STATISTICAL QUALITY CONTROL

1
Control Charts for
Variables

2
Introduction
• Variables are those quality characteristics that are measurable on a
numerical scale
– Example for variables are length, tensile strength, viscosity, etc.
• It is necessary to control the mean value of a quality characteristic
as well as its variability
• Mean gives an indication of the central tendency of a process
• Variability provides an idea of the process dispersion
• When there is a change in process mean or process standard
deviation, the proportion of parts that do not meet specification
increases
• Control chart aid in detecting such changes in process parameters
• Variables provide more information than attributes
• Attributes deal with qualitative information, whether an item is non-
conforming or not ok, but didn’t show the degree to which a quality
characteristic is non conforming
• Eg. 40 ± 0.5. Both 40.6 and 42 are nonconforming

3
Introduction – Contd..
• Cost of obtaining variable data is usually higher than for
attributes because
– Attribute data is collected by means such as go / no-go gages,
which are easier to use and hence less costly also
– Total cost of data collection is the sum of two costs – fixed and
variable cost
– Fixed cost include cost of inspection equipment, while variable
cost include cost of inspecting
– More the parts inspected, higher the variable costs and fixed
cost is unaffected
– With the use of automated devices for measurement, the
differences in variable unit cost between variable and attribute
may not be much, but fixed cost may increase
– Attribute chart for the proportion of non-conforming may
represent the general operational level of the plant but not the
variable chart

4
Control chart for Mean and Range
• Development of chart
– Step 1: Using a pre-selected scheme and sample size record
measurements of the selected quality characteristic
– Step 2: For each sample, calculate the sample mean and range
(Formulae)
– Step 3: Obtain and draw the centre line and trial control limit
• Find the mean of all sample mean (Formula)
• Find the mean range of all samples (Formula)
– 3σ control limits for Mean chart is given by X  3  X  3 ˆ
X
– For normally distributed population, the distribution of the n
statistic’s relative range (w) = R / σ and it is dependent on
sample size ‘n’ .
– Factors for computing center line and the three sigma control
limits given by American Society of Testing and Materials
(ASTM)
5
Control chart for Mean and Range
– Contd..
– Mean of w is given by d2
– Estimate of the process standard deviation is ˆ R /d 2
R R
– UCL = X  3  X  A2 R LCL = X3  X  A2 R
d2 . n d2 . n
– Control limits for R chart is given by R 3 R
– R = σ.w and hence σR = σ. σw
– Mean of σw is given as d3 and we also know
that ˆ R /d 2 Hence  R  R .d 3
d2
– UCL = D4 R
– LCL = D3 R
6
3-Sigma Control Chart Factors

Sample size X-chart R-chart

n A2 D3 D4
2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86

7
Control chart for Mean and Range
– Contd..
• Step 4: Plot the values of the range on the chart and find whether
points are in statistical control
– An R chart is analysed before X-bar chart to determine out of control
situations, as R chart reflect process variability, which should be
brought to control.
– If R chart shows out of control, then the X-bar chart is meaningless
• Delete the out of control points for which remedial action has been
taken to remove special causes and the remaining samples are
used to obtain revised limits
• A point of interest is about the point that falls below the LCL, when
LCL is greater than zero
• These points are desirable because they indicate unusually small
variability, within the sample and might be due to special causes
• This condition helps in further reducing our process variability
• Implement the control chart

8
 Example: Control Charts for Variable Data
Contaminant (ppm)
Sample 1 2 3 4 5 X R
1 5.02 5.01 4.94 4.99 4.96 4.98
0.08
2 5.01 5.03 5.07 4.95 4.96 5.00
0.12
3 4.99 5.00 4.93 4.92 4.99 4.97
0.08
4 5.03 4.91 5.01 4.98 4.89 4.96
0.14
5 4.95 4.92 5.03 5.05 5.01 4.99
0.13
6 4.97 5.06 5.06 4.96 5.03 5.01
0.10 9
7 5.05 5.01 5.10 4.96 4.99 5.02
 Example: Control Charts for Variable Data

Sample 1 2 3 4 5 X R
1 5.02 5.01 4.94 4.99 4.96 4.98
0.08
2 5.01 5.03 5.07 4.95 4.96 5.00
0.12
3 4.99 5.00 4.93 4.92 4.99 4.97
0.08
4 5.03 4.91 5.01 4.98 4.89 4.96
0.14
5 4.95 4.92 5.03 5.05 5.01 4.99
0.13
6 4.97 5.06 5.06 4.96 5.03 5.01
0.10 10
7 5.05 5.01 5.10 4.96 4.99 5.02
 Calculation
From Table above:
• Sigma X-bar = 50.09
• Sigma R = 1.15
• m = 10
Thus;
• X-Double bar = 50.09/10 = 5.009 ppm
• R-bar = 1.15/10 = 0.115 ppm
Note: The control limits are only preliminary with 10 samples.
It is desirable to have at least 25 samples.
11
 Trial control limit
• UCLx-bar = X-D bar + A2 R-bar =
5.009 + (0.577)(0.115) = 5.075
ppm
• LCLx-bar = X-D bar - A2 R-bar = 5.009
- (0.577)(0.115) = 4.943 ppm

• UCLR = D4R-bar = (2.114)(0.115) =

0.243 ppm
• LCLR = D3R-bar = (0)(0.115)
n ==
5 0
ppm
3-Sigma Control Chart Factors

Sample size X-chart R-chart

n A2 D3 D4
2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86

13
 X-bar Chart
5.10
UCL
5.08
5.06
5.04
X bar

5.02
5.00 CL
4.98
4.96 LCL
4.94
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup

14
 R Chart
0.25 UCL

0.20

0.15
Range

CL

0.10

0.05
LCL
0.00
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup

15
 Given Data
Subgro
up X1 X2 X3 X4 X-bar UCL-X-bar X-Dbar LCL-X-bar R UCL-R R-bar LCL-R

1 6.35 6.4 6.32 6.37 6.36 6.47 6.41 6.35 0.08 0.20 0.0876 0
2 6.46 6.37 6.36 6.41 6.4 6.47 6.41 6.35 0.1 0.20 0.0876 0
3 6.34 6.4 6.34 6.36 6.36 6.47 6.41 6.35 0.06 0.20 0.0876 0

4 6.69 6.64 6.68 6.59 6.65 6.47 6.41 6.35 0.1 0.20 0.0876 0
5 6.38 6.34 6.44 6.4 6.39 6.47 6.41 6.35 0.1 0.20 0.0876 0
6 6.42 6.41 6.43 6.34 6.4 6.47 6.41 6.35 0.09 0.20 0.0876 0
7 6.44 6.41 6.41 6.46 6.43 6.47 6.41 6.35 0.05 0.20 0.0876 0
8 6.33 6.41 6.38 6.36 6.37 6.47 6.41 6.35 0.08 0.20 0.0876 0
9 6.48 6.44 6.47 6.45 6.46 6.47 6.41 6.35 0.04 0.20 0.0876 0
10 6.47 6.43 6.36 6.42 6.42 6.47 6.41 6.35 0.11 0.20 0.0876 0
11 6.38 6.41 6.39 6.38 6.39 6.47 6.41 6.35 0.03 0.20 0.0876 0
12 6.37 6.37 6.41 6.37 6.38 6.47 6.41 6.35 0.04 0.20 0.0876 0
13 6.4 6.38 6.47 6.35 6.4 6.47 6.41 6.35 0.12 0.20 0.0876 0
14 6.38 6.39 6.45 6.42 6.41 6.47 6.41 6.35 0.07 0.20 0.0876 0
15 6.5 6.42 6.43 6.45 6.45 6.47 6.41 6.35 0.08 0.20 0.0876 0
16 6.33 6.35 6.29 6.39 6.34 6.47 6.41 6.35 0.1 0.20 0.0876 0
17 6.41 6.4 6.29 6.34 6.36 6.47 6.41 6.35 0.12 0.20 0.0876 0

18 6.38 6.44 6.28 6.58 6.42 6.47 6.41 6.35 0.3 0.20 0.0876 0
19 6.35 6.41 6.37 6.38 6.38 6.47 6.41 6.35 0.06 0.20 0.0876 0
20 6.56 6.55 6.45 6.48 6.51 6.47 6.41 6.35 0.11 0.20 0.0876 0

21 6.38 6.4 6.45 6.37 6.4 6.47 6.41 6.35 0.08 0.20 0.0876 0
22 6.39 6.42 6.35 6.4 6.39 6.47 6.41 6.35 0.07 0.20 0.0876 0
23 6.42 6.39 6.39 6.36 6.39 6.47 6.41 6.35 0.06 0.20 0.0876 0
24 6.43 6.36 6.35 6.38 6.38 6.47 6.41 6.35 0.08 0.20 0.0876 0
25 6.39 6.38 6.43 6.44 6.41 6.47 6.41 6.35 0.06 0.20 0.0876
16 0
 Calculation
From Table :
• Sigma X-bar = 160.25
• Sigma R = 2.19
• m = 25
Thus;
• X-double bar = 160.25/29 = 6.41 ppm
• R-bar = 2.19/25 = 0.0876 ppm

17
 Trial control limit
• UCLx-bar = X-double bar + A2R-bar =
6.41 + (0.729)(0.0876) = 6.47 ppm
• LCLx-bar = X-double bar - A2R-bar =
6.41 – (0.729)(0.0876) = 6.35 ppm
• UCLR = D4R-bar = (2.282)(0.0876) =
0.20 ppm
• LCLR = D3R-bar = (0)(0.0876) = 0
ppm
18
For A2, D3, D4: see Appendix, n = 4.
X-bar Chart

19
R Chart

20
 Example 1
• Consider a process by which feeders are
manufactured. Samples of size 5 are
randomly selected from the process, and
the diameter values (in mm) of the feeder
are measured. The data values are given
in table, as are the sample mean X(bar)
and range R.

21
Example 1

22
23
Interpretation and Inferences
• Caution
– sample plots may fall outside the limit, even though no special
causes are present
– Reason being that desirable standards may not be consistent
with the process conditions
– It is easy to meet a desirable target value for process mean
than it is for process variability (Range)
• Interpretation
– Difficult and needs thorough knowledge about different process
parameters on quality characteristic
– When R-chart is brought to control, many special causes for the
Xbar chart are eliminated as well
– Xbar chart monitors the centring of the process and a jump
indicates process average has jumped

24
Control chart patterns and
corrective action
• A ‘non-random identifiable’ pattern in the plot of a chart might
provide reason to look for special cause in a process
• There are about 15 typical patterns identified by Western
Electric company and 9 of them have been discussed here
• Natural Patterns
– No identifiable arrangement of the plotted point exists
– No point fall outside the control limits
– Majority of the points are near the centre line and few points close to
control limits
– Demonstrates the presence of stable system of common causes
• Sudden shifts in the level
– Can occur because of changes intentional or otherwise in process
settings (temperature, depth of cut etc.)
– New operators, new equipment, new vendors, new methods are the
reasons for sudden shift

25
Natural Pattern

26
Sudden shifts

27
Control chart patterns and
corrective action – Contd..
• Gradual shifts in the level
– Occurs when a process parameter changes gradually over a period
of time
– X-bar chart might exhibit such a shift because of incoming quality of
raw materials that would have changed with time
– Change in style of supervision, maintenance program etc.
– R-chart might exhibit such a shift because of new operator,
decrease in worker skill due to fatigue etc.
• Trending pattern
– Differs from gradual shift in level, that trends do not stabilize or
settle down
– Represents changes that steadily increase or decrease
– For X-bar chart, can be due to tool wear, deterioration of equipment,
build up of debris on jigs and fixtures, change in temperature etc.
– For R-chart, it may be due to improvement in operator skill due to on
job training, decrease due to fatigue etc.

28
Gradual shifts

29
Trending pattern

30
Control chart patterns and
corrective action – Contd..
• Cyclic patterns
– Characterized by repetitive periodic behaviour in the system
– Cycles of low and high points will appear on the control chart
– X-bar chart may exhibit because of rotation of operators,
periodic change of temperature or humidity, seasonal
variation in incoming components
– R-chart may exhibit this pattern because of operator fatigue
and getting energized in subsequent breaks, a difference
between shifts, periodic maintenance of equipments etc.
– If samples are taken so infrequently, only the high and low
points will be represented
• Wild patterns
– Can be classified as Bunches and Freaks
– Cluster of several observation that are different from other
points and special causes are associated with these points

31
Cyclic patterns

32
Control chart patterns and
corrective action – Contd..
• Wild patterns – Contd.
– Freaks
• are caused by external disturbances that influence one or more
samples
• They are points that are too small or large with respect to control
limits and fall outside the control limits and hence easy to
identify
• Care should be taken that no measurement or recording error is
associated with that freak point
• Some special causes may be sudden, very short-lived power
failures, use of new tool for a brief test period etc.
– Bunches
• Cluster of several observation that are different from other points
• Possible causes may be use of new vendor, use of a different
machine, use of new operator etc., for a short time period.

33
Freak pattern

34
Bunching pattern

35
Control chart patterns and
corrective action – Contd..
• Mixture patterns
– Effect of two or more population in the sample
– Characterized by points that fall near the control limits, with
absence of points near the centre line
– Might be due to material from two different vendors, different
production method, two or more machine being represented
• Stratification patterns
– Is also due to presence of two or more population distribution
– Output is combined or mixed and samples are selected from
it
– Majority of the points fall close to centre line, with very few
points near the control limits
– Can be misinterpreted as indicating unusually good control

36
Mixture patterns

37
Stratification pattern

38
Control chart patterns and
corrective action – Contd..
• Interaction patterns
– Occurs when the level of one variable affects the
behaviour of other variables associated with the quality
characteristic
– Interaction pattern can be detected by changing the
scheme for rational sampling
– Example, low pressure and low temperature may
produce a desirable effect on output characteristic
– Effective sampling method would involve controlling the
temperature at several high values and then
determining the effect of pressure on output
characteristic for each temperature value

39
Interaction pattern

40
 Chapter - 8

Control Charts for

Attributes
41
Introduction
• Attribute
– It is a quality characteristic for which a numerical value is not
specified
– It is measured on a nominal scale, i.e., it does or does not meet
certain guidelines
– It is categorized according to the scheme or levels
• Nonconformity
– A quality characteristic that does not meet certain standards or
specification is said to be non conformity
– Eg. Length of a bar 40 ± 0.5. Both 40.6 and 42 are
nonconformity
• Nonconforming item
– A product with one or more non-conformities such that it is
unable to meet the intended standards and is unable to function
as required
– It is possible to have several non-conformities on a product
without being classified as a nonconforming item 42
Introduction – Contd..
• Types of charts
– Based on binomial distribution
• Proportion of non conforming items (p-chart)
• No. of non conforming items (np-chart)
– Based on Poisson distribution
• Total number of non conformities items (c-chart)
• Non conformities per unit chart (u-chart)
– Used in situation where the size of the sample varies from
sample to sample
– Based on weights
• Chart for Demerit per unit (U-chart)
– Deals with combining nonconformities on a weighted basis,
based on the severity of the non conformity

43
Advantages and Disadvantages of
Attribute charts
• A variable quality characteristic can be measured as an
attribute, because of limited time, money, worker
availability etc., if attribute information is alone sufficient
• Advantages
– For a given product, if variable charts are used for each of its
quality characteristic, no. of charts constructed will be very high
and in such case, attribute control chart provides overall quality
information
– Can be used to summarize information about several
components of a product
– Attributes are encountered at all levels of an organization
(company, plant, department, operator level etc), but variable
charts are used at lower only (machine level)
– Provides effective information to top management
– Helps in going from the general to more focussed level

44
Advantages and Disadvantages of
Attribute charts – Contd..
• Disadvantages
– Attribute information does not indicate the degree to which specification
are met or not met, but variable provide more information a process and
performance
– Variable plots provide more information on the potential causes and
hence makes the identification of remedial action easier for out of
control situation
– Variable chart can forewarn, when the process goes out of control, while
attribute does not detect a lack of control, until the process parameters
are changed
– When specification limit are equal or tighter than the inherent variability
of the process, attribute chart indicates out of control process
– Attribute chart requires larger sample size, to ensure adequate
protection against the certain level of process changes
• If no historical information is available, attribute control charts
are used first and once problem area is identified, it is
replaced by a variable control chart

45
Preliminary decisions
• Level
– Decide on the level at which it has to used – plant, department, operator
etc.
• No. of quality characteristic
– Chart for single quality characteristic, multi quality characteristic or for a
product
– Depends on no. of potential quality characteristic, no. of products
produced, cost and time required for inspection
• Sample size
– Should be large enough to allow non conformities or non conforming
items to be observed in the sample
– Eg. Non conformance rate is 2.5%, while sample size is 25, average no.
of non conforming per sample is 0.625
– Small sample size leads to misleading inference
• Nonconformity
– What will be considered a nonconformity should be defined
– It depends on product, functional use and customer needs

46
Preliminary decisions – Contd..
• Frequency of sampling
– Depends on production rate, cost of sampling etc.
• Choice of measuring instruments
– Accuracy of the instruments directly influences the quality of the
data calculated
– Should be calibrated and tested
– Characteristic being controlled, the desired degree of
measurement precision, both impacts the selection
• Design of data recording forms
– Includes part name, sample number, date, time, raw values of
data, no. of non conforming items, operator name, machine,
gauge, comments etc.
• One, two or three-sigma zones and rules related to it are
not used because the underlying theory in non-normal
47
Control chart for proportion
nonconforming (p-chart)
• p-chart is one of the most versatile chart
• Used to control the acceptability of single quality characteristic or a
whole product
• Also used to measure the quality of an operator, machine,
department or entire plant and also the performance of a CEO
• Provides fair indication about the general state of the process based
on the average quality level of the proportion non conforming
• It can act as a source of locating problems and provides information
for improving product quality
• Based on binomial distribution
• Assumptions
– Probability of obtaining a non conforming item must be constant
– Sample must be identical
– Samples are independent, but is not valid for samples
manufactured in groups (Eg. Steel ingots – batch production)

48
Control chart for proportion
nonconforming (p-chart) – Contd..
• No standard given
– Proportion of non conforming is specified, it must be estimated
from the sample information x
ˆ
p
n
– Average of these individual sample proportions non conforming
is used as the centre line g g

g = no. of samples  pˆ i  xi
xi = no. of non conforming items
CL p  p  i 1
 i 1
g ng
– Variance is calculated from
p (1  p )
Var ( pˆ ) 
n
– True value of ‘p’ is not known, hence value of p is used as an
estimate
– Control limits are given by UCL p  3 . p (1  p )
p
n
p (1  p ) 49
LCL p p  3 .
n
 Question
Twenty five samples of size 50 are chosen from a plastic-injection molding
Machine producing small containers. The number of non-conformaing
containers for each sample is shown in Table, as is the proportion non-
confirming for each sample. Find out whether the process is under
statistical control or not.

50
51
52
53
54
55
56
57
58
59
Control chart for proportion
nonconforming (p-chart) – Contd..
• Variable sample size
– Size varies due to rate of production, lack of inspection personnel,
change in unit cost of inspection
– Change in sample size results in change in control limits though the
centre line remains constant
– Sample size increases, control limits become narrower
– Control limits for individual sample sizes are given by
p (1  p )
UCL p  3 .
ni
p (1  p )
LCL p  3 .
ni
– If lower limit turns out to be negative, then LCL is taken as zero
• Control limits for representative sample sizes
– Based on those sizes that occur more frequently
– Should span the range of sample sizes

60
61
62
63
64
65
Chart for No. of nonconforming
items (np-chart)
– Based on the count of no. of nonconforming items in sample
– Operator may feel easy to use this chart
– Assumptions used in p-chart is applicable for this chart also
• Drawback of np-chart
– If sample size changes, the centre line and control limit
changes, and hence inference becomes difficult
• No standard given g

– Centre line is given by

x i
CLnp np  i 1
xi = no. of non-conforming for ith sample g
g = no. of samples
n = sample size
– Standard deviation of number of nonconforming is   np (1  p )
np
– Control limits are given by
UCL np  3 . np (1  p )
np

LCLnp np  3 . np (1  p ) 66
67
68
Control chart for the number of
nonconformities (c-chart)
• Nonconformity
– Defined as the quality characteristic that does not meet some
specification
– Non conforming item has one or more nonconformities that make it non
functional
• Introduction
– A c-chart is used to track the total no. of non conformities in a sample
of constant size
– When the sample size varies, u-chart is used to track the no. of non
conformities per unit
– Size of the sample is also called as “Area of Opportunity”
– Area of opportunity may be a single or multiple units of a product or it
can also be continuous
– If average no. of nonconformities per unit and area of opportunity are
small, then most observations show zero non conformities, which is
misleading and hence it is beneficial to choose large area of
opportunity

69
Control chart for the number of
nonconformities (c-chart) – Contd..
• Introduction – contd..
– Occurrence of nonconformities is assumed to follow a ‘poisson
distribution’
– Poisson distribution is well suited to model the number of
events that happen over a specified amount of time, space or
volume
• Assumptions
– Opportunity for the occurrence of non conforming should be
large
– Average no. of non conformities per unit must be small
– Occurrences of non conformities must be independent of each
other
– Each sample should have an equal likelihood of the occurrence
of non conformities
– Eg. Different screw drivers are used to tighten the screws in a
product, the opportunity for change in torque will vary and 70
hence should not be used
71
72
Control chart for the number of
nonconformities per unit (u-chart)
• Introduction
– Used, when the area of opportunity changes
– Used, when companies inspect all items produced or services
rendered, for the presence of non conformities
– Generally output per production run vary, because of fluctuating
supplies of labour, machines, raw material and hence no. of
units inspected changes, thus resulting in varying sample size
– The control limits change as the sample size varies, but centre
line remains same
• No standard given
– When sample size varies, the no. of non conformities per unit
for the ith sample is given by ui = ci / ni
– ci is the no. of non conformities in the ith sample
– ni is the size of ith sample and it may not be a integer

73
Control chart for the number of
nonconformities per unit (u-chart) – Contd..
– Average no. of nonconformities per unit and the
control limits are given by
u
g
UCLu  u  3 .
c
i 1
i ni
CLu  u  g u
LCLu u  3 .
n i ni
• As the sample sizes increases, control limits
i 1

draws closer
• If ni = 1, all formula will be equal to that of c -
chart

74
75
76
77
78
Charts for Demerits per unit
(U-chart)
• ‘c’ and ‘u’ chart treat all types of non conformities equally,
regardless of their degree of severity
– Eg. Monitor A has trouble in colour while Monitor B has 5
scratch marks on its surfaces – here Monitor A defect is more
serious than Monitor B’s
• An alternative approach is to assign “weights” to non
conformities according to their relative degree of severity
• The quality rating system, which rates demerits / unit is
called U-chart and is often helpful in service applications
• Classification of non conformities
– Classification is based on degree of seriousness, ANSI standard
A3 classifies in the following manner:
• Class 1 defects: Very serious and defects lead directly to ‘severe’
injury or to catastrophic economic losses

79
Charts for Demerits per unit
(U-chart) – Contd..
• Classification of non conformities – contd..
• Class 2 defects: serious and defects that lead to ‘significant’
injury or to significant economic losses
• Class 3 defects: major and defects that cause ‘major’
problems with normal use of product or service rendered
• Class 4 defects: minor and defects that cause ‘minor’
problems with normal use of product or service rendered
• Once classification of defects or non conformities has been
established, demerits per unit are assigned to each class
• Definition of classes and no. of classes are not rigid and
varies with respect to organization and the problem
environment
• Assigned weights for defects is also user dependent, while
ANSI standard uses 100, 50, 10, 1 for the above mentioned
classes

80
Charts for Demerits per unit
(U-chart) – Contd..
• Construction
– Let us have 4 categories of non conformities
– Let the sample size be ‘n’
– Let c1, c2, c3 and c4 denote the total no. of non conformities
in the sample for 4 categories
– Let w1, w2, w3 and w4 denote the weights assigned to each
category
• Assumption
– Non conformities in each category is independent of defect
in other categories
– Occurrence of non conformities in each category is given
by poisson distribution
• For a sample size of ‘n’, total no. of demerits is given by
D = w1c1 + w2c2 + w3c3 + w4c4
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Charts for Demerits per unit
(U-chart) – Contd..
• Demerits per unit of the sample are given by
D w1c1  w2 c2  w3c3  w4 c4
U 
n n
– U is the linear combination of independent poisson
random variable
• Centre line of the U chart is U  w u  w u  w u  w u
1 1 2 2 3 3 4 4
– u ,....u average no. of non conformities per unit
1 4
in respective classes and are calculated as
g

c
i 1
i

u  g

n
i 1
i

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Charts for Demerits per unit
(U-chart) – Contd..
• Estimated standard deviation of U is given by
2 2 2 2
w1 u1  w2 u2  w3 u3  w4 u4
ˆU 
n
• Control limit of the U chart is UCLU U  3 .ˆ U
LCLU U  3 .ˆ U
• If LCL is negative, then take LCL as zero

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 Question
• Nonconformities in automobiles fall into
three categories – serious, major and
minor. Twenty five samples of 5
automobiles are chosen, and the total
number of nonconformities in each
category is reported. Table gives the
results. Assuming a weighing system of
50, 10 and 1 for serious, major and minor
nonconformities, respectively, construct a
demerits per unit control chart.
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