Chapter 6.
Control Charts for Variables
Control Charts for x and R
x: quantity of interest x ∼ N (µ,σ )
x1 , x2 … , xn : samples of x
⎛ σ ⎞
x ∼ N ⎜ µ, ⎟
⎝ n⎠
g p Data with Unknown µ and σ
Subgroup
x : grand average of x, best estimate for µ
R1 , R2 … , Rm : ranges of m samples
Phase I Application of x and R Charts
• Equations
q 5-4 and 5-5 are trial control limits.
– Determined from m initial samples.
• Typically 20-25 subgroups of size n between 3 and 5.
– Any
y out-of-control p
points should be examined for assignable
g
causes.
• If assignable causes are found, discard points from calculations
and revise the trial control limits.
• Continue examination until all points plot in control
control.
• Adopt resulting trial control limits for use.
• If no assignable cause is found, there are two options.
1. Eliminate point as if an assignable cause were found and revise limits.
2. Retain point and consider limits appropriate for control.
– If there are many out-of-control points they should be examined
for patterns that may identify underlying process problems.
Example 5-1
Assume spec tolerance is 1.5 +/- 0.5 micron.
Nonconformance probability:
Cp: Process Capability Ratio (PCR)
Note: 6σ spread is the basic definition of process capability. 3σ above mean and 3σ below.
R
If σ is unknown, we can use σˆ = . σˆ in the example is 0.1398.
d2
P : % of specification band the process uses up
up. P can be estimated as:
Revision of Control Limits and Center Lines
• Effective use of control charts requires periodic review and revision of
control limits and center lines.
• Sometimes users replace the center line on the x chart with a target
value.
• When R chart is out of control, out-of-control points are often
eliminated to re-compute a revised value of R which is used to
determine new limits and center line on R chart and new limits on x
chart.
Phase II Operation of Charts
• Use of control chart for monitoring future production, after a set of
reliable limits are established, is called phase II of control chart
usage (Figure 5-4).
• A run chart showing individuals observations in each sample, called
a tolerance chart or tier diagram (Figure 5-5), may reveal patterns or
unusual observations in the data.
Control vs. Specification Limits
• Control limits are derived from
natural process variability, or
the natural tolerance limits of a
process.
• Specification limits are
determined externally, for
example by customers or
designers.
• There is no mathematical or
statistical
t ti ti l relationship
l ti hi bbetween
t
the control limits and the
specification limits.
Rational Subgroups
• x charts monitor between-sample p variability.
y
• R charts measure within-sample variability.
• Standard deviation estimate of σ used to construct
control limits is calculated from within-sample variability.
• It is not correct to estimate σ using
Guidelines for Control Chart Design
• Control chart design requires specification of sample size, control
li i width,
limit id h andd sampling
li ffrequency.
– Exact solution requires detailed information on statistical characteristics
as well as economic factors.
– The problem of choosing sample size and sampling frequency is one of
allocating sampling effort.
• For x chart, choose as small a sample size consistent with
magnitude of process shift one is trying to detect. For moderate to
large shifts, relatively small samples are effective. For small shifts,
larger samples are needed.
• For small samples, R chart is relatively insensitive to changes in
process standard deviation
deviation. For larger samples (n > 10 or 12)
12), s or
s2 charts are better choices.
• NOTE: Skip Section on Changing Sample Size (pages 209-212)
Charts Based on Standard Values
D1 = d2 - 3d3
D2 = d2 + 3d3
d2 : mean of distribution of relative range
d3 : standard deviation of distribution of relative range
Interpretation of x and R Charts
