FACULTY OF MANUFACTURING ENGINEERING

DESIGN MANUFACTURING
BMFG 3341
MANUFACTURING LAB III
Experiment Title: Quality Control: Control Charts for Attributes and
Variables

LECTURERS NAME :

PROF. MADYA DR. CHONG KUAN ENG

GROUP MEMBERS

AZRI IZZATI BINTI RAMLI

B051410013

ANNISA BINTI NORIZAN

B051310

CHAI FONG LING

B051410097

MICE LESTARI BINTI RUSDI

B051410065

NUR AMIRAH BINTI ARIF

B051410028

SUBMIT ON: 15 March, 2016

1.0 INTRODUCTION
The first experiment conducted for Manufacturing Lab III activity titled Quality
Control: Control charts for attributes and variables. Quality control activity exists in all
production industries as one of the most important step that must be taken before a part or
product is ready to be sent to customers, which is a must to ensure customers
satisfaction.
During the experiment, students were asked to put themselves as a quality control
inspectors. Students were provided with two products, stamped plates and bolts. The
stamped plated were divided into 10 lots and each lot consisted of 10 plates. The bolts
were also divided into 10 lots where each lot consisted of eight bolts. Figures below show
the stamped plates and the bolts.

Figure 1: Samples of stamped plates

Figure 2: Samples of bolts

The purpose of the experiment was to demonstrate an application of quality

control activity, besides to obtain the data for attributes and variables control charts.
Attribute control chart is a chart used when the data collected is not to be measured by its
quantity. Some examples of attributes can be scratches, dented parts, damage, and color.
Variable control chart is a chart that represents the data collected through a quantitative
measurement such as length, diameter, thickness, and width.
During the activity, students were required to inspect each of the stamped plate in
each lot and record all data. If one stamped plate was found to have three of more dents
or/and scratches, the plate must be marked as a rejected part. For the bolt, the
measurements of the diameter and length of the bolt must be taken using a Vernier

caliper, and every data was recorded. During the activity, all team members participated
and took turns to conduct the experiment.
After recording the data, attribute control chart and variable control chart were
produced for the stamped plates and bolts respectively. The charts were analyzed and a
conclusion was made.

2.0 THEORY
The control chart is a graph used to study how a process changes over time. Data
are plotted in time order. A control chart always has a central line for the average, an
upper line for the upper control limit and a lower line for the lower control limit. Lines
are determined from historical data. By comparing current data to these lines, u can draw
conclusions about whether the process variation is consistent (in control) or is
unpredictable (out of control, affected by special causes of variation).
If analysis of the control chart indicates that the process is currently under control
(is stable, with variation only coming from sources common to the process), then no
corrections or changes to process control parameters are needed or desired. In addition,
data from the process can be used to predict the future performance of the process. If the
chart indicates that the monitored process is not in control, analysis of the chart can help
determine the sources of variation, as this will result in degraded process performance. A
process that is stable but operating outside of desired (specification) limits ( scrap rates
may be in statistical control but above desired limits) needs to be improved through a
deliberate effort to understand the causes of current performance and fundamentally
improve the process
The control chart is one of the seven basic tools of quality control. Typically
control charts are used for time-series data, though they can be used for data that have
logical comparability (i.e. you want to compare samples that were taken all at the same
time, or the performance of different individuals), however the type of chart used to do
this requires consideration

2.1 Attribute and Variable Control Chart

There are only two possible outcomes for each item; either it passes or it fails
some preset specification. Each item inspected is either defective (i.e., it does not meet
the specifications) or is not defective (i.e., it meets specifications). Examples of the
yes/no data are phone answered/not answered, product in spec/not in spec, shipment ontime/not on-time and invoice correct/incorrect.

The p and np control charts are based on the assumption that the underlying
distribution is the binomial distribution. The c and u control charts are based on the
assumption that the underlying distribution is the Poison distribution. If the above
conditions are not met, then the control limit calculations for the attribute control charts
are not valid. For example, the control limits for the np control chart are given by:

where n = subgroup size, np is the average number defective and p is he average divided
by n.
These control limits specify how far away from the average the control limits are and
they are a function of the average. The control limits for the c control chart are given
below:

where c is the average number of defects.

Again, the distance the control limits are from the average depend on the average itself.
It will see this is not true for the individuals control chart. The attribute control limits are
theoretical control limits

3.0 OBJECTIVES
1.

To apply quality control tools such as statistical Process Control (SPC) and Process
Capability techniques for analyzing variables and attributes data.

2.

To apply the concept of control charts for attributes and variables.

3.

To develop the skills in constructing and interpreting control charts.

4.

To understand and apply process capability concept.

4.0 PLANNING
At the beginning of manufacturing lab, students are required to form a group of
maximum 5 students. This experiment used Vernier caliper as the tool to perform the
experiment. The experiment is divided into two tasks which is Task 1 (Control Charts for
Attributes) and Task 2 (Control Charts for Variables). Before conducting the experiment,
students are required to read instruction carefully. Each of student need to follow the
instructions and do their own specific tasks.
Table 1: table for task 1
TASK 1
Name
Azri Izzati binti Ramli
Mice Lestari binti Rusdi
Annisa Norizan
Nur Amirah binti Arif
Chai Fong Ling

Activity
Defined the number of defect for sample 1,2 and 3
Defined the number of defect for sample 4,5 and 6
Defined the number of defect for sample 7 and 8
Defined the number of defect for sample 9 and 10
Take the photos
Record the data
Table 2: table for task 2
TASK 2

Name
Azri Izzati binti Ramli
Mice Lestari binti Rusdi
Annisa Norizan
Nur Amirah binti Arif

Activity
Measure the diameter and length of the bolt by

using Vernier calliper for the sample 1, 2 and 3

Measure the diameter and length of the bolt by

using Vernier calliper for the sample 4, 5 and 6

Measure the diameter and length of the bolt by

using Vernier calliper for the sample 7 and 8

Measure the diameter and length of the bolt by

using Vernier calliper for the sample 9 and 10

Take the photos
Chai Fong Ling
Record and tabulate the data
After finished conducting the both experiment, each student opportunity to learn and gain
knowledges for the both experiment. Then, students were been discussed about the result
for the both experiment. After achieve the conclusion of the experiments, divided task for

the content of the report was contributed among the group member is shown as in the
below table.
Table 3: table for part/task and person in charge
Part / Task
Introduction
Theory
Objective
Planning
Procedure
Data and Analysis
Analysis
Discussion
Conclusion
Appendices
References

Discharge
Azri Izzati binti Ramli
Nur Amirah binti Arif
Mice Lestari binti Rusdi
Nur Amirah binti Arif
Mice Lestari binti Rusdi
Chai Fong Ling
Chai Fong Ling
An nisa Norizan
Azri Izzati binti Ramli
Azri Izzati binti Ramli, Mice Lestari Rusdi
Nur Amirah binti Arif, Annisa Norizan

4.1 Flow chart for experiment (Attribute Control chart)

4.2 Flow chart for experiment (Variable Control chart)

5.0 PROCEDURES

5.1 QC Attributes
1.

Ten lots that contains ten stamped plates in each lot is prepared.

Figure 3: Samples of lots that contain stamped plates

Figure 4: Samples of stamped plates in each lot

2.

Visual inspection is done to inspect good and reject part of the stamped part in each
lot. Observe the scratches and dents that occur on the surface of the parts.

Figure 5: Inspection on the stamped plates

3.

The part is accepted when the total number of scratches and dents is two and less.

Figure 6: Samples of accepted stamped plates

4.

The part is rejected when the total number of scratches and dents is three and more.

Figure 7: Samples of rejected stamped plates

5.

The result of accept and reject part is recorded in table form.

6.

The activities is repeated for all ten lots.

5.2 QC Variables

1.

10 lots that contains 8 parts in each lot is setup.

Figure 8: Samples of lots that contain bolts

Figure 9: Samples of bolts

2.

The Vernier caliper is set up and adjusted to zero in order to get the accurate value.

3.

The A and B value is measured by using the Vernier caliper.

Figure 10: Inspection on the length

Figure 11: Inspection on the diameter

4.

The reading of A and B value is then recorded into a table.

5.

The steps is repeated for all the ten lots.

5.0 DATA/RESULTS

5.1 QC Attributes
Data collected using visual inspection of stamped part is shown in Table 4 below.
Sample

Lot

10

10

Table 4: the data for accepted and rejected stamped part

Hints:
/ Accepted

X Rejected

Results after inspection

Subgroup number

Number Inspected,

Number of
Nonconforming,

Proportion of
Nonconforming,

10

0.10

10

0.20

10

0.30

10

0.40

10

0.50

10

0.10

10

0.20

10

0.30

10

0.40

10

10

0.60

Total

100

31

5.2 QC Variables
Data collected for diameter and length of bolts using Vernier caliper.

i.

Diameter of bolt

Lot
1

10

Sample Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diam
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm
1

7.56

7.90

7.59

7.48

7.84

8.52

7.49

7.89

7.49

7.5

7.56

7.56

7.87

7.49

7.90

7.50

7.45

7.78

7.58

7.4

7.56

7.83

7.83

7.50

7.80

7.50

7.46

7.83

7.49

7.5

7.54

7.45

7.94

7.48

7.87

7.50

7.49

7.85

7.49

7.4

7.56

7.86

7.82

7.50

7.81

7.50

7.49

7.89

7.49

7.4

7.60

7.81

7.80

7.48

7.90

7.50

7.49

7.88

7.50

7.4

7.56

7.80

7.90

7.47

7.82

7.50

7.50

7.87

7.50

7.4

7.52

7.51

7.88

7.50

7.82

7.50

7.53

7.88

7.48

7.4

Table 5: the data measured for diameter of bolt.

ii.

Length of bolt
Lot
1

10

Sample Length Length Length Length Length Length Length Length Length Length
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
1

15.10

15.96

16.84

15.05

15.99

14.20

15.50

15.80

15.03

15.68

15.20

16.00

16.20

15.17

15.98

15.00

15.50

16.04

15.13

15.53

15.20

15.90

16.34

15.23

16.06

14.84

15.20

15.79

15.02

15.21

14.71

16.08

16.08

14.95

15.94

15.20

14.99

15.84

15.34

15.33

15.34

16.70

16.18

14.99

15.96

15.00

14.99

15.85

15.29

14.84

15.28

15.80

16.38

15.15

16.12

15.00

15.37

15.67

14.99

14.88

14.92

16.00

15.90

15.22

16.21

15.00

14.36

16.14

15.06

14.88

15.26

16.30

16.18

15.04

16.18

15.00

15.32

16.00

15.26

15.29

Table 6: the data measured for length of bolt

Diameter, mm

Length, mm

Lot,

Average,

Range,

Lot

Average,

Range,

7.56

0.08

15.13

0.63

7.72

0.45

16.09

0.90

7.83

0.35

16.26

0.94

7.49

0.03

15.10

0.28

7.85

0.10

16.06

0.27

7.63

1.02

14.91

0.80

7.49

0.08

15.15

1.14

7.86

0.11

15.89

0.47

7.50

0.10

15.14

0.27

10

7.49

0.02

10

15.21

0.80

Total

76.42

3.06

Total

154.93

6.5

Table 7: the calculation for the average and range for diameter and length of the bolt

6.0 ANALYSIS OF DATA

6.1 CALCULATION
6.1.1

QC Attribute

Calculations for average proportion of nonconforming, upper and lower limits for p chart.
Average proportion of nonconforming,

Upper control limit,

Lower control limit,

6.1.2

QC Variable

For diameter,

For length,

From table of control chart constants,

Sample size
D3

0.223

D4

1.777

10, thus A2

0.308

Calculating upper and lower limits for Diameter, mm

chart

R chart

UCLx

A2

LCLx

A2

UCLR

LCLR

D3

D4

Calculating upper and lower limits for Length, mm

chart

R chart

UCLx

A2

LCLx

A2

UCLR

LCLR

D3

D4

7.0 DISCUSSION
7.1 QC Attributes
Designing a form will be helpful in collecting the experimental data. What is the benefit
using the form in collecting the data?
There are numerous benefits that we may gain to prepare a form for data collection. As
being shown in the appendixes, that form was constructed before the experiment begin.
By using the form for collection data, it is more practical where large amounts of
information can be collected from a large number of people in a short period of time and
in a relatively cost effective way. Besides, the result of the data can usually be quickly
and easily quantified by the use of software (Microsoft Excel) for computation to avoid
miscalculation. Plus, the data can also be analyzed more scientifically and objectively
than making a draft on a piece of paper.
Source: http://libweb.surrey.ac.uk/library/skills/Introduction%20to%20Research%20and
%20Managing%20Information%20Leicester/page_51.htm

What is your opinion about the statement, choice between attributes and variables
control charts?
Sometimes, the quality control engineer has a choice between variable control charts and
attributes control charts. Attribute control charts have the advantage of allowing for quick
summaries of various aspects of the quality of a product, that is the engineer may simply
classify products as acceptable or unacceptable, based on various quality criteria. Thus,
attribute charts sometimes bypass the need for expensive, precise devices, and timeconsuming measurement procedures. Also, type of chart tends to be more easily
understood by managers unfamiliar with quality control procedures; therefore, it may
provide more persuasive (to management) evidence of quality problems.

Next, for variable control chart, it is more sensitive than attribute control charts.
Therefore, variable control charts may alert us to quality problem before any actual
unacceptable as detected by the attribute chart will occur. Montogomery (1985) calls
the variable control charts leading indicators of trouble that will sound an alarm before
the number of rejects increase in the production process

Source: https://documents.software.dell.com/statistics/textbook/quality-control-charts

Give an example application of control charts for attributes for manufacturing and nonmanufacturing environment.

Many quality characteristics cannot be conveniently represented numerically. In such

cases, each item inspected is classified as either conforming or nonconforming to the
specifications on those quality characteristics. Quality characteristics of this type are
called attributes and some of the examples are nonfunctional semiconductor chips,
warped connecting rods and many more. There are four type of attribute charts that is p
chart, np chart, c chart and u chart. P chart shows the fraction of nonconforming or
defective product produced by a manufacturing process and it is also called the control
chart for fraction nonconforming. Np chart shows the number of nonconforming, it is
almost the same as the p chart. C chart shows the number of nonconformities produced
by a manufacturing process. U chart shows the nonconformities per unit produced by a
manufacturing process.
The use of the word process brings to mind the mechanical processes of product
manufacturing. Thus, the manager of a non-manufacturing activity is inclined to dismiss
these ideas as not applicable to his operations. A search of recent literature reveals a great
deal if interest in improving the quality and productivity of non-manufacturing industries.
Following are few examples of non-manufacturing that show the prevalence of various
quality and productivity efforts.
The United States Fidelity and Guaranty Company of Baltimore have implemented four
methods as part of their service quality improvement program. The first method is error
identification. Random sampling is used to find errors and return them to the responsible
employee for correction. The second method is error analysis. This involves employees
and supervisors at all level. Pareto analysis and trend analysis are two of the most
frequently used tools. The third method is corrective action. Short-range corrective action
programs are developed in response to sporadic error problems. The fourth method is
ongoing enhancement. This incorporates quality concepts in the development of new
goods and services.
The Paul Revere Life Insurance Company of Worcester, Massachusetts has implemented
a program known as Quality Has Value. They employ a modified quality circle
technique to generate improvement ideas from the employees and promote top
management participation in the improvement process. Plus, Blue Cross of Western
Pennsylvania has applied a technique they call process management to their clerical
operations and the Continental Illinois Bank in Chicago has done the same

Source: Lawrence William Olson, the Application of Statistical Process Control in NonManufacturing Activities, 1987.

7.2 QC Variables

From Lower Specification Limit and Upper Specification

you draw about the process capability?

Limit what conclusion can

A process capability index is a numerical summary that compares the behavior of a

product or process characteristics to engineering specifications. These measures are also
often called capability or performance indices or ratios; we use capability index as the
generic terms. A capability index relates the voice of the customer (specification limits) to
the voice of the process.
Ongoing process performance requirements are defined by the customer. If no such
requirements have been established, the following default values apply:

For stable processes and normally distributed data, a Cpk value

should be achieved

For chronically unstable processes with output meeting specification and a

predictable pattern, a Ppk value

1.33

1.67 should be achieved

In more mathematical terms,

Process Capability =
Where USL and LSL are the upper and lower specification limits respectively, and and
are the process mean and standard deviation respectively for individual measurement of
the characteristic of interest. Calculating the process capability requires knowledge of the
process mean and standard deviation. These values are usually estimated from data
collected from the process.
By assuming that the specification limits on the diameter are
mm. The control
chart data may be used to describe the capacity of the process to produce bolts relatives to
these specifications. Assuming that diameter is a normally distributed random variable
with mean 7.64 mm and 0.107mm, we may estimate the fraction of nonconforming bolts
produced as

Thus, about 10.31 % of the bolt produced is outside of the specification

Assume that the specification limits on the length are

mm. The control chart
data may be used to describe the capability of the process to produce bolt relative to these
specification. Assuming that length is a normally distributed random variable, with mean
15.49 mm and standard deviation 0.2283mm, we may estimate the fraction of
nonconforming bolts produced as

Thus, about 2.92% of the bolt produced is outside of the specification.

Source: Stefan Steiner, Bovas Abraham and Jock MacKay, 2000, Understanding Process
Capability Indices.

What is the benefit using the form in collecting the data

Collecting data using form enables the data to be arranged orderly and it can be viewed
and understand clearly and easily.

What is your opinion about this statement, choice between attributes and variable control
chart.

I dont know how to explain

Give an example application of control charts for attributes for manufacturing and
non+manufacturing environments.

8.0 CONCLUSION

After completing this experiment, students have applied quality control tools such as
Statistical Process Control (SPC) and process Capability techniques for analyzing
variables and attributes data. Students have also applied the concept of control charts for
attributes and variables to record the data obtained. Besides that, skills of constructing
and interpreting control charts have been developed throughout the activity. The process
capability concept has also been understood and has been applied.
It can be concluded that attribute control chart and variable control chart play an
important role of determining the successive means of quality and measurements from a
process. Besides that, these charts help quality control engineers to suggest improvements
on the production line to reduce rejections on products or parts.

9.0 APPENDICES

APPENDIX B (for Variables Control Chart)

APPENDIX B (for Variables Control Chart)