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Topic 6
Quality Control
Planificacin Agregada
Index
Quality control
Seven Ishikawas tools
Pareto chart / Cause-and-effect diagram / Check sheets /
Histogram / Scatter diagram / Control chart / Stratification
Quality Control
Quality control
Quality Control
Pareto chart
Cause-and-effect diagrams
Check sheets
Histograms
Scatter diagram
Stratification
Control chart
Quality Control
Pareto chart
Quality Control
Defect type
Quantity of
Accumulated
% defective
defective
quantities
products
articles
Grated surface
Arm rupture
Spots
Adjustment
Tension
Others
Total
Quality Control
198
53
28
11
2
8
300
%
accumulated
198
251
279
290
292
300
66,00
17,67
9,33
3,67
0,67
2,67
100,00
66,00
83,67
93,00
96,67
97,33
100,00
100,00
250
80,00
200
60,00
150
40,00
100
Otros
Causes
Tensin
0,00
Ajuste
0
Manchas
20,00
Rupturas
brazo
50
% accumulated
300
Rallado
superficial
prod.
Quantity of defective
Quality Control
Cause-and-effect diagram
Quality Control
Cause-and-effect diagram
Machines
Personnel
Effect
Methods
Materials
Quality Control
Machines
Deformation
Personnel
Training
Stability
Tools
Abilities
Operation
Abrasion
Inspection
Procedure
Work
Concentration
Illness
Variable
dimension
Position
Adjustm.
Angle
Variety
Experience Tirednes
s
Health
Motivation
Diameter
Shape
Raw material
Components
Materials quality
Orden
Methods
Materials
Storage
Final comment: the identified and classified causes are potential causes. This diagram is the
starting point to verify and confirm the real causes.
Quality Control
10
Check sheets
11
Quality Control
Theyre used to detect the type of defects and their frequency percentages
in defective products in order to reduce them.
Plantilla de inspeccin
Cdigo del Producto: 25312-A
Fecha: 12-marzo-97
Operario:
Lote:
Total
Rallado
IIII
IIII
IIII
Fisuras
IIII
IIII
IIII
Deformado
IIII
IIII
IIII
Incompleto
IIII
Otros
IIII
Observaciones:
Quality Control
IIII
IIII
IIII
III
IIII
IIII
37
II
14
23
5
8
III
Total
87
12
Sketches of the
manufactured piece
where defects are
located. They allow to
detect if defects are
always placed in the
same place.
13
Quality Control
5
II
IIII
IIII
IIII
IIII
IIII
IIII
IIII
IIII
IIII
III
I
10
II
IIII
IIII
IIII
IIII
IIII
IIII
IIII
III
IIII
IIII
IIII
IIII
IIII
IIII
IIII
IIII
II
IIII
IIII
IIII
IIII
IIII
40
I
III
IIII
IIII
IIII
IIII
IIII
IIII
IIII
IIII
I
III
45
Total
2
7
21
17
23
38
34
31
17
8
3
1
14
Histogram
15
Quality Control
Histogram. Example
Data
7,38
7,31
7,35
7,40
7,35
7,29
7,53
7,38
7,51
7,33
7,39
7,42
7,33
7,36
7,35
7,29
7,26
7,34
7,52
7,44
7,41
7,43
7,23
7,36
7,38
7,42
7,36
7,42
7,45
7,34
7,19
7,39
7,58
7,38
7,46
7,53
7,42
7,45
7,36
7,34
7,26
7,28
7,39
7,48
7,36
7,38
7,39
7,35
7,38
7,33
7,52
7,33
7,45
7,39
7,39
7,35
7,34
7,38
7,37
7,33
7,39
7,32
7,35
7,44
7,19
7,39
7,34
7,38
7,39
7,37
7,20
7,37
7,29
7,36
7,28
7,39
7,27
7,44
7,46
7,36
7,41
7,36
7,42
7,42
7,41
7,28
7,39
7,29
7,42
7,37
7,40
7,26
7,35
7,28
7,38
7,41
7,20
7,38
7,30
7,41
Max
Min
7,52
7,43
7,58
7,48
7,46
7,53
7,53
7,45
7,52
7,44
7,19
7,26
7,23
7,28
7,19
7,28
7,2
7,29
7,3
7,33
Quality Control
Histogram. Example.
The interval h is the unit to adjust the horizontal axis (bar width).
In this case we consider 0,05.
The number of classes k depends on data collection:
Data collection n
< 50
50 - 100
100 - 250
> 250
Number of classes k
57
6 10
7 12
10 20
The value that limits the first bar is fixed taking into account the
extreme of the amplitude + half of the accuracy of collected data.
In this case, the minimum value is 7,19 accuracy of real data is
0,01. Consequently, the limits of first bar is : 7,19 - 0,01/2 = 7,185
Rest of limits of bars will be: 7,185 - 7,235; 7,235 7,285; 7,285
7,335; ...
17
Quality Control
Histogram. Example
Class
n
1
2
3
4
5
6
7
8
9
Limits
Classes
7,185 7,235
7,235 7,285
7,285 7,335
7,335 7,385
7,385 7,435
7,435 7,485
7,485 7,535
7,535 7,585
7,585 7,635
Aver.
value
7,21
7,26
7,31
7,36
7,41
7,46
7,51
7,56
7,61
Frequencies
IIII
IIII
IIII
IIII
IIII
IIII
IIII
II
I
IIII
IIII
IIII
IIII
I
IIII
IIII
IIII
IIII
IIII
IIII
IIII
IIII
IIII
Frequency
4
5
11
29
35
9
4
2
1
N=
100
These data allows to draw the histogram. In Cartesian axis, horizontal axis
represents a quality characteristic and the vertical axis represents the frequency
(number of data inside one bar).
Quality Control
18
Histogram. Example
40
Frequencyas
35
30
25
20
15
10
5
0
7,15 7,21 7,26 7,31 7,36 7,41 7,46 7,51 7,56 7,61 7,70
Quality Control
Histograms. Examples
LTI
LTS
Case 1
LTI
LTS
Case 2
These two cases show the same frequency distribution BUT case 1
is centered inside the tolerance limits. Nevertheless, case 2 is an
off-centre distribution and shows that some articles are produced
outside specifications (grey bars).
Quality Control
20
10
Histograms. Examples
Case 3
Case 4
Quality Control
Histograms. Examples
Case 5
Case 6
Quality Control
22
11
Histograms. Functions
Quality Control
23
Scatter diagram
Quality Control
24
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
60,8
61,2
60,3
62,5
61,3
60,8
63,0
61,5
63,4
64,1
63,2
61,9
61,7
62,6
63,9
61,8
61,8
60,5
60,9
63,8
64,5
65,0
62,8
63,8
60,9
25,0
26,0
24,8
27,3
27,8
25,9
27,4
26,8
29,5
29,8
26,9
28,3
27,4
28,6
27,3
26,7
26,0
25,3
27,5
29,4
30,6
30,4
29,3
30,1
26,6
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
61,5
64,0
63,1
63,5
64,8
62,0
62,9
62,5
64,0
62,8
63,5
64,3
62,6
62,2
63,1
62,8
62,4
63,5
63,7
62,2
62,0
61,9
63,4
61,0
64,3
25,1
29,3
29,1
28,5
29,9
27,5
26,1
26,0
28,0
27,9
29,9
29,5
26,8
25,8
28,5
27,3
28,4
27,6
28,5
27,0
26,8
25,1
28,2
25,0
28,0
Variable X is
a possible
cause and Y
is the quality
characteristic
that seems
correlated.
25
Quality Control
Scatter diagram
Quality characteristic
31,0
30,0
29,0
28,0
27,0
26,0
25,0
24,0
60,0
61,0
62,0
63,0
64,0
65,0
66,0
Cause
Quality Control
26
13
Scatter diagram
SXY
SXX.SYY
SXX
n
2
(X X)
i
i 1
X i2
X)
i
i1
i1
n
n
SYY
(Yi Y)2
i 1
i1
Yi2
Y)
i
i1
2
n
SXY
i1
(Xi X).(Yi Y)
i1
Xi.Yi
X ).( Y )
i
i1
i1
In the example:
Quality Control
27
Stratification
Quality Control
28
14
Stratification. Example
Diagrama bivariant
700
Variable y
600
500
400
300
200
100
0
10,0 10,1 10,2 10,3 10,4 10,5 10,6 10,7 10,8 10,9 11,0
Variable x
29
Quality Control
30
15
Assignable causes:
They can be studied and are the ones that contribute
most to the variability of the process.
Usually, theyre due to tiredness of workers, different
grade of experience/training, different behaviour of
materials, so that its NOT possible to obtain identical
products.
The same happens in service industries: a cook CANNOT
obtain two identical dishes or a lecturer CANNOT repeat
two identical classes,
31
Quality Control
Process capacity
10 0,05 mm
Quality Control
32
16
Control graphics
33
Quality Control
Control graphics
LCS
Variation due to
assignable causes.
Normal variation
due to random
causes
VC
LCI
Variation due to
assignable causes
Tiempo
Types:
Control graphic by variables.
Control graphic by attributes.
Quality Control
34
17
Quality Control
25 samples of 5
measurements.
Quality Control
Sample
Value1
Value 2
Value 3
Value 4
Value 5
Average
Range
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
15
16
13
15
14
16
15
15
14
14
12
15
15
16
13
18
14
15
16
14
14
13
13
14
17
14
14
15
15
13
15
14
14
16
18
13
15
18
15
16
17
12
13
14
16
18
19
14
12
14
13
12
15
14
16
15
15
15
14
14
12
12
15
15
16
15
14
14
14
18
13
15
15
11
15
14
13
11
15
14
15
16
15
14
14
12
15
14
13
15
13
14
14
12
14
13
14
14
16
13
14
15
12
18
14
16
15
16
13
13
15
11
14
15
16
14
17
15
15
19
18
14
18
12
17
TOTALS
14,0
14,0
13,2
15,4
14,2
15,4
15,0
15,0
14,2
14,6
12,8
13,6
15,2
14,8
15,2
15,4
14,2
14,2
14,2
16,2
15,2
15,0
14,8
13,0
15,2
14,56
2
4
4
4
3
1
2
2
3
5
3
4
4
3
3
5
5
2
4
5
5
6
5
5
4
3,72
36
18
Sample average:
X1 X2 ... Xn
X
i1
15 14 13 14 14
X1
14,0
5
X1 X2 ... Xk
X
i 1
R1 R2 ... Rk
; R
i 1
In the example:
X
; R
2 4 4 ... 5 5 4
3,72
25
37
Quality Control
A2,
D3
y
D4
parameters depend
on n, the number of
elements
of
the
sample:
n
A2
D3
D4
2
3
4
5
6
7
8
9
10
1,880
1,023
0,729
0,577
0,483
0,419
0,373
0,337
0,308
0,000
0,000
0,000
0,000
0,000
0,076
0,136
0,184
0,223
3,267
2,575
2,282
2,115
2,004
1,924
1,864
1,816
1,777
Quality Control
38
19
Averages
18,0
LCS = 16,71
16,0
VC = 14,56
14,0
LCI = 12,41
12,0
10,0
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Samples
Graphic R
Averages
10
8
LCS = 7,89
6
VC = 3,72
4
2
LCI = 0
0
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Samples
39
Quality Control
Quality Control
40
20
41
Quality Control
Sample type
Type of control
Constant
Variable
Graphic np
Graphic p
Graphic c
Graphic u
Number of defects
Quality Control
42
21
Acceptance sampling
43
Quality Control
The acceptance
sampling plan.
sampling
is
performed through
Quality Control
44
22
45
Quality Control
Acceptance probabilityPa(w)
0,9
0,8
Pa (AQL)
0,7
0,6
0,5
0,4
0,3
0,2
Pa (LTPD)
0,1
Defects percentage w
0
AQL
Correct lots
Quality Control
LTPD
Indifference zone
Defective lots
Indicates the
probability that the
plan accepts lots of
different qualities.
46
23
Quality Control
47
Quality Control
48
24
49
Quality Control
les
Tab
Quality Control
10,946
13,349
18,681
0,355
26,184
31,933
44,686
0,149
6,509
7,699
10,280
0,818
12,206
14,439
19,278
0,436
4,890
5,675
7,352
1,366
8,115
9,418
12,202
0,823
4,057
4,646
5,890
1,970
6,249
7,156
9,072
1,279
3,549
4,023
5,017
2,613
5,192
5,889
7,343
1,785
3,206
3,604
4,435
3,286
4,520
5,082
6,253
2,330
2,957
3,303
4,019
3,981
4,050
4,524
5,506
2,906
2,768
3,074
3,707
4,695
3,705
4,115
4,962
3,507
2,618
2,895
3,462
5,426
3,440
3,803
4,548
4,130
10
2,497
2,750
3,265
6,169
10
3,229
3,555
4,222
4,771
11
2,397
2,630
3,104
6,924
11
3,058
3,354
3,959
5,428
12
2,312
2,528
2,968
7,690
12
2,915
3,188
3,742
6,099
13
2,240
2,442
2,852
8,464
13
2,795
3,047
3,559
6,782
14
2,177
2,367
2,752
9,246
14
2,692
2,927
3,403
7,477
15
2,122
2,302
2,665
10,035
15
2,603
2,823
3,269
8,181
16
2,073
2,244
2,588
10,831
16
2,524
2,732
3,151
8,895
17
2,029
2,192
2,520
11,633
17
2,455
2,652
3,048
9,616
18
1,990
2,145
2,458
12,442
18
2,393
2,580
2,956
10,346
19
1,954
2,103
2,403
13,254
19
2,337
2,516
2,874
11,082
20
1,922
2,065
2,352
14,072
20
2,287
2,458
2,799
11,825
21
1,892
2,030
2,307
14,894
21
2,241
2,405
2,733
12,574
22
1,865
1,999
2,265
15,719
22
2,200
2,357
2,671
13,329
23
1,840
1,969
2,226
16,548
23
2,162
2,313
2,615
14,088
24
1,817
1,942
2,191
17,382
24
2,126
2,272
2,564
14,853
25
1,795
1,917
2,158
18,218
25
2,094
2,235
2,516
15,623
50
25
Bibliography:
Quality Control
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26