Quality Control

Statistical Process Control (SPC)

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Step 5 – Control

Statistical Process Control

(SPC)
Use data from the actual
process
Estimate distributions
Look at capability - is good
quality possible
Statistically monitor the process
over time
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Quality
Two types of variation

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Two Types of Variation

Common Cause Variation (low level)

Common Cause Variation (high level)

Assignable Cause Variation

• Need to measure and reduce common cause variation

• Identify assignable cause variation as soon as possible
• What is common cause variation for one person might be
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assignable cause to the other

Detect Abnormal Variation in the Process:
Identifying Assignable Causes

Process
Parameter
Upper Control Limit (UCL)
• Track process parameter over time
- average weight of 5 bags
Center Line - control limits
- different from specification limits

Lower Control Limit (LCL) • Distinguish between

- common cause variation
(within control limits)
- assignable cause variation
Time
(outside control limits)

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Statistical Process Control
Capability Conformance
Analysis Analysis

Eliminate Investigate for

Assignable Cause Assignable Cause

Capability analysis
• What is the currently "inherent" capability of my process when it is "in control"?

Conformance analysis
• SPC charts identify when control has likely been lost and assignable cause
variation has occurred

Investigate for assignable cause

• Find “Root Cause(s)” of Potential Loss of Statistical Control

Eliminate or replicate assignable cause

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• Need Corrective Action To Move Forward
 Statistical process control (SPC) involves testing a random
sample of output from a process to determine whether the
process is producing items within a preselected range.

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Statistical UCL

Process Normal Behavior

Control
LCL
(SPC) Charts 1 2 3 4 5 6 Samples
over time
UCL

Possible problem, investigate

LCL

1 2 3 4 5 6 Samples
over time
UCL

Possible problem, investigate

LCL

www.ePowerPoint.com 1 2 3 4 5 6 Samples
over time
 Control Limits are based on the Normal Curve

x
m
z
-3 -2 -1 0 1 2 3

Standard
deviation
units or “z”
units.
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Control Limits

Forming the Upper control limit (UCL) and the Lower

control limit (LCL):

UCL = Process Mean + 3 Standard Deviations

LCL = Process Mean – 3 Standard Deviations

UCL
+3σ
Process Average
- 3σ
LCL

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 Control Chart Basics

Special Cause Variation:

Range of unexpected variability

UCL
Common Cause +3σ
Variation: range of Process Mean
expected variability - 3σ
LCL

time
UCL = Process Mean + 3 Standard Deviations
LCL = Process Mean – 3 Standard Deviations
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Process Variability

Special Cause of Variation:

A measurement this far from the process average is
very unlikely if only expected variation is present

UCL
±3σ → 99.7% of
process values should
Process Mean
be in this range

LCL

time
UCL = Process Mean + 3 Standard Deviations
LCL = Process Mean – 3 Standard Deviations
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In-control Process

 A process is said to be in control when the control chart does not

indicate any out-of-control condition
 Contains only common causes of variation
 If the common causes of variation is small, then control chart can be used to
monitor the process
 If the common causes of variation is too large, you need to alter the process

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Process In Control
 Process in control: points are randomly distributed around
the center line and all points are within the control limits

UCL

Process Mean

LCL

time
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Process Not in Control

Out of control conditions:

 One or more points outside control limits

 8 or more points in a row on one side of the center line
 8 or more points in a row moving in the same direction

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Process Not in Control

One or more points Eight or more points in a

outside control limits row on one side of the
UCL center line UCL
Process Process
Average Average

LCL LCL

Eight or more points in a

row moving in the same
direction UCL
Process
Average
LCL
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
Out-of-control Processes
When the control chart indicates an out-of-control condition (a point
outside the control limits or exhibiting trend, for example)
 Contains both common causes of variation and assignable causes of
variation
 The assignable causes of variation must be identified
 If detrimental to the quality, assignable causes of variation must be removed
 If increases quality, assignable causes must be incorporated into the process
design

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 Types of Statistical Sampling

 Attribute (Go or no-go information)

 Defectives refers to the acceptability of product across a
range of characteristics.
 Defects refers to the number of defects per unit which may be
higher than the number of defectives. (good or bad, function
or malfunction, 0 or 1)
 p-chart application

 Variable (Continuous)
 Usually measured by the mean and the standard deviation.
 X-bar and R chart applications

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Example of Constructing a p-Chart:
Required Data
Sample No. of Number of
defects found
No. Samples in each sample

1 100 4
2 100 2
3 100 5
4 100 3
5 100 6
6 100 4
7 100 3
8 100 7
9 100 1
10 100 2
11 100 3
12 100 2
13 100 2
14 100 8
15 100 3

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 Statistical Process Control Formulas:
Attribute Measurements (p-Chart)
Given: T o ta l N u m b e r o f D e fe c tiv e s
p =
T o ta l N u m b e r o f O b s e rv a tio n s

p (1 - p) UCL = p + z sp
sp =
n
LCL = p - z sp

Where p is the fraction defective, s p is the

standard deviation, n is the sample size, z is
the number of standard deviations for a
specific confidence. Typically, z  3 (99.7
percent confidence) or z  2.58 (99 percent
confidence) Compute control limits:
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 Example of Constructing a p-chart: Step 1

Sample n Defectives p
1. Calculate the 1 100 4 0.04
sample proportions, 2 100 2 0.02
3 100 5 0.05
p (these are what 4 100 3 0.03
can be plotted on the 5 100 6 0.06
6 100 4 0.04
p-chart) for each 7 100 3 0.03
sample 8 100 7 0.07
9 100 1 0.01
10 100 2 0.02
11 100 3 0.03
12 100 2 0.02
13 100 2 0.02
14 100 8 0.08
15 100 3 0.03
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 Example of Constructing a p-chart: Steps 2&3

2. Calculate the average of the sample proportions

55
p = = 0.036
1500
3. Calculate the standard deviation of the
sample proportion

p (1 - p) .036(1- .036)
sp = = = .0188
n 100
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 Example of Constructing a p-chart: Step 4

4. Calculate the control limits

UCL = p + z sp
LCL = p - z sp

.036  3(.0188)

UCL = 0.0924
LCL = -0.0204 (or 0)
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 Example of Constructing a p-Chart: Step 5

5. Plot the individual sample proportions, the average

of the proportions, and the control limits

0.1
0.09
0.08
0.07
0.06 p
0.05 UCL
0.04 LCL
0.03
0.02
0.01
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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Some notes for p-charts

 The size of the sample must be large enough to allow counting of the
attribute. A rule of thumb when setting up a p chart is to make the
sample large enough to expect to count the attribute twice in each
sample.
 The assumption is that the sample size is fixed. If the sample size varies,
the standard deviation and upper and lower control limits should be
recalculated for each sample.

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Some notes for p-charts

T o ta l N u m b e r o f D e fe c tiv e s
p =
T o ta l N u m b e r o f O b s e rv a tio n s
UCL = p + z sp
LCL = p - z sp

p (1 - p)
nn sp =
n
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 Sample n Defectives p
1 100 4 0.04
2 50 2 0.04
3 100 5 0.05
4 100 3 0.03
5 75 6 0.08
6 100 4 0.04
7 100 3 0.03
8 50 7 0.14
9 100 1 0.01
10 100 2 0.02
11 100 3 0.03
12 100 2 0.02
13 100 2 0.02
14 100 8 0.08
15 100 3 0.03
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 Sample n Defectives p
1 100 4 0.04
2 50 2 0.04
3 100 5 0.05
4 100 3 0.03
5 75 6 0.08
6 100 4 0.04
7 100 3 0.03
8 50 7 0.14
9 100 1 0.01
10 100 2 0.02
11 100 3 0.03
12 100 2 0.02
13 100 2 0.02
14 100 8 0.08
15 100 3 0.03
n-bar sum defects p-bar
91.66666667 55 0.04
sp
0.020467
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UCL 0.101401806
LCL -0.021401806
0.16
0.14
0.12
0.1
p
0.08 UCL
LCL
0.06
0.04
0.02
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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 Process Control With Variable
Measurements: Using X-bar and R Charts

 Size of the samples (keep the sample size small, 4-5 is preferred)
 the sample needs to be taken within a reasonable length of time
 the larger the sample, the more it costs to take.
 Number of samples (25 or so samples is suggested to set up the
chart)
 Frequency of samples

 Control limits

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Example of x-bar and R Charts:
Required Data
Sample Obs 1 Obs 2 Obs 3 Obs 4 Obs 5
1 10.68 10.689 10.776 10.798 10.714
2 10.79 10.86 10.601 10.746 10.779
3 10.78 10.667 10.838 10.785 10.723
4 10.59 10.727 10.812 10.775 10.73
5 10.69 10.708 10.79 10.758 10.671
6 10.75 10.714 10.738 10.719 10.606
7 10.79 10.713 10.689 10.877 10.603
8 10.74 10.779 10.11 10.737 10.75
9 10.77 10.773 10.641 10.644 10.725
10 10.72 10.671 10.708 10.85 10.712
11 10.79 10.821 10.764 10.658 10.708
12 10.62 10.802 10.818 10.872 10.727
13 10.66 10.822 10.893 10.544 10.75
14 10.81 10.749 10.859 10.801 10.701
15 10.66 10.681 10.644 10.747 10.728
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Example of x-bar and R charts: Step 1. Calculate sample
means, sample ranges, mean of means, and mean of
ranges.
3 10.78 10.667 10.838 10.785 10.723 10.759 0.171
4 10.59 10.727 10.812 10.775 10.73 10.727 0.221
5 10.69 10.708 10.79 10.758 10.671 10.724 0.119
6 10.75 10.714 10.738 10.719 10.606 10.705 0.143
7 10.79 10.713 10.689 10.877 10.603 10.735 0.274
8 10.74 10.779 10.11 10.737 10.75 10.624 0.669
9 10.77 10.773 10.641 10.644 10.725 10.710 0.132
10 10.72 10.671 10.708 10.85 10.712 10.732 0.179
11 10.79 10.821 10.764 10.658 10.708 10.748 0.163
12 10.62 10.802 10.818 10.872 10.727 10.768 0.250
13 10.66 10.822 10.893 10.544 10.75 10.733 0.349
14 10.81 10.749 10.859 10.801 10.701 10.783 0.158
15 10.66 10.681 10.644 10.747 10.728 10.692 0.103

Averages 10.728 0.220400

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Example of x-bar and R charts: Step 2. Determine Control
Limit Formulas and Necessary Tabled Values

 E.L.Grant and R.Leavenworth computed a table, where

n is the number of observations in subgroup, A2 is the
factor for X-bar chart, D3 and D4 are factors for R chart.

x Chart Control Limits

n A2 D3 D4
UCL = x + A 2 R 2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
LCL = x - A 2 R 5 0.58 0 2.11
6 0.48 0 2.00
R Chart Control Limits 7 0.42 0.08 1.92
8 0.37 0.14 1.86
UCL = D 4 R 9 0.34 0.18 1.82
10 0.31 0.22 1.78
LCL = D 3 R
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Example of x-bar and R charts: Steps 3&4. Calculate x-bar
Chart and Plot Values

UCL = x + A 2 R  10.728 - .58(0.2204 ) = 10.856

LCL = x - A 2 R  10.728 - .58(0.2204 ) = 10.601

10.900

10.850
UCL
10.800

10.750
Means

10.700
Central
10.650
Line
10.600 LCL
10.550
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
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 Example of x-bar and R charts: Steps 5&6. Calculate
R-chart and Plot Values

UCL = D 4 R  (2.11)( 0.2204 )  0.46504

LCL = D 3 R  (0)( 0.2204 )  0

0 .8 0 0

0 .7 0 0

0 .6 0 0

0 .5 0 0
UCL
R 0 .4 0 0

0 .3 0 0

0 .2 0 0

0 .1 0 0 R
0 .0 0 0
LCL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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The R Chart

 Monitors variability in a process

 The characteristic of interest is measured on a numerical scale
 Is a variables control chart
 Shows the sample range over time
 Range = difference between smallest and largest values in the subgroup

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 The R Chart
1. Find the mean of the subgroup ranges (the center line of the
R chart)
2. Compute the upper and lower control limits for the R chart
3. Use lines to show the center and control limits on the R chart
4. Plot the successive subgroup ranges as a line chart

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The X Chart

 Shows the means of successive subgroups over time

 Monitors process average
 Must be preceded by examination of the R chart to
make sure that the variation in the process is in control

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The X Chart

 Compute the mean of the subgroup means (the center line of

the X chart)
 Compute the upper and lower control limits for the X chart
 Graph the subgroup means
 Add the center line and control limits to the graph

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