TOSHIBA EL-ARABY

Control Charts For Attributes

Mohammed Mokbil
July 2008
To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserved.

Session 2.1 :
Control Charts for Nonconformity

A nonconformity is a quality characteristic that does not meet specifications A nonconforming item has one or more nonconformities If there are 3 scratches on an item then number of nonconformities is counted as 3 Size of the sample is called as area of opportunity

A unit may not be nonconforming, even though it has several nonconformities.

So, nonconforming defects or nonconformities

Area of opportunity is the area that you are looking for nonconformities Examples are 100 m2 of fabric, 10 TV sets, 1 roll of paper This area must be chosen wide enough that there exist a number of nonconformities If the average number of nonconformities for a TV set is 0.08, then sample sizes of 50 would make sense (rather than 10)

Control Chart For Nonconformities (Defects)

Control Chart for The total number of nonconformities in a unit

Control Chart for The Average number of nonconformities per unit

C Chart

u Chart

Control chart for nonconformities { c Chart } Chart parameters :

With standards given:

Without standards given:

Example :
In a process of manufacturing the circuit boards, the number of nonconformities was observed in 26 samples, each sample for reason of convenience was 100 boards. Construct a control chart to control the process.
Sample No. 1 2 3 4 5 6 7 8 9 10 No. of nonconformities 21 24 16 12 15 5 28 20 31 25 Sample No. 14 15 16 17 18 19 20 21 22 23 No. of nonconformities 19 10 17 13 22 18 39 30 24 16

11
12 13

20
24 16

24
25 26

19
17 15

Since the 26 samples contain 516 total nonconformities, we estimate c by

c = 516/26 = 19.85 Therefore, the trial control limits are given by :

= 19.85 + 3 19.85 = 33.22

= 19.85 = 19.85 - 3 19.85 = 33.22

Plotting the points on the control chart results the following :

We noticed that two points plot outside the control limits. 6 and 20
Investigation of sample 6 revealed that new inspector had examined the boards in this sample and he didnt recognize several of the types of nonconformities that could have been present. Furthermore, the unusually large number of nonconformities in sample 20 resulted from a temperature control problem in the wave soldering machine.

Therefore, it seems reasonable to exclude these two samples and revise the trial control limits.

the estimate of c now computed as

c = 472/24 = 19.67 And the revised control limits are :

= 19.67 + 3 19.67 = 32.97

= 19.67 = 19.67 - 3 19.67 = 6.37

These becomes the standard values against which production in the next period can be compared.

20 new samples, each of 100 boards are subsequently collected.

Sample No. 27 28 29 30 31 32 33 34 35 36 No. of nonconformities 16 18 12 15 24 21 28 20 25 19 Sample No. 37 38 39 40 41 42 43 44 45 46 No. of nonconformities 18 21 16 22 19 12 14 9 16 21

These points are plotted on the control chart .

No lack of control is indicated, the process is in control on this level. However, The number of nonconformities per board is still unacceptably high. Management action is necessary to improve the process.

Workshop :
The number of nonconformities found on final inspection of a cassette deck is shown here. Can you conclude that the process is in statistical control? What center line and control limits would you recommend for controlling future production? What are the center line and control limits for a control chart for monitoring future production based on the total number of defects in a sample of 4 cassette decks?
Deck No 1 2 3 4 5 6 7 8 no of Nonconformities 0 1 1 0 2 1 1 3 Deck No 10 11 12 13 14 15 16 17 no of Nonconformities 1 0 3 2 5 1 2 1

18

Control chart for Average number of nonconformities per unit { u Chart }

There is no reason why the sample size must be restricted to one inspection unit. We would often prefer to use several inspection units in the sample, thereby increasing the area of opportunity for occurrence of nonconformities.

Sample size should be chosen according to :

- it should be large enough to ensure positive LCL. - to obtain a particular probability of detecting a process shift.

- economic factors could inter into sample size determination.

to illustrate this suppose that we were to specify a subgroup size of n = 2.5 inspection units.

then, the sample size becomes 2.5 * 100 = 250 boards.

to construct a chart once a new sample size has been selected. You can use a control chart based on the average no of nonconformities per inspection unit. m

ci ui ; ni
ui :

u
i 1

average number of nonconformities per unit in a sample. ci: number of nonconformities in sample i (n is not necessary be integer ni: size of sample i

Example :
A personal computer manufacturer wishes to establish a control chart for nonconformities per unit on the final assembly line. The sample size is selected to be 5 computers. Data was collected in the following table for 20 samples.
Sample No. I
1 2 3 4

Sample size n
5 5 5 5

Total no. of nonconformities

10 12 8 14

Average no. of nonconformities per unit ui

2.0 2.4 1.6 2.8

5
6 7 8 9 10

5
5 5 5 5 5

10
16 11 7 10 15

2.0
3.2 2.2 1.4 2.0 3.0

11
12 13 14 15 16

5
5 5 5 5 5

9
5 7 11 12 6

1.8
1.0 1.4 2.2 2.4 1.2

17
18 19 20

5
5 5 5

8
10 7 5

1.6
2.0 1.4 1.0

We would estimate the average no. of nonconformities to be:

u u
i 1 m i

= 38.60/20 = 1.93

m
u n u n

LCL u 3 CL u UCL u 3

= 1.93 + 31.93/5 = 3.79 = 1.93 = 1.93 - 31.93/5 = 0.07

The Control chart is shown in the following fig.

a control chart for nonconformities per unit

4 UCL=3.794

Sample Count Per Unit

_ U=1.93

0 1 3 5 7 9 11 Sample 13 15 17 19

LCL=0.066

The preliminary data dont exhibit lack of statistical control , The trial control limits above would be adopted for current control purposes. the process is in control on this level. Although the process is in control, the average number of nonconformities per unit is still unacceptably high. Management action is necessary to improve the process.

Demerit Systems for Defects

Session 2.2 :
Control charts for Attributes with variable sample size

In some applications of the control chart for the fraction nonconforming, the sample is a 100% inspection of the process output over some period of time. Since different numbers of units could be produced in each period, the control chart would then have a variable sample size.

Three Approaches for Control Charts with Variable Sample Size

1. 2. 3.

Variable Width Control Limits Control Limits Based on Average Sample Size Standardized Control Chart

Variable Width Control Limits

Determine control limits for each individual sample that are based on the specific sample size. The upper and lower control limits are

p(1 p) p3 ni

Control Limits Based on an Average Sample Size

Control charts based on the average sample size results in an approximate set of control limits. The average sample size is given by

n i 1 m

ni

The upper and lower control limits are

p (1 p ) p3 n

The Standardized Control Chart

The points plotted are in terms of standard deviation units. The standardized control chart has the follow properties: Centerline at 0 UCL = 3 LCL = -3 The points plotted are given by:

Example
Sample No. i
1 2 3 4 5 6 7 8 9 10 11 12

Sample size ni
100 80 80 100 110 110 100 100 90 90 110 120

No. of nonconforming units Di

12 8 6 9 10 12 11 16 10 6 20 15

13
14 15 16 17 18 19 20 21 22 23 24 25

120
120 110 80 80 80 90 100 100 100 100 90 90

9
8 6 8 10 7 5 8 5 8 10 6 9

Solution
Sample No. i
1 2 3 4 5 6 7 8 9 10 11 12

ni
100 80 80 100 110 110 100 100 90 90 110 120

Di
12 8 6 9 10 12 11 16 10 6 20 15

Di / ni
0.120 0.100 0.075 0.090 0.091 0.109 0.110 0.160 0.110 0.067 0.182 0.125

zi
0.029 0.033 0.033 0.029 0.028 0.028 0.029 0.029 0.031 0.031 0.028 0.027

UCL
0.009 0 0 0.009 0.012 0.012 0.009 0.009 0.003 0.003 0.012 0.015

LCL
0.1183 0.195 0.195 0.183 0.180 0.180 0.183 0.183 0.189 0.189 0.180 0.177

13
14 15 16 17 18 19 20 21 22 23 24 25

120
120 110 80 80 80 90 100 100 100 100 90 90

9
8 6 8 10 7 5 8 5 8 10 6 9

0.075
0.067 0.055 0.100 0.125 0.088 0.056 0.080 0.050 0.080 0.100 0.067 0.100

0.027
0.027 0.028 0.033 0.033 0.033 0.031 0.029 0.029 0.029 0.029 0.031 0.031

0.015
0.015 0.012 0 0 0 0.003 0.009 0.009 0.009 0.009 0.003 0.003

0.177
0.177 0.180 0.195 0.195 0.195 0.189 0.183 0.183 0.183 0.183 0.189 0.189

Control chart using the variable width control limits :

0.20
1

UCL=0.1885

0.15

Proportion

0.10

_ P=0.0955

0.05

0.00 1 3 5 7 9 11 13 15 Sample 17 19 21 23 25

LCL=0.0026

Control chart using the average sample size :

1

0.20 UCL=0.1846

0.15
Proportion

0.10

_ P=0.0955

0.05

0.00 1 3 5 7 9 11 13 15 Sample 17 19 21 23 25

LCL=0.0064

Notes on control charts with variable sample size : We must be careful in analyzing runs or abnormal patterns on control charts with variable sample sizes. The problem is that a change in the sample fraction nonconforming must be interpreted relative to the sample size. Example: p = 0.2 p1 = 0.28 p2 = 0.24 n1 = 50 n2 = 250 1 = 1.41 2 = 1.58 It is clear that looking for runs or other random patterns is virtually meaningless here.

Tests

for runs and pattern could safely be applied to the standardized control charts.
The

difficulty in the standardized control chart is large for operating personal to understand and interpret. As the actual fraction nonconforming has been lost.
The

standardized control charts is also recommended when the length of production runs is short.
In

Control charts for nonconformities with variable sample size, it will be very difficult to use these procedures with c chart because both the center line and control limits will vary with the sample size.
The

correct procedure is to use u chart.

Process Capability
Tolerances
design

specifications reflecting product requirements

Process
Once

Stability and Capability

a process is stable, the next emphasis is to ensure that the process is capable. Process capability refers to the ability of a process to produce a product that meets specifications.

 The

Difference Between Capability and Stability?

Once

again, a process is capable if individual products consistently meet specifications. A process is stable if only common variation is present in the process.

Design Specifications (a) Natural variation exceeds design specifications; process is not capable of meeting specifications all the time. Process Design Specifications (b) Design specifications and natural variation the same; process is capable of meeting specifications most of the time.

Process

Design Specifications (c) Design specifications greater than natural variation; process is capable of always conforming to specifications. Process Design Specifications (d) Specifications greater than natural variation, but process off center; capable but some output will not meet upper specification.

Process

Process Capability and control

Control
In Control Capable
IDEAL

Out of Control

Capability
Not Capable