Introduction to Control Charts
Dr. Shahul Hamid Khan
Introduction to Control chart
Symbols
Ѳ – parameter
Ѳ
ˆ - estimator
α - probability of type I error
β - probability of type II error
σ - process standard deviation
σ―x - standard deviation of sample mean
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A control chart is a graphical tool for
monitoring the activity of an ongoing
process.
Sometimes referred as Shewhart’s
control chart
Control charts for variables
Control charts for Attributes
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Benefits of Control chart
1. When to take corrective actions
2. Type of remedial action necessary
3. To find Process capability
4. Possible means of quality improvement
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Causes of variation
Special Causes Common causes
Special causes or Assignable
Methods
causes
People
15% of all problems are due to Equipments
Special cause. Materials
§ Wrong tool Policies
§ Improper raw materials
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Common causes
Inherent to a process
Inherent part of process design
Cannot be totally eliminated
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Type I Error
o Inferring that a process is out of control
when it is actually in control
o The probability of this error is denoted by
α
o For 3s
Type II Error
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Tolerance Limits vs. Process Capability
Specification Width
Actual Process Width
Specification Width
Actual Process Width
Control chart makes it very easy
for you to identify visually
points and processes that are out
of control without using complicated
statistical tests.
Analysis of patterns in Control Charts
Rule 1
A process is assumed to be out of control
if a single point plots outside the
control limits.
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Warning limits
Construct two lines at two sigma
deviations above and below center line
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Rule 2
A process is assumed to be out of control if two
out of three consecutive points falls outside
the two sigma warning limits on the same side of
the center line.
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Rule 3
A process is assumed to be out of control if
four out of five consecutive points falls beyond
1 sigma limit on the same side of the center
line.
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Rule 4
A process is assumed to be out of control
if nine or more consecutive points fall
to one side of the center line.
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Rule 5
A process is assumed to be out of control if
there is a run of six or more consecutive points
steadily increasing or decreasing .
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Control Charts for Variables
§ Control Charts for Mean and Range (Constant
Sample size)
X – bar chart
R – chart
Control Charts for Mean and Range
Average
Range
g – No of Samples
x Chart Control Limits
UCL = x + 3 s X
LCL = x - 3 s X
x Chart Control Limits
UCL = x + 3 s X
LCL = x - 3 s X
x Chart Control Limits
UCL = x + A 2 R where
LCL = x - A 2 R
R Chart Control Limits
UCL = D 4 R
LCL = D 3 R Trial Control
Limits
Example
Revised Control Limits
x Chart Control Limits
UCL = x + A 2 R
LCL = x - A 2 R
X- bar chart
= 0
Control Charts for Mean and Std Deviation
S- Chart
S chart is preferable when the sample size is greater than 10
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(1)
(
2)
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S- Chart (With no Given
Standard)
By Eqn (1)
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