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    Control Charts Quality Control

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    sudipitm
    The document discusses quality control techniques used by a company to improve product quality. It implemented total quality management and began using control charts to monitor the production process. This led to defects rates dropping to 0.01%. Control charts were used to monitor the quality of inputs, partially completed products, and outputs. Statistical concepts like random sampling and variables/attributes were also used. The document then discusses different types of control charts for both variables and attributes to monitor processes.

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    Control Charts Quality Control

    Uploaded by

    sudipitm
    158 views28 pages
    The document discusses quality control techniques used by a company to improve product quality. It implemented total quality management and began using control charts to monitor the production process. This led to defects rates dropping to 0.01%. Control charts were used to monitor the quality of inputs, partially completed products, and outputs. Statistical concepts like random sampling and variables/attributes were also used. The document then discusses different types of control charts for both variables and attributes to monitor processes.

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    Control Charts

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    Control Charts

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    The document discusses quality control techniques used by a company to improve product quality. It implemented total quality management and began using control charts to monitor the production process. This led to defects rates dropping to 0.01%. Control charts were used to monitor the quality of inputs, partially completed products, and outputs. Statistical concepts like random sampling and variables/attributes were also used. The document then discusses different types of control charts for both variables and attributes to monitor processes.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    158 views28 pages

    Control Charts Quality Control

    Uploaded by

    sudipitm
    The document discusses quality control techniques used by a company to improve product quality. It implemented total quality management and began using control charts to monitor the production process. This led to defects rates dropping to 0.01%. Control charts were used to monitor the quality of inputs, partially completed products, and outputs. Statistical concepts like random sampling and variables/attributes were also used. The document then discusses different types of control charts for both variables and attributes to monitor processes.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 28

    Control Charts Quality Control

    Quality Control Case


    Company producing dependable and high performance products. Implemented TQM Product Quality improved with the use of control charts Products did not conform to product specifications and had variation in product performance. Self Charting at each production centre, work team meet and detect undesirable trends before and after every shift. Defect rates dip to 0.01%

    Inputs

    Conversion process

    Output

    Raw Materials, Parts and supplies

    Production Process

    Products and Services

    Control Charts and Acceptance Tests Quality of Inputs

    Control Charts
    Quality of Partially Completed Products

    Control Charts and Acceptance Tests Quality of Outputs

    Statistical Concepts in QC
    Random Sampling Attributes (Defective or Non Defective) Variables are characteristics which can be measured Sample Size 100% inspection for First Class quality Goods

    Central Limit Theorem


    Sampling Distributions can be assumed to be normal even if the population distributions are not normal Sample mean = Population mean Standard Error of Sample is less than Standard error of population by 1/(n), where n is the sample size

    Accuracy versus Precision in Process Control

    Inaccurate due to bias

    Precise small variability Accurate

    Imprecise large variability

    bias
    x1 u=0 x2=0 u=0 s2

    s1

    s1 < s2

    What to Inspect?
    Product or Service Ball bearing Automobile
    Bank customer service

    Critical Characteristic
    Internal/external diameter Fuel efficiency, polluting emissions, reliability of brakes Waiting time & service time per visit, accuracy of bank statements Service quality & time, food quality, atmosphere

    Restaurant Service

    When to Inspect?
    Inspect after operations that are likely to produce faulty items Inspect before costly operation Inspect before operations that cover up defects Inspect before assembly operations that cannot be undone On automatic machines, inspect first and last pieces of production and in between the process Inspect finished products

    Acceptance Sampling
    Acceptance Sampling is a quality control screening procedure for lots of purchased or internally processed items. Based on the evidence about quality contained in the sample(s) taken, acceptance sampling leads to acceptance or rejection of the submitted lots.

    Acceptance Sampling
    Decision to accept or reject the lot is based on the quality evidence in the samples. A good lot may be rejected (Type 1 error) penalises the producer for unwarranted inspection and replacements. A poor quality lot may be accepted (Type II error) forces on the consumer costs of passing defective units to subsequent stages (cost of rework, rejects, increased repair)

    Inspection methods classified by measurement type and inspection timing


    Type of Measurement By Variable Time of inspection Acceptance Process Sampling Control Sampling Plan Single Double Sequential Sampling Plan Single Double Sequential X Chart R Chart

    By Attribute

    p Chart c chart

    1.0 a

    Producers risk a (Good Lots rejected) P(accept) = 1.0, p< AQL


    AQL = Acceptable Quality Level LTPD = Lot Tolerance Percent Defective

    Probability of Acceptance

    Ideal OC Curve (100% inspection)

    Operating Characteristic OC Curve


    Consumers risk b (Bad lots accepted)

    0 p1 = AQL p2 = LTPD 1.0 Actual Incoming Quality Bad Quality Good Quality Percent Defectives

    Process Control
    A process is under control when it is both accurate and precise.
    The presence of significant bias (lack of accuracy and/or excess variability (lack of precision)) suggests that the process is not meeting the desired process specifications and requires inspection for removing any causes of such deviation that result in poor quality output.

    Process Control
    Process Control is a procedure designed to identify any significant departure from the natural range of variation of some critical product characteristic. The presence of nonrandom variations is attributed to assignable causes and generally prompts management to take corrective action to bring the process under control.

    Process Control Charts for variables


    Whenever the evaluation of process performance requires considerable detail, we single out critical output characteristics that can be measured on a continous scale (length, weight, volume, processing time). Helps to evaluate process accuracy and precision in terms of average level and accuracy Mean X Chart and Range R Chart

    Mean or X Chart
    An X Chart, or mean chart, is a control chart that monitors the accuracy of a process by observing whether the means from periodic sample measurements fall within predetermined limits Centre line- Avg Value Upper Control Line = Mean + 3(StdDev) Lower Control Line = Mean - 3(StdDev)

    Sample Number 1 2 3 4 5 6 7 8 9 10 11 12 Total Mean SD UCL LCL Normal

    1 8.02 8.13 8.01 8.17 7.89 8.15 7.99 8.03 8.03 7.88 8.01 7.88

    X and R Charts for Shaft Diameter in cms Observation Mean Range 2 3 4 5 8.00 8.14 8.15 8.13 8.088 0.150 7.91 8.04 7.84 7.95 7.974 0.290 8.04 7.81 7.91 7.94 7.942 0.230 8.05 7.93 8.08 8.10 8.066 0.240 8.07 8.01 7.97 7.93 7.974 0.180 7.96 8.07 8.03 7.82 8.006 0.330 8.13 7.95 7.92 8.07 8.012 0.210 7.99 8.02 8.00 7.83 7.974 0.200 8.04 8.04 8.04 8.05 8.040 0.020 8.06 8.04 7.96 8.05 7.998 0.180 7.99 8.22 7.99 7.91 8.024 0.310 7.96 7.90 8.00 7.90 7.928 0.120 96.026 8.002 0.048 8.145 7.859

    Min 8.00 7.84 7.81 7.93 7.89 7.82 7.92 7.83 8.03 7.88 7.91 7.88

    Max 8.15 8.13 8.04 8.17 8.07 8.15 8.13 8.03 8.05 8.06 8.22 8.00

    Mean + 3*SD Mean - 3*SD

    2.460 0.205 0.086 0.463 0.000 Negative

    Mean X Chart
    8.100 1 4 8.050 9 11 7 10 8

    UCL

    Shaft Diameter

    8.000 2 7.950 3 5

    Mean

    12 7.900

    Mean Values

    LCL
    7.850

    7.800 1 2 3 4 5 6 7 8 9 10 11 12

    Sample Number

    Range R Chart
    An R Chart, or range Chart, is a control chart used to monitor the precision of a process by observing whether the ranges computed from periodic sample measurements fall within predetermined limits

    Centre line - Avg Range Value Upper Control Line = Mean + 3(StdDev) Lower Control Line = Mean - 3(StdDev)

    Range R Chart
    0.350 6

    UCL

    11 0.300 2

    Range (Shft Diameter)

    0.250 4 3 7 0.200 5 0.150 1 12 0.100 8 10 Range Values

    Mean

    0.050 9 0.000 1 2 3 4 5 6 7 8 9 10 11 12

    LCL

    Sample Number

    Process Control Charts for Attributes


    For many operations, all we need to know is whether the quality of an item or some aspect of the process is satisfactory or not. This may not require any detailed measurements, and process control can be assessed by describing the process or its output in terms of some critical attributes

    P Chart for Proportion of Defectives C Chart for Number of Defects per unit

    P Chart for Proportion of Defectives


    A P Chart, or Proportion-defective chart, is a control chart used to monitor a process by observing the proportion with which some selected attribute appears in samples taken periodically Centre line - avg proportion of defectives Upper Control Limit = Mean +3(StdDev) Lower Control Limit = Mean - 3(StdDev) Std Dev = SQRT(p(1-p)/n), LCL = 0 if LCL < 0

    Abseentism % for Nurses P Chart Day Sample Nurses Proportion Siz e Absent Absent P 1 64 4 6.25% 2 64 3 4.69% 3 64 2 3.13% 4 64 4 6.25% 5 64 2 3.13% 6 64 5 7.81% 7 64 3 4.69% 8 64 4 6.25% 9 64 8 12.50% 10 64 2 3.13% 11 64 3 4.69% 12 64 2 3.13% 13 64 1 1.56% 14 64 3 4.69% 15 64 4 6.25% Total Avg P SD SD UCL LCL BiNomial 960 50/960 50 78.13%

    5.21% 5.21% 2.80% 2.62% SQRT(((AvgP*(1-AvgP))/N) 13.61% 0.00%

    P Chart
    14.00%

    9 12.00%

    UCL

    Abseentism Percentage

    10.00%

    8.00%

    6 %Absent

    6.00%

    15

    Mean
    2 7 11 14

    4.00% 3 2.00% 13 5 10 12

    LCL
    0.00% 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

    Days

    C Chart for Number of Defects per unit


    A C Chart is a control chart used to monitor a process by counting the number of undesirable occurrences C, such as defects or complaints, per unit of output samples Centre line - avg proportion of defectives Upper Control Limit = Mean +3(StdDev) Lower Control Limit = Mean - 3(StdDev) STD Dev = SQRT(Mean) LCL = 0 if LCL is negative

    C Chart
    Month Sample Unit 1 2 3 4 5 6 7 8 9 10 11 12 Number of Accidents 5 3 4 2 1 4 3 6 5 12 4 3 52 52/12 SQRT(Avg) 4.33 2.08 10.58 0.00 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total Avg SD UCL LCL Poisson

    C Chart (No of Accidents)


    14

    12

    10

    UCL
    10

    No of Accidents

    8 Accidents 6 1 4 2 2 4 5 0 1 2 3 4 5 6 7 8 9 10 11 12 3 6 7 8 9 11 12

    Mean

    LCL

    Months

    Some Quality Tests for Health and Hygiene


    Water Potability (Fit for Drinking Purpose) Contamination of Food Puffing of Cans and Bottles Disinfectants and Time Kill Tests Anti Bacterial and Fungal Tests Testing for Claims

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