + (4)(2)RQ 2R + (4)(2)R a 2P 2 + (4)(3)R a 2 R
3 2
+ (3)(4)R a P + •••
2 2
-- 2 2 . 2 2
= 4R(l + 2R~ + 3R a 2 + ••• ) + 4RP 2(1 + 2RQ 2 + 3R a 2 + ••• ) + •••
·~,
32
4R 4RP2
= +---
(l-RQ2)2 (l-RQ2)2
4 (l-R) + 4R (l-Q )
2
=
(l-RQ2)2
4
= l•RQ = d =average number of times that a group of four consecutive
2 units is examined.
Therefore,
u + fv
Since,
AFI = u + d + fv
u+d+v'
and
AOQ = p (1-A_F I),
33
then,
AO Q = (l _ u + fv + d)
p u+v+d
= ( v (1-f) )·
p \u+d+v
j j ( 1 ) k+4 4 4f I
f (l-q ) + q k+4 (l-q +q )+ 114
1-q 1-q
(1-f) qi (2-qk+4) ]
AO Q = P [ i - k+4 i k+4 i k '
f (1-q )(1-q ) + q (2-q ) + 4fpq q
4
given in error by Dodge and Torrey. In the Dodge and Torrey formula, the
apparent assumption was that in the part of the cycle requiring four units
4
Dodge and Torrey, op. cit., p. 11.
34
CHAPTER IV
This chapter will describe the techniques used for obtaining the results,
tables representing 100 different AOQ and AFI curves were generated for
Choice of i, f, and p
for the variables under consideration. For example, the AOQ and AFI ~clues
generated when i exceeds 200 units would be of little use in most instances.
Also, the general shape of both the AOQ and AFI curves for values of i greater
than 200 units becomes obvious by examining AOQ and AFI curves for values of
i slightly less than 200 units. Therefore, AOQ and AFI tables were generated
using i values of 5, 10, 20, 30, 40, 50, 60, 80, 100, and 200 units.
36
Another variable for which the range was limited in this study was
f, the fraction of units sampled. The sampling i:ates used began with 5 per cent
and terminated with 50 per cent, in increments of 5 per cent. In earlier works
of Dodge and Torrey concerning CSP-1 and CSP-2, the upper limit off was
1
established at 50 per cent. In many instances a sampling rate greater than
50 per cent would be of little practical value because the cost of administering
the plan would be more than the savings realized by use of the plan.
The choice of the levels of p, the per cent defective, was dependent
upon the level of p at which the AOQL occurred. Initially, a program was
written with p varying from 0.5 to 20.0 per cent in increments of 0.5 per cent.
However, for small values of f and i, the AOQL approximations were not
was modified with p varying from 0.5 to 50.0 per cent in increments of 0.5
per cent. By using increments of p of 0.5 per cent, AOQL values could be
1
Harold F. Dodge, "A Sampling Inspection Plan for Continuous Pro-
duction," The Annals of Mathematical Statistics, 14:272, September, 1943;
and Harold F. Dodge and Mary N. Torrey, "Additional Continuous Sampling
Inspection Plans," Industrial Quality Control, 7:8, March, 1951.
37
The Program
AOQ ond AFI tables for various levels off, p, and i. The-program was written
in such a manner that AOQ ond AFI volues were generated for a given i at
various levels of f and p with only one data card. By writing the program in
this manner, AOQ and AFI values could be generated for any values off, p,
and by merely changing the data cards without altering the program itself.
errors. In order to verify the program, several AOQ and AFI values were
determined with the use of a desk calculator. The maximum difference between
the programmed values and the desk calculator values was found to be 0.000013.
This close agreement between programmed and calculated values was inter-
preted as prima .facie evidence that the AOQ and AF I values generated were
accurate.
38
and examples of AOQ and AFI curves. Also, a chart for determining f and i
AOQ Results
relationship between the incoming and outgoing. quality is based on two funda-
mental principles: (1) the AOQ values are not to be applied to an isolated
of many production runs, and (2) ar.iy defective units found are to be repaired
or replaced with good units. So, the AOQ may be thought of as the long-run
used to derive these curves as well as other AOQ values are presented in
the effect of varying i while holding f constant at 30 per cent. The important
fact concerning the AOQ curves pictured in Figure ·3 is that for a constant f,
p at which the AOQL occurs decreases. For example, when i= 5, the AOQL
is about 9 per cent and occurs at p = 24 per cent; however, when i is increased
39
10.0-
,; = 5
Y.0
..,. 8.0
c
"'
u
~ 7.0
~6.0
c
0 5.0
Cl
c
·c;
"3"' 4.0
0
"'"'
1:! 3.0
"'~
2.0
1.0
10 15 30 35
Per Cent DefectivP., p
FIGURE 3
10.0
9.0•--
...
c
8,0
" 7.0
u
~
a.
c
~6.0
0
:>
"Dl 5.0
c
·c;
-5 4.0
0
"w3.o
~"
2.0
1.0
0
5 10 25 30 35
Per Cent [)efP.r.tive, p
FIGURE 4
to 20, the AOQL decreases to about 3.2 per cent with p also decreasing to
increases. The level of p at which the AOQL occurs, however, changes only
varying and f constant. For example, when f = 25 per cent, the AOQL is about
3.6 per cent and occurs at p = 8 per cent, but when f is increased to 50 per
cent, the AO QL is reduced to about 1.8 per cent with p decreasing to only
AFI Results
is the AFI curve. These curves show the fraction of the total items inspected
Figure 5 displays a group of AFI curves with i varying and f held constant
at 30 per cent. As expected, for a constant p the total fraction of units inspected
increas·es as- i increases. Figure 6 shows a group of AFI curves with f varying
42
100
?O
..,.c 80
"u
:;;
a. 70
c
-0
2 60
u
"~
a.
50
.e
·c:
::::>
~ 40
0
c
-~u
30
E!
u..
] 20
,_0
10
0
5 10 15 20 25 30 35
Per Cent Defective, p
FIGURE 5
100
·~
-;::-
c:
Q)
u
Q;
a. 70
~
-0
2
u
Q)
a.
~
50
.t!
·c:
::>
0 40
c:
.!!
u 30
e
u..
0
0 20
I-
FIGURE 6
Curves for Deter-mining Values off and i for a Given Value of AOQL
l·n order- to obtain curves for determining values off and i for a given
value of AOQL for CSP-3, it was necessary to expand the computer program
number of AOQ curves in order to extract the AOQL values needed to plot
Figure 7 may be used to determine the most desirable combination off and
i for a given situation. For example, an AOQL of 5 per cent may be achieved
with f = 20 per cent and i = 17 units, or with f = 3 per cent and i = 41 units.
the fact that fora constantvalueof f, the AOQL values are reduced as i increases.
In addition to the curves for determining values off and i for a given
value of AOQL for CSP-3, Figure 7 also shows the corresponding curves
2
for CSP-2. An examination of the curves shows that for a given value of
45
i, Number of Units
FIGURE 7
AOQL and f, the values of i for CSP-3 are decre~ed from their corresponding
CSP-2 values. For example, if. AOQL =2 per cent and f = 10 per cent, the
value of i for CSP-3 is 68 units, whereas i = 72 units for CSP-2. Also, from
Figure 7, it is shown that the difference between the i values of CSP-2 and
CSP-3 at 2 per cent is about 4 units; the difference at 3 per cent AOQL is
about 3 units; and for AOQL values greater than 3 per cent the difference
is about 2 units.
Dodge and Torrey stated that the CSP-:3 values of i for. a given AOQL
arid f are equal to those for CSP-2 when AOQL is less than 2 per cent and are
less than those for CSP-2 by no more than 2 units when AOQL is 10 per
3 .
cent. A difference of about 2 units at 2 percentAOQLwasnotedbetween
the Dodge and Torrey study and the results of this study; otherwise, there
is close agreement between the two studies. The slight differences between
the two studies mentioned above could probably be attributed to the use of
not be significant depending upon the size of i, the cost of inspection, and the
3
1bid., p. 10.
47
CHAPTER V
This study was prompted by the need to know AOQ and AFI values for
I. SUMMARY
1
This formula is different from the formula given in error by Dodge and Torrey.
for the IBM 7090 computer in order to determine AOQ and AFlvalues. For
each set of values generated, the per cent defective, p, ranged from 0.5 to
50.0 per cent in increments of 0.5 per cent. The values of i used in this study
ranged from 5 to 200 units, and the sampling rate, f, began with 5 per cent
1
Harold F. Dodge and Mary N. Torrey, "Additional Continuous Sampling
Inspection Plans," Industrial Quality Control, 7: 10, March, 1951.
48
which was made throughout this study is that i = k. The computer program
was written in such a manner that AOQ and AFI values could be generated
for a given i value at various lev·elsof f and p with only one data card. Therefore,
AOQ and AFI values other than those appearing in this study may be generated
an examination revealed that the i values for CSP-3 were reduced by about
4 units when AOQL is 2 per cent; at 3 per cent AOQL the CSP-3 i values
were about 3 units less than the CSP-2 values; and for AOQL values greater
than 3 per cent, the i values for CSP-3 were about 2 units less than the CSP-2
values. Whether or not these differences are significant depends upon the
II. RECOMMENDATIONS
sampling inspection plans, there are several areas which could warrant further
1. Since the first level of the H-106 multi-level plan is very similar
of this nature, one could determine the values off and i for which
beneficial investigation.
·3. The CSP-3 plan states that upon finding a defective item, inspect
Some preliminary work with values other than 4 has been done
2
by Dodge and Torrey, but these works are unpublished.
ficial.
2
statement by Harold F. Dodge, personal interview.
3
c. C. Thigpen, "Extension of the Dodge CSP-2 Continuous Sampling Plan
to the Case i Not Equal to k" (unpublished Master's thesis, The University of
Tennessee, Knoxville, 1957).
>-
:::c
a..
~
<.!>
0
_J
co
co
...
52
BIBLIOGRAPHY.
Girshick, M. A., Technical Report No. 16, Applied Mathematics and Statistics
Laboratory, Stanford University, July, 1954.
APPENDIX A
DIMENSION PPllOCl,AAllOOl,AFillDOl
IT AB#C
2 READ( 5, I IPS,PE,PD,FS,FE,FO.,K
I FORMATl6FI0.3,I51
Flff S
5 P#P S
L #I
3 Q #I .-P
QK #QtHK
QP #QtH( K+4 I
QF#QiH4
A#P * ( I .- FI •QK• ( I • +QF-QP I I ( F * (I • -QK I * 11 • -QP I+ QK • ( I.• +QF-QP I +4. •F•P•Q
IK I
PP ( L I #P
AAILl#A+l.E-E
AF I IL I# I .- I A /P I
L #L +I
P #P +P 0
IF( P-PE 13, 4, 4
4 ITABllITAB+I
100 FORMAT<IHI/ IH0,42X,SHTABLE,75X,I4/IH0,34X,28HAOQ ANC AFI VALUE
IS FOR CSP-3/IH ,40X,IH#,F6.3,8H AND #,14/IH0,19X,IHP,8X,3HAOQ,8X
2,3HAFI,12X,IHP,ex,3HAOQ,8X,3HAFI/ IH)
200 FORMAT< IHI/ IH0,42X,5HTABLE,75X,I4/IH0,3~X,29HAOQ AND AFI VALUE
IS FOR CSP-3/IH ,40X,IH#,F6.3,8H AND #,I3/IH0,19X,IHP,8X,3HAOQ,8X
2,3HAFI,!2X,IHP,EX,3HAOQ,8X,3HAFI/ IHI
IFIK.GE.ICdl wRITE (6,1001 ITAB,F,K
IFIK.LT.ICOI WRITE (6,2001 ITAB,F,K
00 20L #I , 50
WR ITE ( 6, I CI I PP ( LI , AA IL I , AF I ( Ll , PP ( L+ 50 l , AA ( L +SO I , AF I I L +5 JI
I 0 I FORM AT I I 7 X, F 6. 3 , F I 1 • 6, F I I • 6 , F I .3 • 3 , F I I • 6 , FI I • 6 I
20 CONTINUE
WRITEl6, 1021
102 FORMATllH9,15XI
F#F+t=D
IF I F- FE I 5, 2, 2
E\I D
56
APPENDIX B
TABLE I
TABLE 11
TABLE Ill
TABLE IV
TABLE V
TABLE VI
TABLE VII
TABLE VIII
TABLE IX
TABLE X
TABLE XI
TABLE XII
TABLE XIII
TABLE XIV
TABLE XV
TABLE XVI
TABLE XVII
TABLE XVIII
TABLE XIX
TABLE XX
76
TABLE XXI
TABLE XXll
TABLE XXlll
TABLE XXIV
TABLE XXV
TABLE XXVI
TABLE XXVll
TABLE XXVI 11
TABLE XXIX
TABLE XXX
p AOQ AF I p AOQ A FI
TABLE XXXI
TABLE XXXll
TABLE XXXlll
TABLE XXXIV
[. [1]5 o. no.s 968 ri. 21]6 543 l).255 o. ooo 195 0.999236
[.CIC C.007822 U.217754 0.26D D .ODD 161 0.999380
C. CI 5 0. fJ I I 5 C2 (1.23.3171 D.265 D. noD 1 33 0. 99 94 97
G.C2C C.014959 0.252068 o. 270 0 .11DO I ID 11.999593
C.C25 0. fj I 31 46 0.274152 0.275 n .DDOD9 I 0.999670
C.CJC c.021023 0.299229 0.280 0.000015 0. 9997 34
[,[35 0.023550 D.327129 D.285 []. 00f1Cl6 I 0.999785
(i,(4[ 0. 02 5 6911 0.357658 D.290 o.oono5D 0 .999827
[.[45 0.027424 Cl.390574 ']. 29 5 O.DOOD41 0. 9998 61
[.[5[ o.02s122 !1.425566 0.300 D.ODOCJ34 0.9998138
[.[55 n.D29576 D.462252 o •.3D5 0 .ODl1027 0. 9<; 99 I 0
C.C6C o. [29989 0.5DOl79 0.31D o. onon22 D. 9999 28
[.[65 C.fJ29975 o. 538841 0.315 o. ormD 1 a 0. 99 99 l! '.1
[ .[7[ C.029562 o. 577692 0.328 0.DOIJO15 0.9<;9954
[.[75 0.[)28787 n.616178 D.325 o.OOODl2 0. 9<; 9963
[.[l:l[ C.027699 0.653765 0.330 D.OOODIO 0. 9<;99 71
[.CBS 0.026353 !l. 689964 0.335 D.ODOODB 0. 9999 77
[.[9[ [.Q24P.08 n.724355 o.340 D.ODCJOD6 0. 9<; 99 82
[.[95 D.!]23123 n. 756605 0.345 o.ooDoo5 0. 9999 85
L 1 OC [.[}21353 o. 786475 D.350 o.OOOOD4 0. 9999 88
C.105 C.Dl9549 n.813s20 0.355 0. OD0003 n. 99 99 91
C. I I [ C.017756 n.338584 0.360 n.oonoo3 0. 9c; 99 93
C. II 5 0.016([9 J. 860789 D,365 o.OD0002 0. 9c; 99 94
G.12[ C.Cl4338 0.8BO':il7 o. 370 o.oonOD2 0.999996
C. I 2 5 O. 0 I 2 7b2 o. 897902 0.375 O,DOOllOI 0.999997
[ .13[ C.011296 fJ. 91 3 I OB 0.380 D.OODOOI 0. 9c; 99 97
C. I :3 5 0.009947 0. 92 6 3 I 9 D.385 o. noooD 1 0. 9999 98
C.14[ C.008719 n. 93 7729 D.390 n. OOODO I 0. 9999 98
C. I 4 5 c.001608 0.947530 o. 395 D. oonoo 1 0.999999
c.1sc C.C06613 o. 95 5 91 0 0.40Cl o.nDoooo 0.999999
[.I 55 0.005728 n.963044 D. 4D5 o.onoooD 0. 99 99 99
r;. I 6C C.004945 o. 969095 0.410 0. OODDDO 0. 9999 99
[.165 C.004255 0.97421D 0.415 0. DOfJDOO • OCOO OD
C. I 7( 0.00~651 n. 978s21 0.420 (l.OOOODO .000000
C,175 O.OC3125 0.982143 0.425 o. nDnoDo • 000000
[.18( C.002668 0.985181 0,430 o.oDnooD .000000
(.105 C.002272 o. 987721 0.435 D. ODOOOO .000000
[.I 9( c.oc::1 930 0.989842 D.44D 0. ODQOOD • DODD 00
C. I 95 0.[01636 o. 991 6DB 0.445 O.DOOODD • OCOD OD
C.20( [.0[1384 0.993078 0.45[] 0. OOODDD • ocoooo
C.205 0.001169 o. 99~298 D.455 n. noooDo • oooD no
[. 21 [ fJ. 000985 0,995309 0.460 D. 00!1000 • ocoDoo
C. 2 I 5 0.000829 0.996146 0.465 D.OOIJOOD • OCOOOO
(.22( Q,OC0696 n.996838 o. 4 70 o.oooooD .OOODOD
0.225 [.0011583 n. 9971~09 0.475 n.DDDooo .oooDno
C.23( [.000488 o. 997879 D.4AO o.OODODO .000000
C.235 O.OC0407 0,998267 D.485 D.DOOOOD .ornooo
0.240 C. OC0'140 0.998585 D.490 0. 000000 .oonooD
Q.245 Q.OOD283 0.998846 0.495 D. 000000 .000000
[ .2 5[ (1.f100235 0.999061 0.5DO 0. ODOOOD .DCODOO
90
TABLE XXXV
TABLE XXXVI
TABLE XXXVll
TABLE XXXVlll
TABLE XXXIX
TABLE XL
TABLE XLI
TABLE XLll
TABLE XLill
TABLE XLIV
TABLE XLV
p "-00 AF i p AOQ A FI
101
TABLE XLVI
TABLE XLVll
TABLE XLVlll
TABLE XLIX
TABLE L
TABLE LI
TABLE Lii
TABLE Liii
TABLE LIV
TABLE LV
TABLE LVI
TABLE LVll
3
113
TABLE LVlll
TABLE LIX
TABLE LX
TABLE LXI
~
117
TABLE LXll
TABLE LXlll
TABLE LXIV
TABLE LXV
TABLE LXVI
TABLE LXVll
TABLE LXVll I
TABLE LXIX
TABLE LXX
TABLE LXXI
TABLE LXXll
128
TABLE LXXlll
TABLE LXXIV
TABLE LXXV
TABLE LXXVI
TABLE LXXVll
TABLE LXXVlll
TABLE LXXIX
135
TABLE LXXX
136
TABLE LXXXI
TABLE LXXXI I
TABLE LXXXll I
TABLE LXXXIV
TABLE LXXXV
p AOQ AF I p AOQ A FI
TABLE LXXXVI
TABLE LXXXVll
_,
143
TABLE LXXXVI 11
TABLE LXXXIX
..
145
TABLE XC
TABLE XCI
147
TABLE XCll
TABLE XClll
TABLE XCIV
TABLE XCV
. _ _:.._.__...__..._.....__...:_ ___ i
~~
151
TABLE XCVI
•
152
TABLE XCVll
"
..,,
153
TABLE XCVlll
\ I
154
TABLE XCIX
,..,
.. c • 65
c. 7(
c. 75
c. 8(
Q.QOOOOO
c.000000
o. 0[0[100
o. ocoooo
' • 000000
l • 000000
t • 'JOO ODD
' • 000000
0.415
0.420
0.425
0.430
0.000000
0.000000
0.000000
0.000000
• ocoo 00
.ocoooo
.OOQOOO
.000000
ii c. 85 [1.000000 l • 000000 0.435 0.000000 • DCOO DO
c. 9[ c.000000 ' • ooonoo o. ~4f'l 0.000000 .000000
c. 95 o. ocoooo ' • 000000 0.445 O.OOr:JOOO • 0000 00
( .2 DC c.ocoooo I • 000000 0.450 0.000000 .000000
C.205 O.IJOOOOO I • IJOOOOD n.455 n.nnnnnn .nnmnn
C.21[ o.ocoooo I • 000000 J.460 0.000000 • ocoo 00
0.215 O.OC:OOOO ! • 000000 o.~65 0.000000 • 0000 OD
C.22C c.000000 I • 000000 D.470 O.OOrJOOO .000000
c .22 5 c.000000 I • 000000 0.475 0.000000 .ocoooo
(.23( c.000000 I. 000000 0.480 0.000000 .000000
0.235 O. QOOOOO I • 000000 0.485 0.000000 .ocoooo
C.24[ c.000000 I • 000000 D.491J 0.000000 .OOOOQO
c. 24 ': C.QQOOOO l • 000000 o.495 0.000000 .ocoooo
c .2 5[ c.000000 I. 000000 o.soo 0.000000 .000000
"
<}~~\
w.
155
TABLE C
"'·
•
~