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Control Charts For Variables

There are three main categories of variation in production: within pieces, between pieces, and over time. Control charts help monitor four main sources of variation: equipment, materials, environment, and operators. The X-bar and R charts are most commonly used. The X-bar chart plots sample means to monitor the process mean, while the R chart plots sample ranges to monitor process variability. Both use control limits based on statistical process control principles like the central limit theorem. The appropriate chart depends on whether the process shift indicates a change in central tendency or dispersion.

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Zahurul Islam
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37 views

Control Charts For Variables

There are three main categories of variation in production: within pieces, between pieces, and over time. Control charts help monitor four main sources of variation: equipment, materials, environment, and operators. The X-bar and R charts are most commonly used. The X-bar chart plots sample means to monitor the process mean, while the R chart plots sample ranges to monitor process variability. Both use control limits based on statistical process control principles like the central limit theorem. The appropriate chart depends on whether the process shift indicates a change in central tendency or dispersion.

Uploaded by

Zahurul Islam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Control Charts for

Variables
Variables due to Variation
Concept of variation
No 2 things are alike
Variation exists
Even if variation small and appears same,
precision instruments show differences
Ability to measure variation is necessary before can
control

Control Charts for


Variables
Variation Area
Basically 3 categories of variation in piece part
production (e.g. Light bulbs, washer, nuts, etc.)
Within piece Piece to piece Time to time and afternoon,

surface roughness
dimensions
different outcomes e.g. morning
tool wear, workers tiredness

Control Charts for


Variables

Sources of Variation

Equipment
- tool wear, electrical fluctuations for welding
Material
- tensile strength, moisture content (e.g. raw material)
Environment
- temperature, light, humidity etc.
Operator
- method, SOP followed, motivation level, training
Inspection
- inspector, inspection equipment, environment

Control Charts for


Variables
X-bar chart
In this chart the sample means are plotted in order to
control the mean value of a variable (e.g., size of
piston rings, strength of materials, etc.).

R chart
In this chart, the sample ranges are plotted in order
to control the variability of a variable.

S chart
In this chart, the sample standard deviations are
plotted in order to control the variability of a variable.

S2 chart
In this chart, the sample variances are plotted in
order to control the variability of a variable.

Control Charts for


Variables
Central Limit Theorem
Regardless of the distribution of population, the distribution of sample
means drawn from the population will tend to follow a normal curve

1. The mean of the sampling


distribution (x-double bar) will
be the same as the population
mean
2. The standard deviation of the
sampling distribution (x) will
equal the population standard
deviation () divided by the
square root of the sample size,
n

x=

x =
n

Control Charts for


Variables
Statistical Basis
Usually and are unknown, so they are estimated from
preliminary samples and subgroups.
20-25 samples are taken usually each of which contains 4-6
observations
If m samples are taken and n observations are made in each
sample then the best estimator of process mean is the grand
average.

Where

are the average of each sample

Control Charts for


Variables
Statistical Basis (contd.)
If x1, x2, . . . , xn is the observations for sample size n,
then the range of the sample is the difference between the
largest and smallest observations; that is,

Let R1, R2, . . . , Rm be the ranges of the m samples. The


average range is

Control Charts for


Variables
In case of 3-sigma x chart, the control limits can be written as follows

Where

is the standard deviation of range values of m samples

In case of 3-sigma R chart, the control limits can be written as follows

Where

is the standard deviation of range values of m samples

Control Charts for


Variables

Control Charts for


Variables
Sample Size

Factor for x-Chart

Factors for R-Chart

(n)

A2

D3

D4

2
3
4
5
6
7
8
9
10
11
12
13
14
15

1.88
1.02
0.73
0.58
0.48
0.42
0.37
0.34
0.31
0.29
0.27
0.25
0.24
0.22

0.00
0.00
0.00
0.00
0.00
0.08
0.14
0.18
0.22
0.26
0.28
0.31
0.33
0.35

3.27
2.57
2.28
2.11
2.00
1.92
1.86
1.82
1.78
1.74
1.72
1.69
1.67
1.65

Control Charts for


Variables
Example

Control Charts for


Variables
Example
0.07
0.06
0.05
0.04
R

0.03

UCL
CL

0.02

LCL

0.01
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
-0.01
-0.02

R- chart

Control Charts for


Variables
Example
10.75
10.74
10.74
10.73
10.73

10.72

CL

UCL
LCL

10.72
10.71
10.71
10.7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

X- chart

Control Charts for


Variables
(Sampling mean is
shifting upward but
range is consistent)

UCL

x-chart
LCL

(x-chart
detects shift in
central
tendency)

UCL

R-chart
LCL

(R-chart does not


detect change in
mean)

Control Charts for


Variables
(Sampling
mean is
constant but
dispersion is
increasing)
UCL

x-chart
LCL

(x-chart does not


detect the
increase in
dispersion)

UCL

R-chart
LCL

(R-chart detects
increase in
dispersion)

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