Chapter 4
Statistical Quality Control
SPC
CO2: Analyse the effectiveness of
industrial processes using SPC tools
and six sigma
1
Learning Objectives
• Describe categories of SQC
• Describe the use of control charts
• Identify the differences between x-bar, R-,
p-, and c-charts
2
Three SQC Categories
Statistical quality control (SQC): the term used to describe
the set of statistical tools used by quality professionals; SQC
encompasses three broad categories of:
1. Statistical process control (SPC)
2. Descriptive statistics include the mean, standard deviation,
and range
Involve inspecting the output from a process
Quality characteristics are measured and charted
Helps identify in-process variations
3. Acceptance sampling used to randomly inspect a batch of goods to
determine acceptance/rejection
3
Sources of Variation
• Variation exists in all processes.
• Variation can be categorized as either:
– Common or Random causes of variation, or
• Random causes that we cannot identify
• Unavoidable, e.g. slight differences in process variables like
diameter, weight, service time, temperature
– Assignable causes of variation
• Causes can be identified and eliminated: poor employee training,
worn tool, machine needing repair
4
Descriptive Statistics
• Descriptive Statistics include:
– The Mean- measure of central
tendency n
– The Range- difference between
largest/smallest observations in a x i
x i 1
set of data
– Standard Deviation measures n
the amount of data dispersion
around mean
x
– Distribution of Data shape n
2
• Normal or bell shaped or i X
• Skewed σ i 1
n 1
5
n
x i
x i 1
x
n 2
i X
σ i 1
n 1
6
Distribution of Data
• Normal distributions • Skewed distribution
7
Control Chart Patterns
UCL UCL
LCL LCL
Sample observations Sample observations
consistently below the consistently above the
center line center line
3-8
Control Chart Patterns
3-9
SPC Methods-Developing Control
Charts
Control Charts show sample data plotted on a graph with CL, UCL, and LCL
Control chart for variables are used to monitor characteristics that can be
measured, e.g. length, weight, diameter, time
Control charts for attributes are used to monitor characteristics that have
discrete values and can be counted, e.g. % defective, # of flaws in a shirt, etc.
10
Control Charts for Variables
• Use x-bar and R-bar
charts together
• Used to monitor different
variables
• X-bar & R-bar Charts
reveal different problems
• Is statistical control on
one chart, out of control
on the other chart? OK?
12
Control Charts for Variables
• Use x-bar charts to monitor the changes in
the mean of a process (central tendencies)
• Use R-bar charts to monitor the dispersion
or variability of the process
• System can show acceptable central
tendencies but unacceptable variability or
• System can show acceptable variability but
unacceptable central tendencies
13
Constructing an X-bar Chart: A quality control inspector at the Cocoa Fizz soft drink
company has taken three samples with four observations each of the volume of
bottles filled. If the standard deviation of the bottling operation is .2 ounces, use the
below data to develop control charts with limits of 3 standard deviations for the 16 oz.
bottling operation.
Center line and control limit
formulas
Time 1 Time 2 Time 3
Observation 1 15.8 16.1 16.0
x x 2 ...x n σ
x 1 , σx
k n
Observation 2 16.0 16.0 15.9
where (k) is the # of sample means and (n)
is the # of observations w/in each sample
Observation 3 15.8 15.8 15.9
UCL x x zσ x
LCL x x zσ x Observation 4 15.9 15.9 15.8
Sample 15.875 15.975 15.9
means (X-bar)
Sample 0.2 0.3 0.2
ranges (R)
14
Solution and Control Chart (x-bar)
• Center line (x-double bar):
15.875 15.975 15.9
x 15.92
3
• Control limits for±3σ limits:
.2
UCL x x zσ x 15.92 3 16.22
4
.2
LCL x x zσ x 15.92 3 15.62
4
15
X-Bar Control Chart
16
Control Chart for Range (R)
• Center Line and Control Limit • Factors for three sigma control limits
Factor for x-Chart Factors for R-Chart
formulas: Sample Size
(n) A2 D3 D4
2 1.88 0.00 3.27
0.2 0.3 0.2 3 1.02 0.00 2.57
R .233 4 0.73 0.00 2.28
3
5 0.58 0.00 2.11
6 0.48 0.00 2.00
UCLR D4 R 2.28(.233) .53 7 0.42 0.08 1.92
8 0.37 0.14 1.86
LCLR D3 R 0.0(.233) 0.0 9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
17
R-Bar Control Chart
18
Control Charts for Attributes –P-
Charts & C-Charts
Attributes are discrete events: yes/no or pass/fail
– Use P-Charts for quality characteristics that are discrete and involve
yes/no or good/bad decisions
• Number of leaking caulking tubes in a box of 48
• Number of broken eggs in a carton
– Use C-Charts for discrete defects when there can be more than one
defect per unit
• Number of flaws or stains in a carpet sample cut from a production run
• Number of complaints per customer at a hotel
20
P-Chart Example: A production manager for a tire company has inspected
the number of defective tires in five random samples with 20 tires in each
sample. The table below shows the number of defective tires in each
sample of 20 tires. Calculate the control limits.
Sample Number Number of Proportion
of Tires in Defective
Defective each
Tires Sample
1 3 20 .15 # Defectives 10
9
CL p .09
0.1
2 2 20 .10 Total Inspected 100
3 1 20 .05 p(1 p ) (.09)(.91)
σp 0.64
4 2 20 .10 n 20
5 2 20 .10 UCLp p z σ .09 3(.064) .282
Total 10 100 LCLp p z σ .09 3(.064) .102 0
21
P- Control Chart
22
C-Chart Example: The number of weekly customer
complaints are monitored in a large hotel using a
c-chart. Develop three sigma control limits using the data
table below.
Week Number of
Complaints
1 3 Solution:
2 2
3 3
4 1 # complaints 22
CL 2.2
5 3 # of samples 10
6 3
7 2
UCLc c z c 2.2 3 2.2 6.65
8 1 LCLc c z c 2.2 3 2.2 2.25 0
9 3
10 1
Total 22
23
C- Control Chart
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