Control Chart for

Attributes

Bahagian 1

Introduction

Many quality characteristics cannot be

conveniently represented numerically.
In such cases, each item inspected is
classified as either conforming or
nonconforming to the specifications on
that quality characteristic.
Quality characteristics of this type are
called attributes.
Examples are nonfunctional semiconductor
chips, warped connecting rods, etc,.

Types of Control Charts

Control Charts for Variables Data
X and R charts: for sample averages and ranges.
X and s charts: for sample means and standard deviations.
Md and R charts: for sample medians and ranges.
X charts: for individual measures; uses moving ranges.

Control Charts for Attributes Data

p charts: proportion of units nonconforming.
np charts: number of units nonconforming.
c charts: count of nonconformities.
u charts: count of nonconformities per unit.

Type of Attribute Charts

p charts
This chart shows the fraction of nonconforming or defective
product produced by a manufacturing process.
It is also called the control chart for fraction nonconforming.
np charts
This chart shows the number of nonconforming. Almost the
same as the p chart.
c charts
This shows the number of defects or nonconformities
produced by a manufacturing process.
u charts
This chart shows the nonconformities per unit produced by a
manufacturing process.

p charts
In this chart, we plot the percent of
defectives (per batch, per day, per machine,
etc.).
However, the control limits in this chart are
not based on the distribution of rate events
but rather on the binomial distribution (of
proportions).

Formula

Fraction nonconforming:
p = (np)/n
where p = proportion or fraction nc in the
sample or subgroup, n = number in the
sample or subgroup, np = number nc in the
sample or subgroup.

Example

During the first shift, 450 inspection are made of

book-of the month shipments and 5 nc units are
found. Production during the shift was 15,000
units. What is the fraction nc?

p = (np)/n = 5/450 = 0.011

The p, is usually small, say 0.10 or less.

If p > 0.10, indicate that the organization is in
serious difficulty.

p-Chart contruction for

constant subgroup size

Select the quality characteristics.

Determine the subgroup size and method
Collect the data.
Calculate the trial central line and control
limits.
Establish the revised central line and
control limits.
Achieve the objective.

Select the quality

characteristics
The quality characteristic?

A single quality characteristic

A group of quality characteristics
A part
An entire product, or
A number of products.

Determine the subgroup size and

method

The size of subgroup is a function of the

proportion nonconforming.
If p = 0.001, and n = 1000, then the average
number nc, np = 1. Not good, since a large
number of values would be zero.
If p = 0.15, and n = 50, then np = 7.5, would
make a good chart.
Therefore, the selection subgroup size requires
some preliminary observations to obtain a rough
idea of the proportion nonconforming.

Collect the data

The quality technician will need to collect

sufficient data for at least 25 subgroups.
The data can be plotted as a run chart.
Since the run chart does not have limits, its is
not a control chart.

Calculate the trial central line and

control limits

The formula:

p (1 p )
UCL p 3
n
p (1 p )
LCL p 3
n

np = average of p for many subgroups

p
n=
number
inspected in a subgroup
n

 np

138
p

0.018
n 7500
0.018(1 0.018)
UCL 0.018 3
300
0.041
0.018(1 0.018)
300
0.005 0.0

LCL 0.018 3

Subgroup
Number

Number
Inspected
n

np

300

12

0.040

300

0.010

300

0.030

300

0.013

300

0.0

300

0.020

300

0.020

300

0.003

19

300

16

0.053

25

300

0.007

7500

138

Total

Negative value of LCL is possible in a theoritical

result, but not in practical (proportion of nc never
negative).

p Chart
0.053

p
UCL

0.04
0.03
0.02

p-bar

0.01

LCL
5

10

15

20

Subgroup

25

Establish the revised central line

and control limits

Determine the standard or reference value for

the proportion nc, po.

pnew

np np

n n

where npd = number nc in the discarded

subgroups
nd = number inspected in the discarded
subgroups

Revised control limits

po pnew
po (1 po )
UCL po 3
n

po (1 po )
LCL po 3
n

where po is central line

pnew

138 16
0.017
7500 300

0.017(1 0.017)
UCL 0.017 3
300
0.039
0.017(1 0.017)
300
0.005 0.0

LCL 0.017 3

Achieve the objective

The first 5 steps are planning (p304-308).

The last step involves action and lead to the
achievement of the objective.
The revised control limits were based on data
collected in May.
For June, July, August? See Fig 8-3, p.310
Quality improved?

Analysis of June results shows the quality

improved.
Using June data, a better estimation of
proportion nc is obatained.
The new value: po = 0.014, UCL = 0.036
Data from July are used to determine CL &
UCL for August.

np Chart

The np chart is almost the same as the p chart.

Central line = npo

UCL npo 3 npo (1 po )

LCL
npo it3must
npbe
po ) by
If po
is unknown,
determined
o (1
collecting data, calculating UCL, LCL.

Example

c Chart

The procedures for c chart are the same a s

those for the p chart.
If count of nonconformities, co, is unknown, it
must be found by collecting data, calculating
UCL & LCL.

UCL c 3 c

LCL c 3 c

= average count of nonconformities

c
c
g

Example c

c 141
UCL 5.64 3 5.64 12.76

5.64
g
25

LCL 5.64 3 5.64

1.48 0

c-Chart
25

20

Count of Nonconformities

c
UCL
c-bar
15

LCL

10

0
1

10

11

12

13

14

15

Subgroup Num ber

16

17

18

19

20

21

22

23

24

25

Revised

Out-of-control: sample no. 5, 11, 23.

c c d 141 20 14 14
c new

4.23
g gd
25 3

UCL co 3 co 4.23 3 4.23 10.40

LCL co 3 co 4.23 3 4.23 1.94 0

u Chart

The u chart is mathematically equivalent

to the c chart.

c
u
n

u
n

u
UCL u 3
n

u
LCL u 3
n

Example

c 3389

1.20
n 2823

For January 30:

c 120
u Jan 30
1.09
n 110
1.20
UCL Jan 30 1.20 3
1.51
110

LCL Jan 30 1.20 3

1.20
0.89
110

Nonconformity Classification

Critical nonconformities

Major nonconformities

Indicate hazardous or unsafe conditions.

Failure

Minor nonconformities

Control Charts for Variables

vs. Charts for Attributes

Sometimes, the quality control engineer has

a choice between variable control charts and
attribute control charts.

Advantages of attribute
control charts

Allowing for quick summaries, that is, the engineer

may simply classify products as acceptable or
unacceptable, based on various quality criteria.
Thus, attribute charts sometimes bypass the need
for expensive, precise devices and time-consuming
measurement procedures.
More easily understood by managers unfamiliar with
quality control procedures.

Advantages of variable
control charts

More sensitive than attribute control charts.

Therefore, variable control charts may alert us to
quality problems before any actual "unacceptables"
(as detected by the attribute chart) will occur.
Montgomery (1985) calls the variable control charts
leading indicators of trouble that will sound an alarm
before the number of rejects (scrap) increases in the
production process.