Escolar Documentos
Profissional Documentos
Cultura Documentos
1-Jul-2010, Rev 0
1
Quality Control
1. What is Quality Control?
2. What is Statistical Process Control (SPC)?
3. Why use SPC?
4. Benefit of SPC
5. Type of Statistical Control Chart.
6. Type of Variable Control Chart
7. Type of Attribute Control Chart
8. Which control chart to use?
Quality Assurance
1. What is Quality Assurance?
2. What is acceptance sampling?
3. Why use acceptance sampling?
4. How/When to use acceptance sampling?
5. Acceptance sampling explained
Control:
An evaluation to indicate needed corrective responses; the act of
guiding a process in which variability is attributable to a constant
system of chance causes.
Quality control:
The observation techniques and activities used to fulfill
requirements for quality
e.g on-line inspection, use of control-chart
3
What is Statistical Process Control (SPC)?
5
Why use SPC?
6
Benefit of SPC
7
Type of Statistical Control Chart.
8
Type of Common Variable Control Chart use in Quality.
X-Bar chart
• Deals with a average value in a process.
R chart
• Takes into count the range of the values
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Example of Variable Control Chart – Xbar Chart
= ∑x 50.09
x= = = 5.01 cm
k 10
where
x = average of sample means
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Example of Variable Control Chart – Xbar Chart
5.10 –
5.08 –
UCL = 5.08
5.06 –
5.04 –
5.02 –
x= = 5.01
Mean
5.00 –
4.98 –
4.96 –
LCL = 4.94
4.94 –
4.92 –
| | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number
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Example of Variable Control Chart – R chart
where
R = range of each sample
k = number of samples
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Example of Variable Control Chart – R chart
0.28 –
0.24 –
UCL = 0.243
0.20 –
Range
0.16 – R = 0.115
0.12 –
0.08 –
0.04 – LCL = 0
0– | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10
Sample number
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Quality Control
Determining Control Limits for x-bar and R-Charts
P chart
• A chart of the percent defective in each sample set with
unequal sample sizes.
C chart
• A chart of the number of defects per unit in each sample set.
U chart
• A chart of the average number of defects in each sample set.
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Example of Attribute Control Chart – P chart
NUMBER OF PROPORTION
SAMPLE DEFECTIVES DEFECTIVE
1 6 .06
2 0 .00
3 4 .04
: : :
: : :
20 18 .18
200
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Example of Attribute Control Chart – P chart
total defectives
p = total sample observations = 200 / 20(100) = 0.10
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Example of Attribute Control Chart – P chart
0.20
0.16
0.14
Proportiondefective
0.12
p = 0.10
0.10
0.08
0.06
0.04
2 4 6 8 10 12 14 16 18 20
Sample number
19
Example of Attribute Control Chart – C chart
A new hotel had completed. The hotel room need to be
inspected before ready for opening. The quality inspector
collected the following data:
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Example of Attribute Control Chart – C chart
24
UCL = 23.35
21
18
Number of defects
c = 12.67
15
12
3 LCL = 1.99
2 4 6 8 10 12 14 16
Sample number
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Example of Attribute Control Chart – U chart
A transcription company wants to assess its accuracy. An
analyst samples transcribed documents and counts the number
of errors. Because the number of pages in each document
differs, comparing the number of errors across documents is
misleading. Instead, the analyst compares the average errors
per page.
_ _ . 0.243
= 0.243 −3 = − 0.0416 OR 0
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901 219
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Quality Control
Example of Attribute Control Chart – U chart
23
Which Control Chart to use?
%
Variable No Defective or Defects
Data? Defects?
Yes %
Defective
No Constant Constant
Rational
I & MR chart Sample Sample
Subgroups?
Size? Size?
No No
Yes Yes Yes
p-chart u-chart
Yes Easy to
Subgroup
Compute
Size >8?
sigma?
np- or p-chart c- or u-chart
No Yes
No
Attribute charts require larger sample sizes 50
to 100 parts in a sample
X-bar & R chart X-bar & S chart
Variable charts require smaller samples 2 to 10
parts in a sample
24
What is Quality Assurance?
Assurance:
The act of giving confidence, the state of being certain or the
act of making certain.
Quality assurance:
The planned and systematic activities implemented in a quality
system so that quality requirements for a product or service will
be fulfilled.
25
What is acceptance sampling?
• Acceptance Sampling
To ensure that the quality level is within the level that has
been predetermined
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Quality Assurance
What is acceptance sampling?
Lot size = N
Sample size = n
Acceptance number = c
Defective items = d
If d <= c, accept lot
If d > c, reject lot
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Why use acceptance sampling?
28
How/When use acceptance sampling?
29
How/When use acceptance sampling?
30
How/When use acceptance sampling?
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Quality Assurance
How/When use acceptance sampling?
32
Quality Assurance
Acceptance sampling explained
• Sampling Plan -
Forms after n and c values have been found.
• Producers risk -
Risk associated with a lot of acceptable quality rejected.
• Consumers risk -
Receive shipment, assume good quality, actually bad quality.
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Quality Assurance
Acceptance sampling explained
• Alpha (α) –
Type I error(producers risk).
• Beta (ß) -
Type II error(consumers risk)
• N-
Sample size taken for your sampling plan.
• C-
Where rejections would occur when defects exceeded this
percent
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Quality Assurance
Acceptance sampling explained
0%
0 1 2 3 4 5 6 7 8 9 10
Cut-Off % Defective in Lot
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Quality Assurance
Acceptance sampling explained
Attributes(“go no-go”)
Variables
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Quality Assurance
Acceptance sampling explained
• Attributes(“go no-go”) -
Defectives-product acceptability across range
Defects-number of defects per unit
• Variable(continuous) -
Usually measured by mean and standard deviation
Remember
You are not measuring the quality of the lot, but, you are to
sentence the lot to either reject or accept it
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Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
• Normal inspection -
Use of a sampling plan with acceptance criteria devised to
secure the producer a high probability of acceptance when the
process average of the lot is better than the AQL. Used when
there is no reason to suspect the process
average differs from an acceptable level.
• Tightened inspection –
Use of a sampling plan with an acceptance criteria that is
tighter than that for the corresponding plan for normal
inspection. Invoked when the inspection results of consecutive
lots indicate that the process average might be poorer than the
AQL.
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Quality Assurance
Acceptance sampling explained
• Sampling:
Sample selection must be drawn from the lot by simple
random sampling.
42
Quality Assurance
Acceptance sampling explained
43
Quality Assurance
Acceptance sampling explained
26 50 C D E
51 90 C E F
91 150 D F G
151 280 E G H
281 500 F H J
501 1,200 G J K
1,201 3,200 H K L
3,201 10,000 J L M
10,001 35,000 K M N
35,001 150,000 L N P
150,001 500,000 M P Q
500,001 and Over N Q R
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Quality Assurance
Acceptance sampling explained
S am p le 0.010 0.015 0.025 0.040 0.065 0.10 0.15 0.25 0.40 0.65 1.0 1.5 2.5 4.0 6.5 10 15
S iz e
Code S am p le Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc Ac Rc
L etter S iz e
A 2 0 1
B 3 0 1 1 2
C 5 0 1 1 2 2 3
D 8 0 1 1 2 2 3 3 4
E 13 0 1 1 2 2 3 3 4 5 6
F 20 0 1 1 2 2 3 3 4 5 6 7 8
G 32 0 1 1 2 2 3 3 4 5 6 7 8 10 11
H 50 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15
J 80 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
K 125 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
L 200 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
M 315 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
N 500 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
P 800 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
Q 1 ,2 5 0 0 1 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
R 2 ,0 0 0 1 2 2 3 3 4 5 6 7 8 10 11 14 15 21 22
45
Quality Assurance
Acceptance sampling explained
46
Quality Assurance
Acceptance sampling explained
• Example
A lot containing 210 units is to be inspected using General
Inspection Level II to a 2.5% AQL. Single sampling is to be
used.
The sampling plan for sample size code letter G is (Slide 45)
32 and we accept the lot if 2 or lower not acceptable items
are found. We reject the lot if 3 or more not acceptable
items are found.
47
Quality Assurance
Acceptance sampling explained
Introduction
48
Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
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Quality Assurance
Acceptance sampling explained
Inspection 100%
i consecutive No
acceptable
unit
Yes
Inspect fraction f of
the unit
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Quality Assurance
Acceptance sampling explained
The condition that must exist before the sampling plans may be
used are:
Moving product.
54
Quality Assurance
Acceptance sampling explained
55
Quality System & Tools
Total Quality Management (or TQM)
2. Zero defects
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Quality System & Tools
Total Quality Management (or TQM)
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Quality System & Tools
Total Quality Management (or TQM)
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Quality System & Tools
TQM Wheel
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Quality System & Tools
ISO 9001 : 2008
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Quality System & Tools
ISO 9001 : 2008
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Quality System & Tools
ISO 9001 : 2008
• Management Responsibility
• Resource Management
• Product Realization
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Quality System & Tools
Seven Basic Tool of Quality
They are called basic because they are suitable for people with
little formal training in statistics and because they can be used
to solve the vast majority of quality-related issues.
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
Appearance Responsiveness
equipment time
personnel
facility
Attention Reliability
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Quality System & Tools
Seven Basic Tool of Quality
• First, clearly identify and define the problem or effect for which
the causes must be identified. Place the problem or effect at
the right or the head of the diagram.
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
5. Test the check sheet for a short trial period to be sure it collects
the appropriate data and is easy to use.
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
5. Establish the control limits and use the chart to monitor and
improve.
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Quality System & Tools
Seven Basic Tool of Quality
4. The histogram:
Histogram
70 65
# times ordered
60
50
40 33
30
20
12
8
10
0 0 1
0
1 2 3 4 5 6 7
Slices of Pizza
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Quality System & Tools
Seven Basic Tool of Quality
Creating a Histogram
6. For each category, find the related frequency and make the
horizontal marks to show that frequency.
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
2. Draw the process flow chart and fill it out in detail about each
element.
3. Analyze the flow chart. Determine which steps add value and
which don’t in the process of simplifying the work.
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Quality System & Tools
Seven Basic Tool of Quality
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Quality System & Tools
Seven Basic Tool of Quality
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