Chapter 10- Advanced Control

Charting Techniques

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 1

Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 2
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 Learning Objectives

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 3

Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 4
Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 5
Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 6
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 Example
Sample Part Type M1 M2 M3
number
1 A 105 102 103 Use the following
2 A 101 98 100 data to set up short
3 A 103 100 99 run x bar and R chart
4 A 101 104 97 using the DNOM
5 A 106 102 100
approach.
6 B 57 60 59
The nominal dimensions
7 B 61 64 63
for each part are
8 B 60 58 62
TA = 100, TB = 60
9 C 73 75 77
10 C 78 75 76
TC = 75 and TD =50
11 C 77 75 74
12 C 75 72 79
13 C 74 75 77
14 C 73 76 75
15 D 50 51 49
16 D 46 50 50
17 D 51 46 50
18 D 49 50 53
19 D 50 52 51
20 9
Chapter D
Introduction 53 Quality Control,
to Statistical 51 5th Edition by Douglas
50 C. Montgomery. 7
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Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 8
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Chapter 6 9 Introduction to Statistical
Quality Control, 6th Edition by
 Attribute Charts for Short Production Runs

All standardized attributes control charts have the centerline at zero

and the upper and lower control limits are at +3 and -3 respectively

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 10

Copyright (c) 2005 John Wiley & Sons, Inc.
 Modified and Acceptance Control Limits

• Generally used in situations where the natural

variability or “spread” of the process is considerably
smaller than the spread in the specification limits.
• The ‘six-sigma” approach to variability reduction
• In situation where six-sigma is much smaller than the
spread in the specifications (USL – LSL), the process
mean can sometimes be allowed to vary over an
internal without appreciably affecting the overall
performance of the process.

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 11

Copyright (c) 2005 John Wiley & Sons, Inc.
Statistical background

Some Key measure

Target = m
Statistical background
‘Control’ limits

+/ - 3 s

Target = m
 Statistical background
Required Tolerance
LSL USL
+/ - 3 s

Target = m
 Statistical background

Tolerance
LSL USL
+/ - 3 s

Target = m

+/ - 6 s

Six-Sigma
 Statistical background

Tolerance
LSL USL
+/ - 3 s

1350 1350
ppm ppm

Target = m

+/ - 6 s
 Statistical background

Tolerance
LSL USL
+/ - 3 s

1350 1350
ppm ppm
0.001 0.001
ppm ppm

Target = m

+/ - 6 s
 Statistical background

• Six-Sigma allows for un-foreseen

‘problems’ and longer term issues when
calculating failure error or re-work
rates
• Allows for a process ‘shift’
 Statistical background

Tolerance
LSL USL
1.5s

3.4 66803
0 ppm ppm ppm 3.4
ppm

+/ - 6s
• When this situation occurs, we can use a modified
control chart for x bar instead of the usual x bar chart.
• The modified x bar control chart is concerned only
with detecting whether the true process mean μ is
located such that the process is producing a fraction
nonconforming in excess of some specified value δ.
• In effect, μ is allowed to vary over an interval – say,
μL ≤ μ ≤ μU where μL and μU are chosen as the
smallest and largest permissible value of μ,
respectively, consistent with producing a fraction
nonconforming of at most δ.

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 20

Copyright (c) 2005 John Wiley & Sons, Inc.
 Modified and Acceptance Control Limits

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 21

Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 22
Copyright (c) 2005 John Wiley & Sons, Inc.
 Example
• Consider a normally distributed process with a target
value of the mean of 20 and standard deviation 2. the
upper and lower specifications are at 32 and 8
respectively, so that if the process is centered at the
target, Cp =Cpk = 2.0. This a process with six sigma
capability. In six sigma process it is assumed that the
mean may drift as much as 1.5 standard deviations off
target without causing serious problems.
• Suppose that we want to set up a control chart for
monitoring the mean of this six sigma process with a
sample size of n = 4.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 23
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Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 24
Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 25
Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 26
Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 27
Copyright (c) 2005 John Wiley & Sons, Inc.
 Example
Head
Sample
1 2 3 4
Number
X bar R X bar R X bar R X bar R
1 53 2 54 1 56 2 55 3
2 51 1 55 2 54 4 54 4 A machine has four
3 54 2 52 5 53 3 57 2 heads. Samples of
4 55 3 54 3 52 1 51 5 n = 3 units are
5 54 1 50 2 51 2 53 1
selected from each
6 53 2 51 1 54 2 52 2
head. The data is
7 51 1 53 2 58 5 54 1
8 52 2 54 4 51 2 55 2 shown here.
9 50 2 52 3 52 1 51 3 Set a group control
10 51 1 55 1 53 3 53 5 chart for the process
11 52 3 57 2 52 4 55 1
12 51 2 55 1 54 2 58 2
13 54 4 58 2 51 1 53 1
14 53 1 54 4 50 3 54 2
15 55 2 52 3 54 2 52 6
16 54 4 51 1 53 2 58 5
17 53 3 50 2 57 1 53 1
18 52 1 49 1 52 1 49 2
19 51 2 53 3 51 2 50 3
20 52 4 52 2 50 3 52 2

Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 28

Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 29
Copyright (c) 2005 John Wiley & Sons, Inc.
Chapter 9 Introduction to Statistical Quality Control, 5th Edition by Douglas C. Montgomery. 30
Copyright (c) 2005 John Wiley & Sons, Inc.