Control Charts

Training Slides 02/19/01

Control Charts
Definition: - A statistical tool to determine if a process is in control.

History of Control Charts

Developed in 1920s By Dr. Walter A. Shewhart Shewhart worked for Bell Telephone Labs

Two Types of Control Charts

Variable Control Charts Attribute Control Charts

Variable Control Charts

Deal with items that can be measured . Examples 1) Weight 2) Height 3) Speed 4) Volume

Types of Variable Control Charts

X-Bar chart R chart MA chart

Variable Control Charts

X chart: deals with a average value in a process R chart: takes into count the range of the values MA chart: take into count the moving average of a process

Attribute Control Charts

Control charts that factor in the quality attributes of a process to determine if the process is performing in or out of control.

Types of Attribute Control Charts

P chart C Chart U Chart

Attribute Control Charts

P Chart: a chart of the percent defective in each sample set. 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.

Reasons for using Control Charts

Improve productivity Make defects visible Determine what process adjustments need to be made Determine if process is in or out of control

Real World Use of Control Charts

Example from Managing Quality by Foster.
The Sampson company develops special equipment for the United States Armed Forces. They need to use control charts to insure that they are producing a product that conforms to the proper specifications. Sampson needs to produce high tech and top of the line products, daily so they must have a process that is capable to reduce the risks of defects.

How Will Using Control Charts help your Company? Possible Goals when using Control Charts in your Company:
Line reengineering Increased Employee motivation Continually improve of your process Increased profits Zero defects

Control Chart Key Terms

Out of Control: the process may not performing correctly In Control: the process may be performing correctly UCL: upper control limit LCL: lower control limit Average value: average

Process is OUT of control if:

One or multiple points outside the control limits Eight points in a row above the average value Multiple points in a row near the control limits

Process is IN control if:

The sample points fall between the control limits There are no major trends forming, i.e.. The points vary, both above and below the average value.

Calculating Major Lines in a Control Chart

Average Value: take the average of the sample data UCL: Multiply the Standard deviation by three. Then add that value to the Average Value. LCL: Multiply the Standard deviation by three. Then subtract that value from the Average Value.

Examples of Control Charts

Examples of Control Charts

Control Charts
The following control chart shows the improvement of a process. The standard deviation decreases as the process becomes more capable.

Example of Control Charts

How to Calculate the standard deviation

P chart:
P= percent or rate N= number of trails

How to Calculate the standard deviation

C chart:
X= the average

How to Calculate the control limits

X-bar Chart:
Lower Control Limit:
Mean 3*sigma

Center Line:

n(1/2)

Process mean

Upper Control Limit:

Mean + 3*sigma
n(1/2)

How to Calculate the control limits

R chart:
Lower Control Limit:
R-Bar 3*d3*sigma

Center Line:
R-Bar

Upper Control Limit:

R-Bar + 3*d3*sigma

Sample Size
The sample set of data should be greater than 28. The data should have been collected uniformly The data should contain multiple capable points of data, or the information is incorrect.

Example
First Step: Determine what type of data you are working with. Second Step: Determine what type of control chart to use with your data set. Third Step: Calculate the average and the control limits.

Example
The following slides contain data and questions for your practice with control charts. Please take the process step by step and look back to previous slides for help.

Problem
You have gathered a sample set of data for your company. The data is in the form of percents. Your company wants your recommendation, is the process in control. What type of control chart should you use? (Variable or Attribute)

Problem
What type of specific control chart should you use with that type of sample set? (X-bar, Rchart, MA-chart, P-chart, Rchart, or U-chart)

Problem
Now that you have determined the control chart to use, you have to calculate the average and standard deviation. Use the data on the following slide. Take notice to the amount of sample data. (n>28)

Sample Data
Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Percent .056 .078 .064 .023 .067 .078 .067 .045 .034 .045 .062 .051 .070 .039 Day 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Percent .068 .038 .077 .068 .053 .071 .037 .052 .072 .047 .042 .051 .064 .071

Example
Now that you have calculated the three important lines for the control chart, plot the data and determine if the process is capable. (i.e. The data falls mostly inside the UCL, and the LCL)

Final Step
Make a recommendation to your company.
The process is capable The process is not capable
The following errors were found. The process needs improvement The variations are normal in the system and we must accept them.

Control Charts Review

What have we learned?
Control Charts are a useful way to determine the capability of a process. The different types of control charts. How to calculate the control limits for a control chart.

Works Cited
Control Charts as a tool in SQC. Internet. January 2001.

http://deming.eng.clemson.edu/pub/tutorials/qctools/ccmain1.htm. 31

Foster, S. Thomas. Managing Quality. Upper Saddle River: Prentice Hall, Inc. 2001. Generating and Using Control Charts. Internet. http://www.hanford.gov/safety/upp/spc.htm. 31 January 2001. Quality and Statistical Process Control. Internet.

http://www.systma.com/tqmtools/ctlchtprinciples.html. 12 February 2001.

Statistical Thinking Tools-Control Charts for the Average. Internet.

http://www.robertluttman.com/yms/Week5/page6.htm. 12 February 2001.