SQC (Chapter 4)
SQC (Chapter 4)
Acceptance sampling
4.1. Introduction
Inspection of raw materials, semi-finished products, or
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made regarding lot disposition.
Usually, this decision is either to accept or to reject
3) Acceptance sampling.
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Acceptance sampling is most likely to be useful in the
following situations:
When testing is destructive
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Advantages of Acceptance Sampling
When acceptance sampling is contrasted with 100%
inspection, it has the following advantages:
It is usually less expensive because there is less
inspection.
There is less handling of the product, hence reduced
damage.
It is applicable to destructive testing.
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Disadvantages of Acceptance sampling
There are risks of accepting "bad" lots and rejecting
"good" lots.
Less information is usually generated about the
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consumer facilities.
Rectifying Inspection: Acceptance sample
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 defective items either
removed for subsequent rework or return to the
supplier, or replaced from a stock of known good
items.
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Average Sample Number (ASN): For a single
sampling LASP (n, c) we know each and every
lot has a sample of size n taken and inspected or
tested. For double, multiple and sequential
LASP's, the amount of sampling varies
depending on the number of defects observed.
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Random Sampling:: the units selected for inspection from the
15 lot.
ii) Inspect each and every unit included in the sample
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b) If X>c, the lot is rejected. In this situation, inspect
the whole lot and replace all defectives found in the lot
by non defectives and release the lot for sale.
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The OC function is defined as the probability of
= =
OC(𝜃) = +
+ + ….+
OC(𝜃) = + + +
….+
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Note that
This OC function is a decreasing function
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I. (Fix c, let c=0): Suppose we want to be at least 95%
certain of rejecting a batch that has 5% of defectives, how
large should we take n?
• c =0 corresponds to taking a sample of n items and
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P(rejecting) ≥0.95 P(accepting) ≤ 1-0.95, that is: OC(𝜃) 0.05
Since OC( ) =(1- )n , for c=0
OC(0.05) = (1-0.05)n
(0.95)n 0.05
By taking natural logarithm on both sides we get,
n*log0.95 log 0.05
= n log 0.05 \log 0.95 =58.4
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n must be an integer so choose n=59, we can use the
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Solution:
2% , OC( ) 0.01
OC(0.02) = (1-0.02)n 0.01
(1-0.02)n 0.01 . By taking natural logarithm on both sides we get,
n*log(0.98) log 0.01
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II. (fix n): If we take n =100, then what value should we
take for c if we want to make sure at least 95% of
rejecting a batch which has 5% of defectives?
We choose c to solve OC (0.05) 0.05 , try c= 0, 1, 2, 3… each in turn.
c= 0, OC(0.05) = P(X ≤ 0) = P(X=0)
=(1-0.05)100 = (0.95)100 = 0.00592
c=1, OC(0.05) = P(X 1) = p(X=0) + P(X=1)
100
= (0.95) 100
+ (0.05)1 (0.95)99 = 0.037
1
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c=2, OC(0.05) =P(X 2) = P(X=0) + p(X=1) +P(X=2)
100 99 100
OC(0.05) = (0.95) 100
+ (0.05) (0.95) + (0.05)2 (0.95)98 = 0.11
1
1 2
< 5%, 𝑐 = 0, 1
Therefore, OC(0.05) = ൜
> 5%, 𝑐 = 2, 3, 4, … , 100
c = 0 and c = 1 both satisfy the constraint.
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c=0 c=1
Buyer’s risk Lower Higher (we might accept a bad lot)
Producer’s risk Higher (we might reject a good lot) Lower
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III. (Fix ): A buyer tests a sample of n fuses from
infinite batch (population) of fuses. She will accept the
batch if the sample contains ≤4% defectives. She is
considering by taking a sample of n = 25, 50, 75, 100
etc fuses. How large should “n” be if she wants to be
90% of certain of rejecting a batch with 10% of
defectives? i.e. if c/n=0.04, find the value of c and n so
that OC (0.1) 10%.
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Possible solutions to check: n=25, c=1; n=50, c=2; n=75, c=3
and n=100, c=4. Therefore, for c =0, n=25, OC(0.1) implies
that OC(0.1)= = P(X=0)+P(X=1)
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The OC function for the 3 sampling schemes is tabulated below.
c= 1, n=25 c=2, n=50 c=3, n=75
𝜃 0.01 0.97 0.986 0.993
0.03 0.83 0.811 0.812
0.04 0.74 0.677 0.647
0.05 0.64 0.541 0.480
0.1 0.27 0.111 0.05
0.2 0.027 0.001 7x10-5
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With an increasing proportion of defectives, the probability
that the lot is accepted decrease.
The ideal OC function is very close to 1 for small values of
and very close to 0 for values of greater than an acceptable
quality limit.
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Case 2: N is small (consider N is finite)
Suppose a lot consists of N (consider N is finite) items
𝜃 = proportion of defectives
n = sample of size
geometric distribution.
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i. The probability of getting x defectives in the sample is:
M N M
x n x
P(X=x) = , where x n , n -x N M
N
n
ii. The probability of accepting the lot having not more than c defectives in the
sample of n items is,
σ 𝑐𝑥=0 ൫𝑀 ൯൫𝑁−𝑀 ൯
𝑥 𝑛−𝑥
P(X≤c) =
൫𝑁
𝑛൯
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Example : Suppose N=1000, c=0 (i.e. we have a batch
of size 1000. We use the rule “accept if lot/batch the
sample contains no defectives”.)
Choose n so that we are 95% certain of rejecting a batch
with 5% defectives
We want to choose n so that OC(0.05) 0.05
𝑀
𝑁
= 5% , N =1000, M=N =50.
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We want to choose n large enough to make sure this
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b) Double-stage sampling plan
A number of extensions of single-sampling plans for
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Example: Consider double – stage binomial sampling
scheme with n= 50, cl = 0, d1=2. m = 150, c2 = 3. That is
to mean “Take a sample of size 50, then
If it contains no defectives accept the batch.
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The OC function for the general case (n, m, c1, d1, c2), X=x and
and c2 =6.
Solution:
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OC() =
+ *.
OC() =
+ P()*
+ P()*.
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2. Suppose we intend to use the plan with n =40, c 1 = 0,
+ *.
= +
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OC() = +
= + 4< 0.05
= < ¼ (0.05 -
= (39 + m) > ln(¼ (0.05 - )/ln(0.9) = 44.9
m > 5.9, take m = 6.
The Average Sample Number (Average total inspected)
In single sampling, the size of the sample 'inspected from the
P(c1<X<d1).
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Hence, the average sample number (average total inspected)
is given as
• ASN = n(P(X≤c1) +P(X≥d1)) + (n+m)P(c1<X<d1)
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4.3. Comparing and Choosing Sampling schemes
The Rejectable Quality Level (RQL) is the value of for
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• Consider single-stage sampling scheme:
OC(0.01)>90%
Solutions
From table 1 From table 2
n= 25 c=0 c≥1 no solution
n= 50 c≤ 1 c≥1 n=50, c=1
n= 70 c≤ 3 c ≥2 n=70, c=2 or 3
n= 80 c≤ 4 c ≥2 n=80, c=2,3 or 4
n= 100 c≤ 5 c ≥2 n=100, c=2,3,4 or 5
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Table 1: Rejectable Quality Level
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Table 2: Acceptable Quality Level
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Average Outgoing Quality (AOQ)
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This maximum, which is the worst possible long term AOQ, is
called the average outgoing quality limit (AOQL) and
AOQL =.
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Example: Suppose we want to design a one-stage
sampling plan with infinite N and c = 0 such that
OC(AQL) > 80% where AQL = 0.01 and AOQL < 3%,
then what values of n satisfy these two constraints?
Solution:
• First, since c = 0, OC () = (1 - . Hence,
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Second AOQ( = OC( = (1 - , as c = 0
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Choose n so that < 0.03, solve by trial and error to give n
12.
Therefore, take n to be any value between 12 and 22.
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Example: Suppose we want to design a one-stage sampling
plan (with infinite N) and then
(i) find n so that AOQL < 2% if c=0
(ii) find AOQL if n=25 and c = 0
Solution:
(i) c = 0 implies OC ( = (1 - , then AOQ () = (1 -
Find its unique maximum by differentiating and equating to
zero, then AOQ() has a maximum at = .
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This implies that AOQL = and now choose n so that <
0.02.
n 16 17 18
nn 0.022 0.021 0.019
(n + 1)n+1
Therefore, AOQL < 2% for all n values greater than or
equal to 18. That is if we take n = 18, we know
< 2% of items sold will be defective
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(ii) c = 0 and n =25, AOQL = =
, that is if we take n = 25, we know
< 1.4% of items sold will be defective.
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4.4 Acceptance Sampling for variate (quantitative variables)
This section summarizes acceptance-sampling techniques for
Each item in the batch has a measurement made on it, X i, X1, X2, X3
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Method: (Case 2)
Fix n and k
Take a sample of size n
1
Measure Xi, X n X i and X n ~ N(µ, 2 / n )
n
If X n > LSL+k , then accept the batch (lot).
Otherwise, reject the batch.
Note that k need not be an integer.
The operating characteristic (OC) function is defined as the probability of
accepting a batch (lot), but this can be regarded as either a function of µ or 𝜃.
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LSL
We have seen (under case 2), 𝜃 = .
LSL
This implies that =
1
Hence, P(Accepting batch/𝜃) = OC𝜃(𝜃)
= n 1 ( ) k
Example: A process makes springs which should be able to support a
weight of 5kg
“Defective”= “X <5kg”. X is the maximum weight the spring can
support. Assume strength springs are iid ~ N(µ, 0.52 ).
We want to choose an acceptance sampling scheme so that
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OC(0.05) < 0.05 and OC𝜃(0.01) > 0.95. Find the values n and k
Solution:
OC(0.05) < 0.05 n 1 (0.05) k 0.05
n 1.645 k 0.05
n (1.645 k ) 1 ( 0.05)
n (1.645 k ) 1.645
1.645
k 1.645 …. (i)
n
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There are an infinite number of solutions. We are likely to find the
solution with smallest value of n. From the graph (k versus n) of
these two inequalities (i and ii) the intersection point gives the
minimum value of n.
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To get the intersection point solve,
1.645
k 1.645 and
n
1.645
k 2.33
n
2k = 2.33+1.645 k=1.987 n=23
Hence we take n=23 , k=1.987
This means if we use the rule “Take a sample of 23 items, and
accept the batch if X 23 > LSL+1.987
Decision rule: “If sample mean is greater than 6 kg, accept the batch.
If sample mean is less than 6 kg , reject the batch.”
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Advantages & Disadvantages of sampling by quantitative
variables.
Advantages
Usually sampling by varitaes requires sample sizes than an
equivalent sampling by attributes(it is important in about
distructive sampling).
It is easier to draw inferences about the batch we are
sampling by variates.
Disadvantages
We need the normality assumption to hold
It involves measuring, this is usually more costly than
classifying an item as good/bad
It can not used if we are dealing with quality that cannot be
measured.
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