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∑ X i
X = i=1
m
DETERMINE CONTROL LIMITS
Xbar chart
• The normal curve displays the distribution
of the sample averages.
• A control chart is a time-dependent pictorial
representation of a normal curve.
• Processes that are considered under control
will have 99.73% of their graphed averages
fall within 6σ.
UCL & LCL calculation
UCL = X + 3σ
LCL = X − 3σ
σ = standard deviation
DETERMINING THE VALUES OF THE
CONTROL LIMITS USING RANGE
m
∑ R i
R = i=1
UCL = X + A 2 R
LCL = X − A 2 R
3-Sigma Control Chart Factors
5.02
5.00 CL
4.98
4.96 LCL
4.94
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
R Chart
0.25 UCL
0.20
0.15
Range
CL
0.10
0.05
LCL
0.00
0 1 2 3 4 5 6 7 8 9 10 11
Subgroup
WHAT DO YOU DO NOW ?
• Revise Control Limits ?
• Equipment
– Tool wear, machine vibration, …
• Material
– Raw material quality
• Environment
– Temperature, pressure, humadity
• Operator
– Operator performs- physical & emotional
CONTROL CHART VIEWPOINT
• Variation due to
– Common or chance causes
– Assignable causes
• Control chart may be used to discover
“assignable causes”
TYPICAL OUT-OF-CONTROL
PATTERNS
• Point outside control limits
• Sudden shift in process average
• Cycles
• Trends
• Hugging the center line
• Hugging the control limits
• Instability
20
Shift in Process Average
Identifying Potential Shifts
Cycles
8-3 Introduction to Control Charts
8-3.4 Analysis of Patterns on Control Charts
8-3 Introduction to Control Charts
8-3.4 Analysis of Patterns on Control Charts
Trend
Process in Control
• When a process is in control, there occurs a
natural pattern of variation.
• Natural pattern has:
– About 34% of the plotted point in an imaginary
band between 1σ on both side CL.
– About 13.5% in an imaginary band between 1σ
and 2σ on each side of CL.
– About 2.5% of the plotted point in an imaginary
band between 2σ and 3σ on both side CL.
The Normal
Distribution
σ = Standard deviation
Mean
-3σ -2σ -1σ +1σ +2σ +3σ
68.26%
95.44%
LSL USL 99.74%
-3σ +3σ
CL
Control Chart Design Issues
• Basis for sampling
• Sample size
• Frequency of sampling
• Location of control limits
29
Setting Control Limits
Pre-Control
LTL UTL
Red Red
Zone Green Zone Zone
nominal
value
Yellow Zones 31