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n 10
Introduction
Attribute
Those quality characteristics that conform to
specifications or do not conform to
specifications.
There are two types:
1.
Where measurements are not possible ( ex.
Visual inspection, scratches, missing parts
etc.
2.
Where measurements can be made but are
not made because of time , cost , or need
( ex, using go-no-go gage instead of
measuring diameter).
Attribute Data
Introduction
Introduction
Types of Attribute Charts:
A.
B.
Count pieces or
units
n fixed
Count
occurrences
n varies
np chart
P chart
n fixed
P chart
n varies
C chart
U chart
U chart
Objectives
1.
2.
3.
4.
5.
6.
P-Chart
1.
2.
3.
4.
5.
B.
C.
a part,
D.
an entire product, or
E.
a number of products.
Operator(s)
2.
Work center
3.
Department
4.
Shift
5.
Plant
6.
Corporation
3. Collect data
UCL = p + 3
P (1- p)
n
LCL = p - 3
P (1- p)
n
Where
p = average proportion nonconforming for
many subgroups
n = number inspected in a subgroup
np = number nonconforming in a subgroup
n
1
TABLE 1
Inspection Results of Hair Dryer Blower Motor Department, May
Subgroup
Number
Number
Inspection
n
Number
Nonconforming
np
Proportion
Nonconforming
P
1
2
3
.
.
.
19
20
21
22
23
24
25
300
300
300
.
.
.
300
300
300
300
300
300
300
12
3
9
.
.
.
16
2
5
6
0
3
2
0.040
0.010
0.030
.
.
.
0.053
0.007
0.017
0.020
0.0
0.010
0.007
Total
7500
138
P (1- p)
= 0.018 + 3
= 0.041
LCL = p - 3
n
0.018 (1- 0.018)
= 0.018 - 3
P ( 1- p )
n
0.018 (1- 0.018)
300
300
= - 0.005 or 0.0
0.053
UCL = 0.041
0.04
0.03
0.02
P = 0.018
0.01
LCL = 0
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Subgroup
Figure 1: p Chart to illustrate the Trail Central Line and Control Limits
Using the Data of Table 1
1
np npd
pnew
n nd
p 0 pnew
p 0(1 p 0)
UCL P 0 3
n
p 0(1 p 0)
LCL P 0 3
n
138 16
pnew
7500 300
0.017
1
p 0(1 p 0)
n
0.017(1 0.017)
300
- 0.005 or 0.0
LCL 0.017 3
The revised control limits and the central line are shown in Figure 2.
2
0.040
UCL = 0.039
UCL = 0.036
UCL = 0.027
0.030
P0 = 0.017
P0 = 0.014
0.020
P0 = 0.010
0.010
0
June
July
August
LCL
Example:
TABLE 2
Preliminary Data of Computer Modern Final Test and Control Limits for
Each subgroup.
SUBGROUP
March
April
NUMBER
INSPECTED
n
29
30
31
1
2.385
1.451
1.935
2.450
2
5
6
7
8
9
12
13
14
15
16
19
20
21
22
23
26
27
1.997
2.168
1.941
1.962
2.244
1.238
2.289
1.464
2.061
1.667
2.350
2.354
1.509
2,190
2.678
2.252
1.641
1.782
28
29
30
NUMBER
NONCONFORMING
np
55
18
50
42
39
52
47
34
29
53
45
26
47
34
31
38
28
30
113
58
34
19
FRACTION
NONCONFORMING
p
0.023
0.012
0.026
0.017
0.020
0.024
0.024
0.017
0.013
0.043
0.020
0.018
0.023
0.020
0.013
0.016
0.018
0.014
0.042
0.026
0.021
0.011
LIMIT
UCL
0.029
0.031
0.030
0.028
0.029
0.029
0.030
0.030
0.029
0.032
0.029
0.031
0.029
0.030
0.029
0.029
0.031
0.029
0.028
0.029
0.030
0.030
0.011
0.009
0.010
0.012
0.011
0.011
0.010
0.010
0.011
0.008
0.011
0.009
0.011
0.010
0.011
0.011
0.009
0.011
0.012
0.011
0.010
0.010
1.993
30
0.015
0.030
0.010
2.382
2.132
17
46
0.007
0.022
0.029
0.029
0.011
0.011
50,515
LCL
1,015
2
np
1015
= 0.020
n
50,515
Using p, the control limits for each day can be obtained. For March 29,
the limits are
UCL29
p (1 p)
=p+3
n
0.020(1 0.020)
= 0.020 + 3
2382
= 0.029
p(1 p)
= p3
n29
LCL29
= 0.020 + 3
= 0.011
0.020(1 0.020)
2382
2
=p+3
= 0.020 + 3
p (1 p)
n
0.020(1 0.020)
2132
= 0.031
LCL30
= p3
= 0.020 - 3
= 0.009
p(1 p)
n3
0.020(1 0.020)
2132
3
= p
= 0.020
= 0.020
p(1 p)
n
3
0.020(1 0.020)
0.42
n
A Graphical illustration of the trial control limits, central line, and
subgroup values are shown in Figure 3.
Note that as the subgroup size gets larger, the control limits are
closer together
2
Fraction Nonconforming
0.043
UCL
P = 0.02
LCL
0.007
March
April
np npd
Pnew =
n nd
=
=
po
1015 53 113 17
50,515 1238 2678 2382
0.019
=
0.019
Po, is used to calculate upper and lower control limits for the next
period.
The limits cannot be calculated until the end of each day, when the
subgroup size,,n., is known.
Table 3 shows the inspection results for three working days in May.
Control limits and, the fraction nonconforming for May 3 are as follows:
TABLE 3
Inspection Results for May 3, 4, and 5.
Subgroup
May
3
4
5
Number
Inspected
Number
Nonconforming
1535
2262
1872
31
28
45
Calculation are made for. May 3, 4 and 5 and the results posted to
the chart in Figure 4.
3
np
=
1535
31
0.020
Po + 3
0.019(1 0.019)
=
0.019 + 3
1535
=
0.029
Po(1 Po)
LCLMay 3
=
nMay 3
Po - 3
0.019(1 0.019)
=
0.019 - 3
1535
=
0.009
3
Fraction Nonconforming
0.030
UCL
0.020
0.010
P0 = 0.019
LCL
May
June
50,515
2020.6,
say 2000
g
25
Using a value of 2000 for the subgroup size, n, and p o = 0.019, the
upper and lower control limits become
UCL
= Po + 3
= 0.019 + 3
= 0.028
Po(1 Po)
nav
0.019(1 0.019)
2000
LCL
= Po - 3
Po(1 Po)
nav
0.019(1 0.019)
= 0.019 - 3
2000
= 0.010
P0= 0.019
LCL = (n =2000)
LCL = 0
May
June
Central line
= npo
Control limits =
npo 3
npo(1 po)
15(1 0.075)
= 3.8
npo(1 - po)
= 15 3 15(1 0.075)
n = 200
UCL = 26.2
20
nP0 = 15.0
10
LCL = 3.8
6-10
13-17
20-24
27-31
October
Figure 6 :
Process Capability
Process Capability
UCL
Percent nonconforming
Operator responsibility
UCL
n = 500
Variation
UCL
n = 200
n = 50
100P0 = 5.0%
LCL
LCL
Management
Responsibility
Variation
LCL
Operator responsibility
c - Chart Construction
5.
c - Chart Construction
1. Select the Quality Characteristic(s).
c chart ( like p chart ) can be established to control :
A.
B.
C.
a part,
D.
an entire product, or
E.
a number of products.
Operator(s)
2.
Work center
3.
Department
4.
Shift
5.
Plant
6.
Corporation
c - Chart Construction
2. Determine the subgroup size and method
3. Collect data
C - Chart Construction
Table 5
Count of non-conformities (c) by produced 25 car (model x)
COUNT
COUNT
SERIAL
OF
SERIAL
NUMBER
NONCONFORMITIES
COMMENT
COMMENT
MY
MY
MY
MY
MY
MY
MY
MY
MY
MY
MY
MY
102
113
121
125
132
143
150
152
164
166
172
184
MY 185
7
6
6
3
20
8
6
1
0
5
14
3
MY 198
3
MY 208
2
MY 222
7
MY 235
5
assignable cause
MY 258
2
MY 259
8
MY 264
0
MY 267
4
MY 278
chance cause
MY 288
5
1
Total
OF
NUMBER
MY 241
14
MY281
assignable cause
4
NONCONFORMITIES
c = 141
C - Chart Construction
4. Calculate the trial central line and control limits.
UCL C 3 C
LCL C 3 C
Where c is the average count of nonconformities c =c/g, For the
data in Table 4, the calculations are:
C - Chart Construction
c 141
5.64
g
25
UCL c 3 c
LCL c 3 c
5.64 3 5.64
5.64 3 5.64
12.76
1.48, or 0
C - chart Construction
20
14
14
UCL = 12.76
c = 5.64
Serial Numbers
FIG. 8 Control chart for count of nonconformities (c chart), Using preliminary data
5
C - chart Construction
5.Establish the revised central line and control
limits.
c new
cc
g gd
Where
cd = count of nonconformities in the discarded
subgroups
gd = number of discarded subgroups
C - chart Construction
UCL c0 3 c0
LCL c0 3 c0
c new
cc
g gd
141 20 14
25 2
4.65
C - chart Construction
Since cnew is the best estimate of the line, co = 4.65. The revised
control limits for the c chart are:
UCL c0 3 c0
4.65 3 4.65
11.1
LCL c0 3 c0
4.65 3 4.65
1.82 , or 0
These control limits are used to start the chart beginning with
cars produced during the coming days and are shown in Figure
9.
C - chart Construction
Type of
Nonconformity
2
mechanical
1
1
others
Count of
Nonconformities (c)
Serial
Number
1
2
1
3
305
310
321
354
373
409
441
469
485
487
electrical
Total
1
3
UCL = 11.1
UCL = 7.9
10
C0 = 4.65
C0 = 3.05
June
FIG. 9
40
7
47
1
48
5
49
129
150
178
185
209
230
260
283
303
321
347
359
visual
August
c Chart for Canoe blemish non-conformities
5
u
n
c
u
n
UCL u 3
Where
c=
n=
u=
u=
u
n
LCL u 3
u
n
TABLE 6
Count of Non-conformities per unit for waybills
DATE
UCL
Jan.
30
31
Feb.
1
2
3
4
6
7
8
9
10
11
13
14
15
16
17
18
20
21
22
23
24
25
27
28
Mar. 1
2
3
4
NUMBER
INSPECTED
n
LCL
COUNT
NONCONFORMITIES
c
110
82
96
115
108
56
120
98
102
115
88
71
95
103
113
85
101
42
97
92
100
115
99
57
89
101
122
105
98
48
Total
NONCONFORMITIES
PER UNIT
u
120
94
89
162
150
82
143
134
97
145
128
83
120
116
127
92
140
60
121
108
131
119
93
88
107
105
143
132
100
60
2823
1.09
1.15
.93
1.41
1.39
1.46
1.19
1.37
.95
1.26
1.45
1.16
1.26
1.13
1.12
1.08
1.39
1.19
1.25
1.17
1.31
1.03
.94
1.54
1.20
1.04
1.17
1.26
1.02
1.25
3389
1.51
1.56
1.53
1.50
1.51
1.64
1.50
1.53
1.53
1.50
1.55
1.59
1.54
1.52
1.51
1.56
1.53
1.70
1.53
1.54
1.53
1.50
1.53
1.64
1.55
1.53
1.49
1.52
1.53
1.67
0.89
0.84
0.87
0.90
0.89
0.76
0.90
0.87
0.87
0.90
0.85
0.81
0.86
0.88
0.89
0.84
0.87
0.70
0.87
0.86
0.87
0.90
0.87
0.76
0.85
0.87
0.91
0.88
0.87
0.73
c 3389
1.20
n 2823
u
UCLJan 30 u 3 nJan 30
1.2 3
UCLJan 30 u 3
1.20
110
1.2 3
1.51
u
nJan 30
1.20
110
0.89
u Jan30
cJan30 120
1.09
nJan 30 110
5
To determine control limits for the next 5-week period, we can use an average subgroup size.
Nonconformities /Unit
(u)
1.7
UCL
1.6
1.5
1.4
1.3
U = 1.20
1.2
1.1
1
0.9
0.8
UCL
0.7
0.6
30
10
13
15
17
20
22
24
27
Nonconformities /Unit
(u)
1.50
1.40
1.30
u0
1.20
1.10
1.00
0.90
LCL
0.80
0.70
7
5
3
31 29 27
24 22 20 17
Mar.
Fig.
.
Apr 11 U Chart For next period
15
13
10
8
6
Attribute Chart
Sample
Size
Nonconforming
Units
Nonconformiti
es
Constant
np
c
(n = 1)
Constant
Or Varies