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Acceptance sampling plan (ASP): ASP is a specific plan that clearly states
the rules for sampling and the associated criteria for acceptance or
otherwise. Acceptance sampling plans can be applied for inspection of (i)
finish items, (ii) components, (iii) raw materials, (iv) materials in process,
(v) supplies in storage, (vi) maintenance operations, (vii) data or records etc.
Three aspects of the sampling are important:
Advantages of Sampling
Disadvantages of Sampling
Single Sampling Plan: Single sampling plan is the sampling inspection plan
in which the lot disposition is based on the inspection of a single sample of
size n .
The selected units for inspection from the lot should be chosen at random,
and they should be representative of all the items in the lot. The random
sampling is an important concept in acceptance sampling plan. Without
random sample, bias will be introduced in the results.
1. From a lot of size N , draw a random sample of size n and observe the
number of nonconforming units d.
2. If d is less than or equal to the acceptance number c , which is the
maximum allowable number of nonconforming units, accept the lot. If d > c ,
do not accept the lot.
15.2.2 OC Curve for Single Sampling Plan
For very large lot size N , both curves give the same information. However,
Type A OC curve will always be below the type B OC curve (see Figure
15.6, page 640). We will discuss about Type B OC curve only and will be
used throughout the chapter.
Suppose the lot size N is large (say infinity). Under this condition, the
distribution of the number of defectives d in a random sample of n items is
binomial with parameters n and p , where p is the fraction defective items
in the lot. The probability of observing exactly d defectives is
n!
P{d defectives} = p (d ) = p d (1 p ) n d (1)
d !(n d )!
p 0.005 0.010 0.020 0.030 0.040 0.050 0.060 0.070 0.080 0.090
0.9897 0.9397 0.7366 0.4985 0.3042 0.1721 0.0919 0.0468 0.0230 0.0109
Pa
Figure 15.2. OC curve of the single-sampling plan n = 89 , c = 2
1.20
1.00
0.80
Pr{acceptance}
0.60
0.40
0.20
0.00
0.000 0.020 0.040 0.060 0.080 0.100 0.120 0.140
A sampling plan that discriminated perfectly between good and bad lots
would have an OC curve looks like Figure 15.3, page 639. The ideal OC
curve in Figure 15.3 never be obtained in practice. Figure 15.4 shows that
the OC curve becomes more like idealized OC curve shape as the sample
size increases. Figure 15.5 shows how the OC curve changes as the
acceptance number changes.
Acceptable Quality Level (AQL): The AQL represents the poorest level of
quality for the vender's process that the consumer would consider to be
acceptable as a process average.
N1 = 5000 N2 = 10000
n1 = 500 n1 = 1000
pmax = 0.0200 pmax = 0.0200
cmax = 10 cmax = 20
binomial binomial
p Pr{d<=10} Pr{reject} Pr{d<=20} Pr{reject} difference
0.0010 1.00000 0.0000 1.00000 0.0000 0.00000
0.0020 1.00000 0.0000 1.00000 0.0000 0.00000
0.0030 1.00000 0.0000 1.00000 0.0000 0.00000
0.0040 0.99999 0.0000 1.00000 0.0000 -0.00001
0.0050 0.99994 0.0001 1.00000 0.0000 -0.00006
0.0060 0.99972 0.0003 1.00000 0.0000 -0.00027
0.0070 0.99903 0.0010 0.99999 0.0000 -0.00095
0.0080 0.99729 0.0027 0.99991 0.0001 -0.00263
0.0090 0.99359 0.0064 0.99959 0.0004 -0.00600
0.0100 0.98676 0.0132 0.99850 0.0015 -0.01175
0.0200 0.58304 0.4170 0.55910 0.4409 0.02395
0.0250 0.29404 0.7060 0.18221 0.8178 0.11183
0.0300 0.11479 0.8852 0.03328 0.9667 0.08151
0.0400 0.00967 0.9903 0.00030 0.9997 0.00938
0.0500 0.00046 0.9995 0.00000 1.0000 0.00046
0.0600 0.00001 1.0000 0.00000 1.0000 0.00001
0.0700 0.00000 1.0000 0.00000 1.0000 0.00000
For N = 5,000, Pa(p = 0.025) = 0.294; while for N = 10,000, Pa(p = 0.025) =
0.182.
Suppose that we wish to construct a sampling plan such that the probability
of acceptance is 1 for lots with fraction defective p1 , and the probability
of acceptance is for lots with fraction defective p2 . Suppose that binomial
sampling (with Type -B OC curves) is appropriate, then the sample size n
and acceptance number c are the solution to
c
n!
1 = p1d (1 p1 ) n d
d =0 d!( n d )!
c
(3)
n!
= p2d (1 p2 ) n d
d =0 d!( n d )!
The two simultaneous equations in (3) are nonlinear, and there is no simple
or direct solution. The nomograph in Figure 15.9, page 643 can be used for
solving theses equations in (3).
Accepting sampling programs usually require corrective action when lots are
rejected. This generally takes the form of 100% inspection or screening of
rejected lots, with all discovered defectives items either removed for
subsequent rework or return to the supplier or replaced from a stock of
known good items. Such sampling programs are called rectifying inspection
programs, because the inspection activity affetcs the final quality of the
outgoing product. This has been illustrtaed in the following Figure 15.10.
Those lots not accepted by a sampling plan will usually be 100% inspected
or screened for nonconforming or defective units. After screening,
nonconforming units may be rectified or discarded or replaced by good
units, usually taken from accepted lots. Such a programmed of inspection is
known as a rectifying or screening inspection. For those lots accepted by the
sampling plan, no screening will be done and the outgoing quality will be
the same as that of the incoming quality p . For those lots screened, the
outgoing quality will be zero, meaning that they contain no nonconforming
items. Since the probability of accepting a lot is Pa , the outgoing lots will
contain a proportion of pPa defectives. If the nonconforming units found in
the sample of size n are replaced by good ones, the average outgoing quality
(AOQ) in lot size of N will be
( N n)
AOQ = pPa
N (4)
= pPa for latge N
In short, one defines the average outgoing quality as the expected quality of
outgoing product following the use of an acceptance sampling plan for a
given value of the incoming quality. Figure 15.11, gives a typical AOQ
curve as a function of the incoming quality.
If the incoming quality is good, then a large proportion of the lots will be
accepted by the sampling plan and only a smaller fraction will be screened
and hence the outgoing quality will be small (good). Similarly, when the
incoming quality is not good, a large proportion of the lots will go for
screening inspection and in this case also, the outgoing quality will be good
since defective items will be either replaced or rectified. Only for
intermediate quality levels, lot acceptance will be at a moderate rate and
hence the AOQ will rise (see Figure 15.11). The maximum ordinate of the
AOQ curve represents the worst possible average for the outgoing quality
and is known as the average outgoing quality limit (AOQL). In other
words, the AOQL is defined as the maximum AOQ over all possible levels
of the incoming quality for a known acceptance sampling plan. The AOQL
of a rectifying inspection plan is very important characteristic. It is possible
to design a rectifying inspection program that have specified value of
AOQL.
Exercise 15.10, page 669.
N = 3000, n = 150, c = 2
(a)
OC Curve for n=150, c=2
1.00
0.80
0.60
Pr{accept}
0.40
0.20
0.00
0.000 0.010 0.020 0.030 0.040 0.050 0.060 0.070 0.080
p
(b)
AOQ Curve for n=150, c=2
AOQL 0.0087
0.0100
0.0090
0.0080
0.0070
0.0060
AOQ
0.0050
0.0040
0.0030
0.0020
0.0010
0.0000
0.000 0.010 0.020 0.030 0.040 0.050 0.060 0.070 0.080
(c)
ATI Curve for n=150, c=2
3500
3000
2500
2000
ATI
1500
1000
500
0
0.000 0.010 0.020 0.030 0.040 0.050 0.060 0.070 0.080
The double sampling OC curve has a primary OC curve that gives the
probability of acceptance as a function of lot or process quality. It also has
supplementary OC curves that show the probability of lot acceptance and
rejection on the first sample. The OC curve for the plan n1 = 50 , c1 = 1 ,
n2 = 100 and c2 = 3 are shown in Figure 15.14.
Average Sample Number Curve for a Double Sampling Plan
Since when using a double sampling plan the sample size depends on
whether or not a second sample is required, an important consideration for
this kind of sampling is the Average Sample Number (ASN) curve. This
curve plots the ASN versus lot fraction defective p . The general formula for
the ASN in double sampling, if we assume complete inspection of the
second sample, is
PI = P{lot is acceptaed on the first sample} + P{lot is rejected on the first sample}
The ASN curve for formula for a double-sampling plan with curtailment on
the second sample is
c2 j + 1
c2
ASN = n1 + P (n , j ) n P (n , c
1 2 L 2 2 j) + PM (n2 + 1, c2 j + 2) (7)
j = c1 +1 p
Rectifying Inspection
[ PaI ( N n1 ) + PaII ( N n1 n2 )] p
AOQ = (8)
N
Note that
Pa = PaI + PaII
is the probability of final lot acceptance and that the acceptance probabilities
depend on the level of lot or process quality p .