Statistical Quality Control-QC

Charts
 Statistical process control
Statistical process control (SPC) is defined as the
application of statistical techniques to control a
process. SPC is concerned with quality of
conformance. There are a number of tools available
to the quality engineer that is effective for problem-
solving process. The seven quality tools are relatively
simple but very powerful tools which every quality
engineer. The tools are: flow chart, run chart,
process control chart, check sheet, pareto diagram,
cause and effect diagram, and scatter diagram
Process
Any activity or set of activities that takes inputs
and create a product. For example: an industrial
plant takes raw materials and creates a finished
product.
 3.2 Check sheets
Check sheets are useful during data collection.
They provide a simple means for recording data
by categories and enable the analyst to
determine the relative frequency of occurrence
of the various categories of the data.
 3.3 Cause and effect diagrams
Cause and effect diagrams (CED) are simple
techniques for dissecting a problem or a
process. CED identifies all possible relationships
among input and output variables, that is, the
five categories on the following skeleton
(materials, machines, man, methods, and
environment).
 3.1 Flow charts
Flow charts are defined as the graphical
representation of the steps of in a process. Flow
charts facilitate an analysis of the steps in a
process to determine relationships between the
steps.
Flowchart for sucuk Production
 3.4 Histograms and pareto charts
A histogram is a bar chart showing the variation or
distribution of the observations from a set of data.
The pareto chart is a form of bar chart with each
bar representing a cause of a problem and always
arranged so that the most influential cause of a
problem can be easily recognized, that is, arranging
the problems in descending order. This information
is helpful in focusing attention on the highest-
priority category (Srikaeo & Hourigan, 2002).
 pareto charts

Pareto analysis is a formal technique useful

where many possible courses of action are
competing for attention.
 pareto charts
This pattern is also called the ‘80/20 rule’ and
shows itself in many ways. For example:

• 80% of sales are generated by 20% of

customers.
• 80% of Quality costs are caused by 20% of
the problems.
• 20% of stock lines will account for 80% of
the value of the stock
 pareto charts
This technique helps to
identify the top 20% of
causes that needs to be
addressed to resolve the
80% of the problems.
 History of Pareto Analysis
The Pareto effect is named after Vilfredo Pareto,
an economist and sociologist who lived from
1848 to 1923.
HOW TO USE IT ?
 The Pareto Chart
A Pareto chart is
a graphical
representation
that displays
data in order of
priority.
 This is a simple example of a Pareto diagram using sample
data showing the relative frequency of causes for errors on
websites. It enables you to see what 20% of cases are causing
80% of the problems and where efforts should be focused to
achieve the greatest improvement.
 3.5 Scatter diagrams
Scatter diagramming is a tool to study how
different variables relate to each other or how
they correlate. A scatter diagram demonstrates
the results of a series of experiments which is
conducted to document the relationship
between the variables. Table 4. represents the
mathematical models.
 3.6 Process control charts
The primary function of a control chart is to determine which
type of variation is present and whether adjustments need to be
made to the process. Variables data are those data which can be
measured on a continuous scale. Variable data are plotted on a
combination of two charts- usually an x-bar (x) chart and a range
(R) chart. The x-bar chart plots sample means. It is a measure of
between-sample variation and is used to asses the centering and
long term variation of the process.
 3.6 Process control charts
The range chart measure the within sample variation and
asses the short term variation of the process Attribute
charting is used for various types of defects, primarily by
counting the number of nonconforming units or the
nonconformities per units. The most commonly used
attribute control chart is p-chart or the percentage of
defective unit with variable sample size. The npchart is
used to monitor the percentage defective unit for constant
sample size. The c-chart is used to monitor the number of
defects on an item for constant sample size. The u-chart is
fro number of unlimited defects in variable sample size.
 SQC can be divided into three categories

1- Descriptive statistics
That is used to describe quality
characteristics and their relationship
Includes:
1)- Mean, 2)- SD, 3)- Range, 4)- Measure of
distribution of data
 Division of SQC

2- Statistical process control (SPC)

Involves inspection of a random sample of an
output of a process and deciding whether
process is producing products within the
predetermined range of characteristics
3-Acceptance sampling
It is a process of randomly inspecting a sample
of a goods and deciding whether to accept or
reject the entire lot based on the results
 Controlled Variation

 The variation that you can never eliminate totally. There

are many small, unobservable chance effects that
influence the outcome.
 This kind of variation is said to be "in control" not
because the operator is able to control the factors
absolutely, but rather because the variation is the result
of normal disturbances, called common causes, within
a process.
 This type of variation can be predicted. In other words,
given the limitations of the process, these common
causes are controlled to the greatest extent possible.
 Uncontrolled Variation

 Variation that arise at irregular intervals and for which

reasons are outside the normal functioning process,
induced by a special cause.
 Special causes include differences between machines,
different skill or concentration levels of workers,
changes in atmospheric conditions, and variation in the
quality of inputs.
 Unlike controlled variation, uncontrolled variation can
be reduced by eliminating its special cause.
 Control Charts
As long as the points remain between the lower
and uppercontrol limits, we assume that the
observed variation iscontrolled variation and
that the process is in control
 Control Chart.

• Control chart is graphical representation

of the collected information.
• It pertains to the measured or otherwise
judged quality characteristics of the items
or samples.
 What Do thEsE Charts Do.

• It detects variations in the processing and

warns if there is any departure from the
specified tolerance limits.
• It is primarily a diagnostic technique.
• It depicts whether there is any change on
the characteristics of items since the start
of the production run.
 PurPosE anD aDvantagEs.

1. A control chart indicates whether a process is in

control or out of control.
2. It determines processes variability and detects
unusual variations taking place in a process.
3. It ensures product quality level.
4. It warns in time and if the process is rectified in
time scrap percentage can be reduced.
 ComParIson of varIablE
anD attrIbutE Chart.

1. Variable charts involve the measurement of the

job dimensions whereas an attribute chart only
differentiates between a defective item and a
non-defective item.
2. Variable charts are more detailed and contain
more information as compared to attribute charts.
3. Attribute charts is based on ‘GO and NO GO’
data require comparatively bigger sample size.
4. Variables charts are expensive.
 X-bar chart.

1. It shows changes in process and is affected by

changes in process variability.
2. It is a chart for the measure of central
tendency.
3. It shows erratic or cyclic shifts in the process.
4. It detects steady progress changes, like tool
wear.
5. It is most commonly used variables chart.
 R-bar chart.

1. It controls general variability of the process

and is affected by changes in process variability.
2. It is a chart for measure of spread.
3. It is used generally along with X-bar chart.
 Control Chart

 Other types of suspicious patterns may appear in

control charts
 Control chart makes it very easy to identify visually
points and processes that are out of control without
using complicated statistical tests
 This makes the control chart an ideal tool for the
quick and easy quality control
 Variable and Attribute Charts

 Categories of control charts:

 that monitor variables and
 that monitor attributes.
 Variable charts display continuous measurements such as weight,
diameter, thickness, purity and temperature. Its statistical analysis
focuses on the mean values of such measures.
 Attribute charts differ from variable charts in that they describe a
feature of the process rather than a continuous variable. Attributes
can be either discrete quantities, such as the number of defects in a
sample, or proportions, such as the percentage of defects per lot.
 Fish canning

Records should be simple to complete, so as not to discourage their use,

and easy to interpret. In some cases it may be appropriate to record data
on a quality control chart which shows the change in some variable
against time (e.g., fill weight, as in Figure 4). The scales can be chosen to
show the change in values about the target value and also include
permissible maxima and minima (i.e., tolerances); action levels can be
included to alert operators of trends that may cause production to move
out of control. Quality control charts are well suited to continuous
operations where monitoring takes place throughout production, they
are less frequently used when the function being evaluated is a batch
operation.
 Fish canning

Figure 4 Quality control chart for recording container fill

weight
 A case study: Some applications of SPC in
traditional sucuk processing
A traditional sucuk processing was partly investigated by
SPC. The process data were retrieved from an industry and
analyzed by SPC techniques. Data were obtained over a
period of 3 months. The process variables considered were
and moisture content, pH change during ripening. In
addition to these, some and product variables (flavor,
texture, saltiness etc.) were determined from a survey
conducted in Gaziantep, Turkey. The SPC techniques
included Check sheets, Cause and effect diagrams,
Histograms and pareto charts, Scatter diagrams, Process
control charts, Failure mode and effect analysis
A case study: Some applications of SPC in
traditional sucuk processing
 4.1 Traditional sucuk processing
Sucuk dough is prepared from meat (about 18% fat) mixed with
ail fat, salt, sugar, clean dry garlic, spices, NaNO2, NaNO3
egetable oil (generally olive oil), antioxidants and antimicrobial
Meat, fat and spices are added into sucuk dough according to the
ollowingrecipe; 900 g sheep red meat (about 18% fat), 200 g tai
at, 5.5 g cumin, 1.1 g cinnamon, 11.42g allspice, 0.48 g cloves
5.5 g red pepper, 11 g black pepper, 20.76 g garlic, 4.4 g sugar, 18
gsalt and 2.1 g olive oil are used to prepare sausage dough. A
flow-chart of sucuk preparationis given in Figure 3. The meat i
minced in a meat mincer to about 1.3–2.5 cm. After thatspice
and starter culture are added and mixed with minced meat
Starter culture mixture(P. acidilactici, L. plantarum and S
arnosus) is used as a 20 g commercial culture mixture per100 kg
meat. After that nitrate/nitrite, potassium pyrophosphate
 4.1 Traditional sucuk processing
phosphate, ascorbic acid and potassium sorbate which
are dissolved in 25 ml of distilledwater, are added into
the prepared of sucuk dough. The sucuk dough is
conditioned at 0-4°C for 12 hours. The minced
refrigerated tail fat is added and mixed into the sucuk
dough.After that, the dough is filled into artificial
collagen casings, of 38 mm diameter, underaseptic
conditions, using a fillingmachine. Sucuks are fermented
and matured from 95% to60% RH and from 22 to 18 °C
during 15 days. Sucuk samples are then stored at 50% RH
and30 °C
4.2 Application of pareto analysis in traditional sucuk processing

A survey study was done to collect customer

complaints about the properties of sucuk
products. According to Pareto analysis; the
percentage of complaints are listed by the
descending order and cumulative percentages
are obtained by adding each other to
previous ones. The priority problems are being
identified by this order.
4.3 Application of control charts in traditional sucuk processing

The amount of moisture in the production of

sucuk is one of the quality parameters.
Moisture content should be around 40%. The X-
bar (x) and R-chart graphics in Table 7 are
created from the moisture contents of 5 samples
of 10 runs. The control limits drawn in both
plots were obtained by using equations given in
Table 5.