Lot-by-Lot Acceptance Sampling For Attributes

Chapter 15
Lot-by-Lot Acceptance Sampling

for Attributes
The Acceptance-Sampling
Problem
• Acceptance sampling is concerned with
inspection and decision making regarding
products.
Three aspects of sampling
• The purpose of acceptance sampling is to

sentence lots, not to estimate the lot quality
– Although, some plans do this
• Acceptance sampling is not quality control
– Reject or accept lots only
– Even if lots are of the same quality, sampling
will accept some lots and reject others
Three aspects of sampling
• Quality cannot be inspected into the product

– Acceptance sampling is an audit tool that
insures that the output of a process conforms to
requirements
Problem
• Three approaches to lot sentencing:

1. Accept with no inspection
2. 100% inspection
3. Acceptance sampling
Problem
Why Acceptance Sampling and Not 100%
Inspection?
• Testing can be destructive
• Cost of 100% inspection is high
• 100% inspection is not feasible
– Requires too much time
– Can be inaccurate
• If vendor has excellent quality history
Problem
Advantages and Disadvantages of Sampling
Advantages
• Less expensive
• Reduced damage
• Reduces the amount of inspection error
Disadvantages
• Risk of accepting “bad” lots, rejecting “good” lots
• Less information generated
• Requires planning and documentation
Problem
Types of Sampling Plans
• There are variables sampling plans and attribute
sampling plans (this chapter is about attributes)
1. Single sampling plan
2. Double-sampling plan
3. Multiple-sampling plan
4. Sequential-sampling
Problem
Lot Formation
• Considerations before inspection:
– Lots should be homogeneous
• Produced by the same machine, same operators,
common raw materials, approximately the same
time
Lot Formation
• Considerations before inspection:
– Larger lots more preferable than smaller lots
• More economical
– Lots should be conformable to the materials-
handling systems used in both the vendor and
consumer facilities.
Problem
Random Sampling
• The units selected for inspection should be chosen
at random.
• If random samples are not used, bias can be
introduced.
• If any judgment methods are used to select the
sample, the statistical basis of the acceptance-
sampling procedure is lost.
Guidelines for Using acceptance
Sampling
• It is a statement of the sample size to be
used and the associated acceptance or
rejection criteria.
• Sampling scheme is defined as the set of
procedures consists of acceptance sampling
plans in which lot sizes, sample sizes, and
acceptance criteria along with the 100%
inspection and sampling are related.
• Acceptance sampling procedure depends upon the
objectives and the history of the organization.
• Application of methodology is not static. It keep

on moving from one level to another. e.g, we
might begin with attribute sampling, and as our
experience with the supplier increase then move to
much less inspection and variable sampling
Single-Sampling Plans For
Attributes
Definition of a Single-Sampling Plan
• A single sampling plan is defined by sample size, n, and the
acceptance number c. Say there are N total items in a lot.
Choose n of the items at random. If more than c of the items
are unacceptable, reject the lot.
• N = lot size
• n = sample size
• c = acceptance number
• d = observed number of defectives
• The acceptance or rejection of the lot is based on the results
from a single sample - thus a single-sampling plan.
Example
• N = 10000, n = 89, c = 2
– From a lot of 10,000, take a sample of size 89
– Observe the number of defectives, d
– If d < 2, accept
– Otherwise, reject
Single-Sampling Plans For
Attributes
The OC Curve
• The operating-characteristic (OC) curve measures
the performance of an acceptance-sampling plan.
• The OC curve plots the probability of accepting the
lot versus the lot fraction defective.
• The OC curve shows the probability that a lot
submitted with a certain fraction defective will be
either accepted or rejected.
Example
• If p = .01, Pa = .9397
• If p = .02, Pa = .7366 means that 73.66% of
lots will be expected to be accepted and
26.34% will be rejected
Effect of n and c on OC curves
• Fig. 15.3 is the ideal OC curve
– Pa = 1.0 until a level of quality that is
considered ‘bad’ is reached
– But it can never be attained in practice.
OC curve for different values of n
– By increasing the sample size, we get closer to
the ideal OC curve
OC curve for different values of c
– As c is decreased, the OC curve shifts to the left
– When c = 0, it is very hard on the vendor
• Type A or Type B OC curves
– In the type B OC curve, it is assumed that the samples
come from the large lot or from a stream of lots
selected at random.
– Binomial distribution is used as p is constant
– In the Type A OC curve, isolated lot of finite size is
used with size N
– The exact probability distribution is ‘hypergeometric’
as p is not constant.
– Type A OC curve will lie below Type B
Rectifying inspection
• Acceptance sampling require corrective action
when lots are rejected
– 100% screening of rejected lots
– Defective items are removed, returned to the supplier,
or replaced.
– Such sampling programs are known as “rectifying
inspection programs”
– Affects the outgoing quality
– Fraction defective =po, average fraction defective = p1
Rectifying inspection
Rejected lots
Fraction
defective
0
Incoming lots Outgoing lots
Inspection
Fraction defective activity
p0 Fraction defective
Fraction p1<p0
Accepted defective
lots p0
Average outgoing quality
• AOQ is the quality in the lot resulting from
applying rectifying inspection
– In a lot of size N, there will be
• n items in the sample that, after inspection, contain
no defectives (all of the defectives were replaced)
• N-n items that, if the lot is rejected, also contain no
defectives (the balance of the lot was inspected
100%)
• N-n items that, if the lot is accepted, contain p(N-n)
defectives
Average outgoing quality
• AOQ = [Pa p (N-n)]/N
• Example
– N = 10000, n = 89, c = 2, p = .01
– Previously determined that Pa = .9397
– AOQ [(.9397)(.01)(10000-89)]/10000
– AOQ = .0093
– Since (N-n)/N 1, AOQ ~ Pap
AOQ curve for rectifying inspection
for n = 89, c = 2
• When incoming quality is very good,
average fraction defective of outgoing lots
is low
• When incoming quality is very poor,
average fraction defective of outgoing lots
is low
Average outgoing quality limit
• AOQL = .0155
– No matter how bad the incoming lots are, the
outgoing quality level will never be worse than
1.55% fraction defective
Military Standard 105E
(ANSI/ASQC Z1.4 ISO 2859)
Description of the Standard
• Developed during World War II
• MIL STD 105E is the most widely used
acceptance-sampling system for attributes
• Gone through four revisions since 1950.
• MIL STD 105E is a collection of sampling
schemes making it an acceptance-sampling
system
(ANSI/ASQC Z1.4 ISO 2859)
• Three types of sampling are provided for:
1. Single
2. Double
3. Multiple
• Provisions for each type of sampling plan
include
1. Normal inspection
2. Tightened inspection
3. Reduced inspection

• The acceptable quality level (AQL) is a primary focal
point of the standard
• The AQL is generally specified in the contract or by the
authority responsible for sampling.
• Different AQLs may be designated for different types of
defects.
• Defects include critical defects, major defects, and
minor defects.
• Tables for the standard provided are used to determine
the appropriate sampling scheme.

• Switching Rules
– Normal to tightened
– Tightened to normal
– Normal to reduced
– Reduced to normal
– Discontinuance of inspection
Procedure
1. Choose the AQL
2. Choose the inspection level
3. Determine the lot size
4. Find the appropriate sample size code letter from Table 15-
4
5. Determine the appropriate type of sampling plan to use
(single, double, multiple)
6. Enter the appropriate table to find the type of plan to be
used.
7. Determine the corresponding normal and reduced
inspection plans to be used when required.
Example
• Suppose a product is submitted in lots of size
N = 2000. The AQL is 0.65%. Say we wanted
to generate normal single-sampling plans.
• For lots of size 2000, (and general inspection
level II) Table 15-4 indicates that the appropriate
sample size code letter is K.
• From Table 15-5 for single-sampling plans
under normal inspection, the normal inspection
plan is n = 125, c = 2.
Discussion
• There are several points about the standard that
should be emphasized:
1. MIL STD 105E is AQL-oriented
2. The sample sizes selected for use in MIL STD 105E
are limited
3. The sample sizes are related to the lot sizes.
4. Switching rules from normal to tightened and from
tightened to normal are subject to some criticism.
5. A common abuse of the standard is failure to use the
switching rules at all.
Switching rules
“And” conditions Start
O Production steady
O 10 consecutive lots
2 out of 5
accepted consecutive lots
O Approved by
rejected
responsible authority
Normal Tightened
Reduced
“Or” conditions
O Lot rejected 5 consecutive

O Irregular production lots accepted
O Lot meets neither accept
nor reject criteria

O Other conditions 10 consecutive Discontinue
warrant return to lots remain on
inspection
normal inspection tightened inspection
Dodge-Romig Plans
• For rectifying inspection
• See Table 15-8 for an example for
AOQL = 3%
– Indexed by lot size (N) and process average (p)
Example
• N = 5000, p = .01
• Want a single sampling plan (w/rectifying
inspection) with AOQL = 3%
• Read n = 65, c = 3 from the table
• These plans minimize ATI
– Pa = .9957 at p = .01 (determined as previously)
– ATI = 65 + (1 - .9957)(5000 – 65) = 86.22
Example, cont.
• Also, note that LTPD = 10.3%
• This is the point on the OC curve for which
Pa = .10
– That is, this plan provides that 90% of
incoming lots that are as bad as 10.3%
defective will be rejected
LTPD plans
• Can also develop a plan for a specified
LTPD
• Table 14-9 is for LTPD = 1%
Example
• N = 5000, p = .25%
• We want a single sampling plan
(w/rectifying inspection) with LTPD of 1%
• Find n = 770, c = 4

Lot-by-Lot Acceptance Sampling For Attributes

Uploaded by

Copyright:

Available Formats

Lot-by-Lot Acceptance Sampling For Attributes

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lot-by-Lot Acceptance Sampling For Attributes

Uploaded by

Copyright:

Available Formats

Chapter 15

Lot-by-Lot Acceptance Sampling

• The purpose of acceptance sampling is to

• Quality cannot be inspected into the product

• Three approaches to lot sentencing:

• Application of methodology is not static. It keep

Description of the Standard

Description of the Standard

“And” conditions Start

O Lot rejected 5 consecutive

nor reject criteria

You might also like