Department of Science and

Technology IX
Regional Standards and
Testing Laboratory
Seminar-Workshop on

ISO 8258:

SHEWHART CONTROL CHARTS

by Janice T. Ong

February 26, 2
Grand Astoria Hotel, Zamboanga C

Presentation Outline

1 2 3

General
Principle
s

Developi
ng
Control
Charts

Out-ofControl
Trends

General
Principles

Introduction

Quality Control ISO 17025:2005

5.9
Assuring the quality of test and calibration
results
5.9.1 The laboratory shall have quality control
procedures for monitoring the validity of tests
and calibrations undertaken. The resulting
data shall be recorded in such a way that
trends are detectable and, where
practicable, statistical techniques shall
be applied to the reviewing of the results.
This monitoring shall be planned and reviewed
and may include, but not be limited to, the
following:

ISO 8258 Dr. Walter A. Shewhart (1924)

He was the first to

propose the use of
control charts as
graphical means of
applying the
statistical principles
pertaining to the
significance of
control in a
production process.

ISO 8258 Statistical Process Control

A statistical tool that involves inspecting a
random sample of the output from a
process and deciding whether the process
is producing products with characteristics
that fall within a predetermined range.

SPC answers the question of

whether the process is
functioning properly or not.

ISO 8258 Variation

The variation concept is a law

of nature in that no two
natural items in any category
are the same.
The variation may be quite large and easily
noticeable
The variation may be very small. It may
appear that items are identical; however,
precision instruments will show otherwise
The ability to measure variation is necessary
before it can be controlled

ISO 8258 Variation (Categories)

There are three categories of variation in
piece part production:
1. Within-piece variation: Surface
2. Piece-to-piece variation: Among pieces
produced at the same time
3. Time-to-time variation: Difference in
product produced at different times of the
day

ISO 8258 Variation (Sources)

Sources of Variation in production
processes:

Input

Materials
Tools

Measurements
Instruments

Human Inspection
Performance

Process
Operators
Methods

Machines
Environment

Output

ISO 8258 Variation (Types)

Variation may be due to chance

causes (random causes) or
assignable causes.
When only chance causes are present,
then the process is said to be in a
state of statistical control. The
process is stable and predictable.

Glossary of Terms
Assignable cause, n.an identifiable factor that
contributes to variation in quality and which it is feasible to
detect and identify. Sometimes referred to as a special cause.

Chance cause, n.an identifiable factor that exhibits

variation which is random and free from any recognizable
pattern over time. Sometimes referred to as a common cause.

Lot, n.a definite quantity of some commodity produced

under conditions that are considered uniform for sampling
purposes.

Sample, n.a group of units, or portion of material, taken

from a larger collection of units or quantity of material, which
serves to provide information that can be used as a basis for
action on the larger quantity or on the production
process. May be referred to as a subgroup in the construction
of a control chart.

Glossary of Terms
Subgroup, n.one of a series of groups of observations
obtained by subdividing a larger group of observations;
alternatively, the data obtained from one of a series of samples
taken from a series of lots or from sublots taken from a process.
One of the essential features of the control chart method is to
break up the inspection data into rational subgroups, that is,
to classify the observed values into subgroups, within which
variations may, for engineering reasons, be considered to be due
to non-assignable chance causes only, but between which there
may be differences due to one or more assignable causes whose
presence is considered possible. May be referred to as a sample
from the process in the construction of a control chart.

Unit, n.one of a number of similar articles, parts, specimens,

lengths, areas, etc. of a material or product.

Sublot, n.an identifiable part of a lot.

Glossary of Symbols

n
k
X

subgroup or sample size, that is, the

number of units or observed values in a
sample or subgroup
number of subgroups or samples under
consideration
observed value of a measurable
characteristic; specific observed values are
designated X1, X2, X3, etc.; also used to
designate a measurable characteristic
average (arithmetic mean); the sum of the
n observed values divided by n
average value of the subgroup averages.

Glossary of Symbols

Me
R

True mean value of the process.

Median value of a subgroup . For a set of
n numbers X1, X2, ... Xn arranged in order
of ascending and descending magnitude,
the median is the middle value in the set
if n is odd and the arithmetic mean of the
two middle numbers if n is even.
Average median value of the subgroups.
Subgroup Range: difference between the
largest and smallest observations of a
subgroup.

Glossary of Symbols
Mean of R values for all subgroups

M
R

the absolute value of the difference of two

successive values plotted on a control
chart.
Average moving range of n-1 moving
ranges from a series of n values

Standard deviation of the sample:

Glossary of Symbols
Average value of the standard deviations
of the sub-samples.

True value of the standard deviation of

the process within the subgroup.
Estimated value of the standard deviation
of the process within the subgroup.

Proportion or fraction of nonconforming

units in a subgroup:

Glossary of Symbols
Average value of the ratio or fraction
nonconforming:

n
n
p
p

Number of nonconforming units in a

Number of nonconforming units in a
subgroup.
subgroup.
Number of nonconformities in a subgroup.
Average value of c values for all subgroups.
Average value of c values for all subgroups.

Glossary of Symbols

Number
Number of
of nonconformities
nonconformities per
per unit
unit in
in a
a
subgroup.
subgroup.
Average value of u values:

Developing
Control
Charts

Nature of a

CONTROL
C H A RT

CONTROL CHART Definitions

A control chart (or process chart or
quality control chart) is a graph that
shows whether a sample of data falls
within the common or normal range
of variation.
It is a graphical method of presenting
and comparing information based on
a series of samples representing the
current state of a process against
established limits after considering
the inherent variability of the process.

CONTROL CHART Definitions

A control chart has upper and lower control
limits that separate common from assignable
causes of variation.
A process is out of control when a plot of
data reveals
that one or more samples fall outside the
control limits.

CONTROL CHART Definitions

The x axis represents samples taken from the
process over time.
The y axis represents the quality
characteristic that is being monitored (e.g.
ounces of liquid).

CONTROL CHART Definitions

The centerline (CL) of the control chart is the mean, or
average, of the quality characteristic that is being measured.
The upper control limit (UCL) is the maximum acceptable
variation from the mean for a process that is in a state of
control. (3 above from CL)
The lower control limit (LCL) is the minimum acceptable
variation from the mean for a process that is in a state of
control. (3 below from CL)

CONTROL CHART Definitions

The warning
limits (UWL and
LWL), which are
also called 2
control limits,
serves as a warning
of a situation with
imminent loss of
control whenever
sample value falls
beyond this limit.

CONTROL CHART Types of Errors

Type I error occurs
when the corresponding
process remains under
control but a point falls
outside the control limits
by chance.
An incorrect
conclusion that the
process is out of
control
is made;
incur
Type II error
occurs
when the corresponding
to
find non-existent
process
is out of control but the generated point falls
problems.
within the control limits by chance.
Incorrect conclusion: the process is in
statistical control

Elements of a

CONTROL
C H A RT

Data Collection
Section

The counts or
measurements
are recorded in
the data
collection section
of the Control
Chart prior to
being graphed.

Title

Briefly describes
the information
which is
displayed.

Legend
A list that explains
the significance of
each coloured lines
on the chart. It also
include values of
important statistic
such as mean and
standard deviation,
and traceability of
the control samples
used.

Vertical or YAxis
This axis affects the
magnitude of the
data collected. The Yaxis shows the scale
of the measurement
for variables data, or
the count (frequency)
or percentage of
occurrence of an
event for attribute
data.

Horizontal
or X-Axis

This axis displays

the chronological
order in which the
data were
collected.

Centerline
This line is drawn
at the average or
mean value of all
plotted data. The
upper and lower
graphs each have
a separate
centerline.

Control
Limits
These are set at a
distance of 3
above and 3 below
the centerline. They
indicate the
variation from the
centerline and are
calculated by using
the actual values
plotted on the
Control Chart.

Warning
Limits
These are set at a
distance of 2
above and 2
below the
centerline. They
are calculated by
using the actual
values plotted on
the Control Chart.

Acceptable
Limits
These are set at a
distance of 1
above and 1
below the
centerline. They
are calculated by
using the actual
values plotted on
the Control Chart.

Types of

CONTROL
C H A RT

MEASURABLE Characteristics
A variable is a product characteristic that
can be measured and has a continuum of
values (e.g. height, weight, or volume).
continuous value - there are potentially an
infinite number of values between adjacent units.
(e.g., between 1 and 2 seconds: 1.1, 1.01, 1.001
seconds, etc.)

An attribute is a product characteristic

that has a discrete value and can be
counted.
discrete value - the value changes in fixed
amounts, with no intermediate values possible.
(e.g., Number of children in a family)

CONTROL CHARTS for Variables

These describe process data in terms of
dispersion (variability from sample to sample)
and location (average of the process). Because of
this, control charts for variables usually are
prepared and analysed in pairs: one chart for
location and one for the dispersion.
1. Control chart for mean () and range

(R) or standard deviation (s)

2. Control chart for individual
observations (X) and moving range
(MR)
3. Control chart median (Me) and
range (R)

CONTROL CHARTS for Mean and Range/Standard Deviation

1. Mean (X bar) Chart

It is used to monitor changes in the mean
of a process.
and
and
and
where,

Lets Review Example

For k 50, and k

represents the
number of
replicates per
6.1
subgroup

CONTROL CHARTS for Mean and Range/Standard Deviation

1. Mean (X bar) Chart

Another way to construct the control
limits is to use the sample range as an
estimate of the variability of the process.
In this case control limits would be
constructed as follows:
and
where, A2 is a factor obtained from Table 6 of ASTM
Manual on Quality Control of Materials.
Lets Review Example 6.2

CONTROL CHARTS for Mean and Range/Standard Deviation

2. Range (R) Chart

Range charts monitor the dispersion or
variability of the process. The method for
developing and using R-charts is the
same as that for x-bar charts.
CL=
and
where, D4 and D3 are factors obtained from Table 6
of ASTM Manual on Quality Control of Materials.
Lets Review Example 6.3

CONTROL CHARTS for Mean and Range/Standard Deviation

3. Standard deviation (s) Chart

It also monitors the dispersion or variability
of the process.
CL=
and
where, D4 and D3 are factors obtained from Table 6
of ASTM Manual on Quality Control of Materials.

Lets Try This Activity

CONTROL CHARTS for Attributes

1. P-Charts
are used to measure the proportion of
items in a sample that are defective.
(e.g., proportion of broken cookies in a batch and the
proportion of cars produced with a misaligned fender.)

2. C-Charts
count the actual number of defects.
(e.g., the number of complaints from customers in a
month, the number of bacteria on a petri dish, or the
number of barnacles on the bottom of a boat.)

defective a unit that fails to meet acceptance

criteria due to one or more defects
defects a failure to meet one part of an
acceptance criteria

Out-ofControl
Trends

Rule #1
Any single point
beyond 3 limits
(or beyond UCL and
LCL).
Requires immediate
action:
Measurement should
stop until the cause of
the action limit
violation is identified
and corrected.

Rule #2
Two consecutive
points beyond 2
limits on the same
or both sides of
the centerline.
Measurement
should stop until the
cause of the action
limit violations are
identified and
corrected.

Rule #3
Two out of three
points in a row
beyond 2 limits
on the same or both
sides of the
centerline.
Measurement should
stop until the cause of
the action limit
violations are
identified and
corrected.

Rule #4
Eight points in a
row on one side
of the centerline.
There has been a
shift in the mean:
work can continue,
however the cause
of the shift needs to
be identified and the
limits re-set if
justified.

Rule #5
Six points in a row
that are moving away
or toward the
centerline with no
change in direction
(also called as trend
rule).
The measurements are
shifting with time:
needs investigation, since
the action and warning
limits will eventually be
exceeded.

Rule #6
Fourteen
consecutive points
alternating up and
down (sawtooth
pattern).
Suggests a cyclical
change in
conditions: may be
due to two different
operators..

Rule #7
Four out of five
points beyond
1 limits on the
same side of the
centerline.
This may indicate a
mean shift.

Rule #8
Fifteen points in a
row within the 1
limits on either side
of the centerline
also called
stratification
rule.
This may arise after the
procedure has been
operated for some time
and may require the
limits to be re-set.

Rule #9
Eight consecutive
points outside the
1 limits on
both sides of the
centerline also
called mixture
rule.
This may indicate a
mean shift.

Thank You!

But wait
Lets Answer Activity 8!