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Acceptance Sampling (As)

This document summarizes key concepts related to acceptance sampling (AS) including: - AS is used to inspect lots after production to determine quality level and ensure it meets requirements. - Common forms of AS include attribute and variable sampling to determine if a lot should be accepted or rejected. - Standard sampling plans like ANSI/ASQ CZ1.4 provide tables to design sampling plans based on factors like acceptable quality level, sample size, acceptance number. - Characteristics of different sampling plans like single, double, multiple can be compared using metrics like average outgoing quality, average total inspection, average sample number.

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58 views

Acceptance Sampling (As)

This document summarizes key concepts related to acceptance sampling (AS) including: - AS is used to inspect lots after production to determine quality level and ensure it meets requirements. - Common forms of AS include attribute and variable sampling to determine if a lot should be accepted or rejected. - Standard sampling plans like ANSI/ASQ CZ1.4 provide tables to design sampling plans based on factors like acceptable quality level, sample size, acceptance number. - Characteristics of different sampling plans like single, double, multiple can be compared using metrics like average outgoing quality, average total inspection, average sample number.

Uploaded by

Joji Jina
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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CHAPTER 10 ACCEPTANCE SAMPLING (AS)

INSPECTION AFTER PRODUCTION. HOWEVER - SHOULD NOT TRY TO INSPECT QUALITY INTO PRODUCT. AS IS AN AUDITING TOOL. OUR APPROACH - CONCEPTS ARE MOST IMPORTANT - FORMULAS FOR APPLICATIONS.

Basic Forms of Statistical Sampling for Quality Control Sampling to accept or reject the immediate lot of product at hand (Acceptance Sampling). Sampling to determine if the process is within acceptable limits (Statistical Process Control)

Acceptance Sampling
Purposes
Determine quality level Ensure quality is within predetermined level

Advantages
Economy Less handling damage Fewer inspectors Upgrading of the inspection job Applicability to destructive testing Entire lot rejection (motivation for improvement)

Statistical Sampling--Data
Attribute (Go no-go information)
Defectives--refers to the acceptability of product across a range of characteristics. Defects--refers to the number of defects per unit--may be higher than the number of defectives.

Variable (Continuous)
Usually measured by the mean and the standard deviation.

Acceptance Sampling--Single Sampling Plan


A simple goal Determine (1) how many units, n, to sample from a lot of size N and (2) the maximum number of defective items, c, that can be found in the sample before the lot is rejected.

DESIGNING THE PLAN


Acceptable Quality Level (AQL) = Max. acceptable percentage of defectives defined by producer. (Producers risk) = The probability of rejecting a good lot. Limiting Quality Level (LQL) = Lot Tolerance Percent Defective (LTPD) = Percentage of defectives that defines consumers rejection point. (Consumers risk) =The probability of accepting a bad lot.

Operating Characteristic Curve


1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 1 2

Probability of acceptance

= .05 (producers risk) n = 99 c=4

=.10 (consumers risk)

10 11 12

AQL

LTPD Percent defective

The OC Curve
Why is OC Curve So Important? It Provides Trade-Offs between, N, n, c, AQL, , LTPD, and . The Resulting OC Curve should achieve the desired characteristics for producer and consumer. Study the previous OC Curve or Fig. 10-2 versus the Ideal of Figure 10-1.

Example: Acceptance Sampling


A manufacturer of computers, PH Electronics purchases motherboards from a vendor, HAL Inc.. HAL has set an acceptable quality level of 1% and accepts a 5% risk of rejecting lots at or below this level. PH Electronics considers lots with 3% defectives to be unacceptable and will assume a 10% risk of accepting a defective lot. Develop a sampling plan for PH and determine a rule to be followed by the receiving inspection personnel.

DESIGN THE PLAN


For this example, determine AQL = = LTPD = =

DESIGN THE PLAN


To achieve the design of the plan AQL, , LTPD, and , specify: N = Lot Size, n = Sample Size, c = Acceptance # ANSI/ASQC, ISO, AND Military Standards exist to define the desired plan. I.E., after Defining AQL, , LTPD, and , go to these standards for n and c.

TYPES OF PLANS
TYPE A FININTE POP n>N/10 W/O Replacement Hypergeometric Dist. Eq. 10-1 Applies TYPE B LARGE POP nN/10 W/O Replacement Binomial Dist. Eq. 10.3 to 10.4

POISSON DIST.
IF n is large and the Prob. of Nonconformance Low Poisson Dist. can be used This Simplifies Formulas Eq. 10-5 Applies

GENERATING OC CURVES
OC Curves are not difficult to generate Consider Table 10-1 and the resulting Fig. 10-2. Consider the Effect of n on OC Curve, Fig. 10-3. Consider the Effect of c on OC Curve Fig. 10-4

GENERAL TYPES OF PLANS


SINGLE - TAKE A SINGLE SAMPLE, ACCEPT (A) OR REJECT (R) DOUBLE - TAKE A SAMPLE, A, R, OR INSPECT A 2ND LOT, THEN A OR R MULTIPLE - TAKE 1 TO 7 SAMPLES TO REACH A CONCLUSION

SINGLE PLAN
SIMPLER ON AVERAGE, n IS HIGHER INSPECTION COST ARE HIGHER MORE INFO FROM A SINGLE PLAN CONSIDER TABLE 10-9 N=35,000 = J, AQL=.65% n=80, IF d 1, ACCEPT, IF d>1, REJECT

DOUBLE SAMPLING PLAN


CONSIDER TABLE 10-12 N=35,000 = J, AQL=.65% n1=50, IF d 0, ACCEPT, IF d>2, REJECT, OTHERWISE INSPECT AGAIN. n2=50, IF cumulative d 1, ACCEPT, IF d>2, REJECT

MULTIPLE SAMPLING PLAN


CONSIDER TABLE 10-15 N=35,000 = J, AQL=.65% SAMPLE ACCEPT REJECT INSPECT
1 n =20 2 n =20 3 n =20 4 n =20 5 n =20 6 n =20 7 n =20 # # 0 0 1 1 2 2 2 2 3 3 3 3 0 OR 1 0 OR 1 1 1 2 2 N.A.

CHARACTERISTICS OF PLANS
AVG. OUTGOING QUALITY AVG. TOTAL INSPECTION AVERAGE SAMPLE NUMBER THESE STATISTICS BETTER DEFINE EACH PLAN AND THUS HELP US BETTER UNDERSTAND THE PLAN.

AVG. OUTGOING QUALITY


AVERAGE QUALITY LEVEL OF A LARGE NUMBER OF LOTS FROM INCOMING QUALITY OF p PERCENT DEFECTIVES. ASSUMES RECTIFICATION (i.e., REJECTED LOTS ARE 100% INSPECTED). SEE TABLE 10-2 AND FIG. 10-5. PEAK AOQ IS WORST POSSIBLE AVG QUALITY LEAVING A PROCESS. THIS IS AN IMPROTANT BENCHMARK MEASURE OF PLAN GOODNESS.

AVG. TOTAL INSPECTION


AVER. NUMBER INSPECTED PER LOT SEE TABLE 10-3 AND FIG. 10-6. CAN BE USED TO ESTIMATE THE AVERAGE INSPECTION COST.

AVG. SAMPLE NUMBER


AVER. NUMBER INSPECTED OVER MANY LOTS FOR SINGLE PLAN ASN = n. SEE TABLE 10-4 AND FIG. 10-7. ASN IS LOWER FOR DOUBLE AND MULTIPLE SAMPLING PLANS THESE PLANS DISCRIMINATE BETWEEN GOOD AND DEFECTIVE EARLIER THAN SINGLE PLAN

USING STD. PLANS


Using the previous statistics (AOQ, ATI, ASN), n, c, AQL, , LTPD, and can be selected to achieve desired results. However, standard plans exists which yield simple tables embodying commonly accepted values of AQL, , LTPD, and . Consider these plans.

STD. SAMPLING PLANS


ATTRIBUTE PLANS MIL-STD-105E = ANSI/ASQCZ1.4 =ISO2859 VARIABLE PLANS MIL-STD-414 = ANSI/ASQCZ1.9

ANSI/ASQCZ1.4
ATTRIBUTE PLANS TABLES INDEXED BY AQL VARIES FROM 1 TO 10% USUAL AQLs CRITICAL .10% MAJOR 1% MINOR 2 - 4% FOCUSES ON AQL AND PRODUCERS SEGMENT OF OC CURVE

ANSI/ASQCZ1.4
MANY TABLES EXIST FOR GENERATING OTHER OC CURVES TABLES ASSIST WITH SELECTING , LTPD, and COMMON LQL (LTPD) WITH B OF 5 OR 10%

ANSI/ASQCZ1.4
GENERAL INSPECTION LEVELS ABOUT A*100% WILL REJECTED THREE LEVELS OF CONSUMER PROTECTION (B-RISKS) I - LEAST II-BETTER III-BEST SEE FIG. 10-15

STEPS IN USING ANSI/ASQCZ1.4


SELECT AQL SELECT GEN. LEVEL (USUALLY II) SELECT LOT SIZE/CODE FROM TABLE SELECT TYPE OF PLAN (S, D, or M) IDENTIFY PLAN (C OF A AND R) CHOOSE NORMAL PLAN AND SWITCH AS NECESSARY AS DEFINED BELOW.

TYPES OF INSP. AND SWITCHING


STD. PLANS FACILITATE CONDITIONAL INSPECTIONS NORMAL - WITH NORMAL LEVEL OF DEFECTS TIGHTENED - WITH HIGH LEVEL OF DEFECTS REDUCED - WITH OUTPUT REDUCED DEFECTS SEE FIG. 10-16 - OC CURVE OF EACH

SWITCHING RULES
FIGURE 10-17 ILLUSTRATES SWITCHING RULES N > T (NORMAL TO TIGHTENED) T>N N>R R>N DISCONTINUANCE BECAUSE OF POOR QUALITY

DODGE-ROMIG PLANS
DESIGNED TO PROVIDE HIGHER AQL BY REQUIRING 100% AS RECTIFICATION STEP. THEY ARE SINGLE AND DOUBLE PLANS TABLES SET UP BY LQL AND Beta AND AVERAGE OUTGOING QUALITY LEVEL

OTHER PLANS
CHAIN SAMPLING PLANS SEQUENTIAL SAMPLING PLANS SKIP-LOT SAMPLING PLANS CONTINUOUS PRODUCTION PLANS DEMINGS kp RULE EACH HAS UNIQUE GOOD AND BAD CHARACTERISTICS

VARIABLE PLANS
MIL-STD-414 = ANSI/ASQCZ1.9 = ISO 3951 TWO TYPES OF PLANS CONTROL MEAN AND STD. DEV. CONTROL OF PROPORTION NOT MEETING SPECIFICATIONS OF THE PROCESS

ADV. OF VARIABLE PLANS


SAMPLE SIZES ARE SMALLER THAN ATTRIBUTE PLANS MORE INFO FROM VAR. PLANS THIS MORE INFO PROVIDES INSIGHTS INTO IMPROVED METHODS

DISADV. OF VAR. PLANS


EACH CHARACTERISTIC REQUIRES A SEPARATE PLAN. ADMIN. AND UNIT INSP. COSTS ARE HIGH. MEASURING INSTRUMENTS ARE MORE EXPENSIVE. MUST KNOW THE UNDERLYING DISTRIBUTION OF PROCESS.

QUESTIONS YOU SHOULD BE ABLE TO ANSWER


QUESTIONS 1 TO 5, 7, 8, AND 16 PROBLEMS 41, 42, AND 43 AS MENTIONED EARLIER THIS SEMESTER, YOU MUST BE ABLE TO GENERATE AN OC CURVE - THIS APPLIES TO THIS CHAPTER AS WELL AS PREVIOUS CHAPTERS. BE ABLE TO USE TABLES AS IN 41 - 43.

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