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Statistical

Process
Control

By: Syed Shahwar Hasan


What is a process?

Inputs PROCESS Outputs

A process can be described as a transformation of


set of inputs into desired outputs.
Types of Measures
• Measures where the metric is composed of a classification
in one of two (or more) categories is called Attribute data.

_ Good/Bad
– Yes/No

• Measures where the metric consists of a number which


indicates a precise value is called Variable data.
– Time
– Miles/Hr

March 3, 2014 3
Population Vs. Sample (Certainty Vs. Uncertainty)

 A sample is just a subset of all possible


values
sample
population

 Since the sample does not contain all the


possible values, there is some uncertainty about
the population. Hence any statistics, such as
mean and standard deviation, are just
estimates of the true population
parameters.
March 3, 2014 4
WHY STATISTICS?
THE ROLE OF STATISTICS ………

LSL T USL

Statistics is the art of collecting, classifying,


presenting, interpreting and analyzing numerical
data, as well as making conclusions about the
system from which the data was obtained.

March 3, 2014 5
Descriptive Statistics

Descriptive Statistics is the branch of statistics


which most people are familiar.

It characterizes and summarizes the most


prominent features of a given set of data (means,
medians, standard deviations, percentiles, graphs,
tables and charts.

March 3, 2014 6
Inferential Statistics

Inferential Statistics is the branch of statistics that


deals with drawing conclusions about a population
based on information obtained from a sample drawn
from that population.

March 3, 2014 7
WHAT IS THE MEAN?
ORDERED DATA SET
The mean is simply the average value of the -5
data. -3
-1

mean = x = ∑ xi − 2
= = −.17 -1
n 12 0
0
n=12 0
0
0
1
3
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
Mean ∑x i = −2
March 3, 2014 8
WHAT IS THE MEDIAN?
If we rank order (descending or ascending) the data set
ORDERED DATA SET
,we find the value half way (50%) through the data points
-5
and is called the median value.
-3
-1 50% of
data
-1 points

0
0
Median
0
0
0
1
3
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
Median
Value
March 3, 2014 9
WHAT IS THE MODE?

If we rank order (descending or ascending) the data


set We find that a single value occurs more often than ORDERED DATA SET
any other. This is called the mode. -5
. -3
-1
-1
0
0
Mode Mode
0
0
0
1
3
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
March 3, 2014 10
WHAT IS THE RANGE?
ORDERED DATA SET
The range is a very common metric .
-5
To calculate the range simply subtract the minimum value -3
in the sample from the maximum value.
-1
-1
Range = x MAX − x MIN = 4 − ( −5) = 9 0
0
0 Range
0
0
1
3
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
Range
Min Max
March 3, 2014 11
WHAT IS THE VARIANCE/STANDARD DEVIATION?

The variance (s2) is a very robust metric .


The standard deviation(s) is the square root of the variance and is the most
commonly used measure of dispersion.
2
DATA SET Xi − X (X − X )
X =
∑ Xi
=
−2
= -.17 -5
i
-5-(-.17)=-4.83 (-4.83)2=23.32
n 12 -3 -3-(-.17)=-2.83 (-2.83)2=8.01
-1 -1-(-.17)=-.83 (-.83)2=.69
2 -1
s 2
=
∑ (X − X)
i
=
61.67
= 5.6
0
-1-(-.17)=-.83 (-.83)2=.69
0 0-(-.17)=.17 (.17)2=.03
n −1 12 − 1 0 0-(-.17)=.17 (.17)2=.03
0 0-(-.17)=.17 (.17)2=.03
0 0-(-.17)=.17 (.17)2=.03
1 0-(-.17)=.17 (.17)2=.03
3
1-(-.17)=1.17 (1.17)2=1.37
-6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 4
3-(-.17)=3.17 (3.17)2=10.05
4-(-.17)=4.17 (4.17)2=17.39
61.67
March 3, 2014 12
Statistical Process Control (SPC)

• Measures performance of a process


• Uses mathematics (i.e., statistics)
• Involves collecting, organizing, & interpreting
data
• Objective: Regulate product quality
• Used to
– Control the process as products are produced
– Inspect samples of finished products
CONTROL CHART

Functions of a Process Control System are

 To signal the presence of assignable causes


of variation

 To give evidence if a process is operating in


a state of statistical control
CONTROL CHART

Essential features of a control chart


Variable Values

Upper Control Limit

Central Line

Lower Control Limit

Time
Control Chart Purposes
• Show changes in data pattern
– e.g., trends
• Make corrections before process is out
of control
• Show causes of changes in data
– Assignable causes
• Data outside control limits or trend in
data
– Natural causes
• Random variations around average
Quality Characteristics

Variables Attributes
1. Characteristics that you 1. Characteristics for which
measure, e.g., weight, you focus on defects
length 2. Classify products as either
2. May be in whole or in ‘good’ or ‘bad’, or count #
fractional numbers defects
– e.g., radio works or not
3. Continuous random
variables 3. Categorical or discrete
random variables
CONTROL CHART

Types of Control Charts for Attribute Data

Description Type Sample Size

Control Chart for proportion non p Chart May change


conforming units
Control Chart for no. of non np Chart Must be constant
conforming units in a sample
Control Chart for no. of non c Chart Must be constant
conformities in a sample
Control Chart for no. of non u Chart May Change
conformities per unit
Control Chart Types

Control
Charts

Variables Attributes
Charts Charts

R `X P C
Chart Chart Chart Chart
X Chart

• Type of variables control chart


– Interval or ratio scaled numerical data
• Shows sample means over time
• Monitors process average and tells whether
changes have occurred. These changes may due
to 1. Tool wear
2. Increase in temperature
3. Different method used in the
second shift
4. New stronger material

• Example: Weigh samples of coffee & compute


means of samples; Plot
R Chart
• Type of variables control chart
– Interval or ratio scaled numerical data
• Shows sample ranges over time
– Difference between smallest & largest values in inspection
sample
• Monitors variability in process, it tells us the loss or gain in
dispersion. This change may be due to:
1. Worn bearing
2. A loose tool
3. An erratic flow of lubricant to machine
4. Sloppiness of machine operator
• Example: Weigh samples of coffee & compute ranges of
samples; Plot
Construction of X and R Charts
• Step 1: Select the Characteristics for applying a
control chart.
• Step 2: Select the appropriate type of control chart.
• Step 3: Collect the data.
• Step 4: Choose the rational sub-group i.e. Sample
• Step 5: Calculate the average ( X) and range R for
each sample.
• Step 6: Cal Average of averages of X and average
of range (R)
Construction of X and R Charts
• Steps 7: Cal the limits for X and R Charts.
• Steps 8: Plot Centre line (CL) UCL and LCL on
the chart
• Steps 9: Plot individual X and R values on the
chart.
• Steps 10: Check whether the process is in
control (or) not.
• Steps 11: Revise the control limits if the points
are outside.
X Chart
Control Limits

UCL = x + A R From
x 2 Tables
LCL = x − A R
x 2

Sub group average X = x1 + x2 +x3 +x4 +x5 / 5

Sub group range R = Max Value – Min value


R Chart Control Limits

UCL R = D 4R
From Tables

LCL R = D 3R
Problem8.1 from TQM by
V.Jayakumar Page No 8.5
p Chart for Attributes

• Type of attributes control chart


– Nominally scaled categorical data
• e.g., good-bad
• Shows % of nonconforming items
• Example: Count # defective chairs &
divide by total chairs inspected; Plot
– Chair is either defective or not
defective
p Chart

• p = np / n where p = Fraction of Defective


np = no of Defectives
n = No of items
inspected in sub group
p= Avg Fraction Defective = ∑np/ ∑n = CL
p Chart
Control Limits

p(1− p)
UCLp = p + z
n z = 3 for
99.7% limits
p(1− p)
LCLp = p − z
n
Purpose of the p Chart
Identify and correct causes of bad quality
The average proportion of defective
articles submitted for inspection, over a
period.
To suggest where X and R charts to be
used.
Determine average Quality Level.
Problem

• Problem 9.1 Page no 9.3 TQM by V.Jayakumar


np CHART
P and np are quiet same
Whenever subgroup size is variable, p chart is used. If sub
group size is constant, then np is used.
FORMULA: Central Line CLnp = n p
Upper Control Limit, UCLnp = n p +3√ n p (1- p )
Lower Control Limit, LCLnp = n p -3 √ n p (1- p )
Where p = ∑ np/∑n =Average Fraction Defective
n = Number of items inspected in subgroup.
Problem

• Problem No 9.11 page No 9.11 in TQM


by V.Jayakumar
c Chart
• Type of attributes control chart
– Discrete quantitative data
• Shows number of nonconformities (defects) in a
unit
– Unit may be chair, steel sheet, car etc.
– Size of unit must be constant
• Example: Count no of defects (scratches, chips etc.)
in each chair of a sample of 100 chairs; Plot
c Chart
Control Limits
UCLc = c + 3 c Use 3 for
99.7% limits

LCLc = c − 3 c

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