Dr.-Ing.

Amr Nounou

SPC and Variable Control Charts

Tutorial 4
Different SPC Tools:

1) Histogram

2) Check sheets

3) Pareto chart

4) Cause-and-effect diagram

5) Defect concentration diagram

6)Scatter diagram

7)Control chart
1) Histogram:
A histogram is the most commonly used graph to show frequency distributions.

Example: The following is a list of prices (in dollars) of

birthday cards found in various drug stores with:
1.45 2.20 0.75 1.23 1.25
1.25 3.09 1.99 2.00 0.78
1.32 2.25 3.15 3.85 0.52
0.99 1.38 1.75 1.22 1.75
Histogram Steps
• Read through the set of data and determine the minimum and
maximum numbers
• Find the range which is deducting the maximum and minimum numbers
• Find the class or bin or interval width which is the range divided by the
required number of classes
• Determine the classes limits
• Round UP the result
Make a frequency distribution table for this data with 7 classes.
Rules:
Range = maximum value of the data – minimum value of the data = 3.85 – 0.52 = 3.33
Class Width = range/ number of classes = 3.33/7 = 0.475 ≈ 0.5
Or if not given number of classes, calculate it by range/cell interval = 3.33/0.5 = 6.66 ≈ 7
Relative Frequency = Frequency of a class/ Total number of data points
Relative Cumulative Frequency = Cumulative Relative Frequency up to a class / Total number of data points

The values go from 0.52 to 3.85, which is roughly 0.50 to 4.00. We can divide this into 7 intervals of equal length: 0.50 - 0.99,
1.00 - 1.49, 1.50 - 1.99, 2.00 - 2.49, 2.50 - 2.99, 3.00 - 3.49, and 3.50 -
3.99. Then we can count the number of data points which fall into each interval--for example, 4 points fall into the first
interval: 0.75, 0.78, 0.55, and 0.99--and make a frequency distribution table:
Intervals (in dollars) Frequency

0.50 - 0.99 4
1.00 - 1.49 7
1.50 - 1.99 3
2.00 - 2.49 3
2.50 - 2.99
3.00 - 3.49 2
3.50 - 3.99 1
Total 20
A histogram is a bar graph which shows
frequency distribution.

To make a histogram, follow these steps:

On the vertical axis, place frequencies. Label

the x-axis "Frequency".

On the y-axis, place the lower value of each

interval. Label this axis with the type of data
shown.
2) Check sheets:
A check sheet is a structured, prepared form for collecting and analyzing data. This is a
generic data collection tool that can be adapted for a wide variety of purposes.

CHECK SHEET PROCEDURE:

1) Decide what event or problem will be observed.

2) Decide when data will be collected and for how long.

3) Design the form. Set it up so that data can be recorded simply by making check
marks or X's or similar symbols.

4) Label all spaces on the form.

5) Each time the targeted event or problem occurs, record data on the check sheet.
3) Pareto chart:
A Pareto chart is a bar graph. The lengths of the bars represent frequency or cost
or time.. etc and are arranged with longest bars on the left and the shortest to the
right. In this way the chart visually show which situations are more significant.

Pareto Chart Procedure:

1) Decide what categories you will use to group items.

2) Decide what measurement is appropriate. Common measurements are frequency, quantity, cost
and time.

3) Decide what period of time the Pareto chart will cover: One work cycle? One full day? A week?

4) Collect the data, recording the category each time.

5) Subtotal the measurements for each category.

6) Determine the appropriate scale for the measurements you have collected. The maximum value will
be the largest subtotal from step 5.

7) Construct and label bars for each category. Place the tallest at the far left, then the next tallest to its
right, and so on. If there are many categories with small measurements, they can be grouped as “other.”

8) Calculate the percentage for each category: the subtotal for that category divided by the total for all
categories. Draw a right vertical axis and label it with percentages. Be sure the two scales match. For
example, the left measurement that corresponds to one-half should be exactly opposite 50% on the right
scale.

9) Calculate and draw cumulative sums: add the subtotals for the first and second categories, and place a
dot above the second bar indicating that sum. To that sum add the subtotal for the third category, and
place a dot above the third bar for that new sum. Continue the process for all the bars. Connect the dots,
starting at the top of the first bar. The last dot should reach 100% on the right scale.
4) Cause and effect diagram: (Fishbone diagram)
The fishbone diagram identifies many possible causes for an effect or problem.

FISHBONE DIAGRAM PROCEDURE:

1) Agree on a problem statement (effect). Write it at the center right of the flipchart or whiteboard. Draw a box around
it and draw a horizontal arrow running to it.

2) Brainstorm the major categories of causes of the problem.

3) Write the categories of causes as branches from the main arrow.

4) Brainstorm all the possible causes of the problem. Ask "Why does this happen?" As each idea is given, the
facilitator writes it as a branch from the appropriate category. Causes can be written in several places if they relate to
several categories.

5) Again ask "Why does this happen?" about each cause. Write sub-causes branching off the causes. Continue to ask
"Why?" and generate deeper levels of causes. Layers of branches indicate causal relationships.

6) When run out of ideas, focus attention to places on the chart where ideas are few.
5) Defect concentration diagram:
• A defect concentration diagram is a visual representation shows
all defects or problem areas in what is being analyzed.
• It may be the drawing of a product, the map of a city, the diagram of
a motherboard, or any other map on which trouble-spots can be
marked down.
6) Scatter Diagram:
Also called: scatter plot, X-Y graph

A scatter diagram is a tool for analyzing relationships between two variables for determining how
closely the two variables are related.

The scatter diagram graphs pairs of numerical data, with one variable on each axis, to study the
relationship between them. If the variables are correlated, the points will fall along a line or
curve. The better the correlation, the tighter the points will form the line.

SCATTER DIAGRAM PROCEDURE:

1) Collect pairs of data where a relationship is suspected.

2) Draw a graph with the independent variable on the horizontal axis and the dependent variable
on the vertical axis. For each pair of data, put a dot or a symbol where the x-axis value intersects
the y-axis value.

3) Look at the pattern of points to see if a relationship is obvious. If the data clearly form a line or
a curve, you may stop because variables are correlated.
Strong Positive Correlation Strong Negative Correlation
Weak Positive Correlation No Correlation
7) Control Chart:
The control chart is a graph used to study how a process changes over time.
A control chart always has a central line for the control limit (average), an upper line
for the upper control limit, and a lower line for the lower control limit.

These lines are determined from historical data.

By comparing the given data to these lines, you can draw conclusions about whether
the process variation in control or out of control.
Types of Control Charts
Statistical basis of the control chart
Types of control chart:
• Variables Control Charts
– These charts are applied to data that follow a continuous
distribution (measurement, data); weight - length

• Attributes Control Charts

– These charts are applied to data that follow a discrete
distribution. good – bad; yes - no
Statistical basis of the control chart
• Attribute charts require larger sample
sizes
50 to 100 parts in a sample
• Variable charts require smaller samples
2 to 10 parts in a sample
Statistical basis of the control chart
• Popularity of control charts
1) Control charts are a proven technique for improving
productivity.
2) Control charts are effective in defect prevention.
3) Control charts prevent unnecessary process adjustment.
4) Control charts provide diagnostic information.
5) Control charts provide information about process capability.
Exercise 1:

A quality control inspector at the Cocoa Fizz soft drink company has taken twenty-
five samples with four observations each of the volume of bottles filled. The data and
the computed means are shown in the table. The standard deviation of the bottling
operation is 0.14 ounces. Use this information to construct x-bar control chart.
Solution
From the Formula Sheet for x-bar control chart:
Charts Based on Standard Values or given value of
Standard Deviation or Sigma 𝝈
C𝑒𝑛𝑡𝑒𝑟 𝐿𝑖𝑛𝑒 𝑓𝑜𝑟 𝑥 𝑐ℎ𝑎𝑟𝑡 = 𝜇 = 15.95
UCL = 𝜇+𝐴𝜎 = 15.95 + (1.5)(0.14) = 16.16
LCL = 𝜇 - 𝐴𝜎 = 15.95 – (1.5)(0.14) = 15.74
Note: The same applies for R Control Chart
C𝑒𝑛𝑡𝑒𝑟 𝐿𝑖𝑛𝑒 𝑓𝑜𝑟 𝑅 𝑐ℎ𝑎𝑟𝑡 = 𝑑2𝜎
𝑈𝐶𝐿 = 𝐷2𝜎
𝐿𝐶𝐿 = 𝐷1𝜎
Exercise 2:

A quality control inspector at the Cocoa Fizz soft drink company has
taken twenty-five samples with four observations each of the
volume of bottles filled. The data and the computed means are
shown in the table. Use this information to construct x-bar control
chart and R control chart.
Exercise 3:

The data shown in Table 6E.1 are X-bar and R values for 24 samples of size n = 5
taken from a process producing bearings. The measurements are made on the inside
diameter of the Bearing.

Set up X-bar and R charts on this process. Does the process seem to be in statistical
control? If necessary, revise the trial control limits.

Center Lines:

= 34

= 4.7083
After removing
Samples 12 and 15,
the number of
samples changed
from N = 24 to N = 22

Centerlines =