SQC Chapter 4
SQC Chapter 4
Acceptance Sampling
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4.1 Lot-By-Lot Acceptance
Sampling for Attributes
4.1.1 The Acceptance Sampling Problems
Acceptance sampling is concerned with
inspection and decision making regarding
products, one of the oldest aspects of quality
assurance.
In the1930s and 1940s, acceptance sampling
was one of the major components of the field
of statistical quality control, and was used
primarily for incoming inspection.
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In more recent years, it has become typical to
work with suppliers to improve their process
performance through the use of SPC and designed
experiments, and not to rely as much on
acceptance sampling as a primary quality
assurance tool.
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A typical application of acceptance sampling is
as follows:
A company receives a shipment of product
from a supplier. This product is often a
component or raw material used in the
company's manufacturing process.
A sample is taken from the lot, and some
quality characteristic of the units in the
sample is inspected.
On the basis of the information in this sample,
a decision is made regarding lot disposition.
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Usually, this decision is either to accept or to
reject the lot. Sometimes we refer to this
decision as lot sentencing.
Accepted lots are put into production; rejected
lots may be returned to the supplier or may be
subjected to some other lot-disposition action.
There are other uses of sampling methods. For
example, frequently a manufacturer will
sample and inspect its own product at various
stages of production. Lots that are accepted
are sent forward for further processing, and
rejected lots may be reworked or scrapped.
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Three aspects of sampling are important:
1. It is the purpose of acceptance sampling to sentence
lots, not to estimate the lot quality
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• Acceptance sampling is most likely to be useful in
the following situations:
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Double-sampling plan
• It is somewhat more complicated. Following an
initial sample, a decision based on the
information in that sample is made either to
(1) accept the lot
(2) reject the lot, or
(3) take a second sample.
• If the second sample is taken, the information
from both the first and second sample is
combined in order to reach a decision whether to
accept or reject the lot.
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Multiple-sampling plan
• It is an extension of the double-sampling concept,
in that more than two samples may be required in
order to reach a decision regarding the disposition
of the lot.
• Sample sizes in multiple sampling are usually
smaller than they are in either single or double
sampling.
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• The ultimate extension of multiple sampling is
sequential sampling, in which units are selected
from the lot one at a time, and following
inspection of each unit, a decision is made either
to accept the lot, reject the lot, or select another
unit.
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4.1.4 Lot Formation
There are a number of important considerations
in forming lots for inspection. Some of these are
as follows:
1. Lots should be homogeneous. The units in the
lot should be produced by the same machines,
the same operators, and from common raw
materials, at approximately the same time.
When lots are non homogeneous, such as when
the output of two different production lines is
mixed, the acceptance-sampling scheme may
not function as effectively as it could. 19
2. Larger lots are preferred over smaller ones. It is
usually more economically efficient to inspect large
lots than small ones.
3. Lots should be conformable to the materials-
handling systems used in both the supplier and
consumer facilities. In addition, the items in the lots
should be packaged so as to minimize shipping and
handling risks, and so as to make selection of the
units in the sample relatively easy. 20
4.1.5 Random Sampling
• The units selected for inspection from the lot
should be chosen at random, and they should be
representative of all the items in the lot.
• The random-sampling concept is extremely
important in acceptance sampling. Unless
random samples are used, bias will be
introduced.
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• For example, the supplier may ensure that the
units packaged on the top of the lot are of
extremely good quality, knowing that the
inspector will select the sample from the top
layer, a lot in this manner is not a common
practice, but if it occurs and nonrandom-sampling
methods are used, the effectiveness of the
inspection process is destroyed.
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4.2 Single-Sampling Plans for Attributes
4.2.1 Definition of a Single Sampling Plan
• Suppose that a lot of size N has been submitted for
inspection. A single-sampling plan is defined by the sample
size n and the acceptance number c. Thus, if the lot size is N =
10,000, then the sampling plan n=89, c = 2 means that from a
lot of size 10,000 a random sample of n = 89 units is inspected
and the number of nonconforming or defective items d
observed.
• If the number of observed defectives d is less than or equal to
c = 2, the lot will be accepted. If the number of observed
defectives d is greater than 2, the lot will be rejected.
• Since the quality characteristic inspected is an attribute, each
unit in the sample is judged to be either conforming or
nonconforming. 23
4.2.2 The Operating Characteristics Curve
(OC Curve)
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• Table 4-2 displays the calculated value of several
points on the curve.
• The OC curve shows the discriminatory power of
the sampling plan.
• For example, in the sampling plan n = 89, c = 2, if
the lots are 2% defective, the probability of
acceptance is approximately 0.74.
• This means that if 100 lots from a process that
manufactures 2% defective product are submitted
to this sampling plan
• we will expect to accept 74 of the lots and reject 26
of them. 26
Table 4-1 Probabilities of Acceptance for the Single-Sampling Plan n=89, c =2
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Effect of n and c on OC Curves
• A sampling plan that discriminated perfectly between
good and bad lots would have an OC curve that looks
like Fig. 4.2.
• The OC curve runs horizontally at a probability of
acceptance Pa = 1.00 until a level of lot quality that is
considered "bad" is reached, at which point the curve
drops vertically to a probability of acceptance Pa = 0.00,
and
• then the curve runs horizontally again for all lot fraction
defectives greater than the undesirable level.
• If such a sampling plan could be employed, all lots of
"bad" quality would be rejected, and all lots of "good"
quality would be accepted. 28
• Unfortunately, the ideal OC curve in Fig. 4-2 can almost
never be obtained in practice. In theory, it could be
realized by 100% inspection, if the inspection were error
free. The ideal OC curve shape can be approached,
however, by increasing the sample size.
4.3
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• As an example, suppose n1 = 50, c1 = 1, n2 = 100, and c2 = 3.
• Thus, a random sample of n1 = 50 items is selected from the lot,
and the number of defectives in the sample, d1, is observed.
• If d1 ≤ c1= 1, the lot is accepted on the first sample.
• If d1 > c2 = 3, the lot is rejected on the first sample.
• If c1 < d1 ≤ c2, a second random sample of size n2 = 100 is drawn
from the lot, and the number of defectives in this second
sample, d2, is observed.
• Now the combined number of observed defectives from the
first and second sample, d1 + d2 is used to determine the lot
sentence.
• If d1 + d2 ≤ c2 = 3, the lot is accepted. However, if d1 + d2 > c2 =
3, the lot is rejected.
• The operation of this double-sampling plan is illustrated
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graphically in Fig. 4-6.
• The principal advantage of a double-sampling plan with
respect to single sampling is that it may reduce the total
amount of required inspection.
• Suppose that the first sample taken under a double-
sampling plan is smaller than the sample that would be
required using a single-sampling plan that offers the
consumer the same protection.
• Consequently, the use of double sampling can often
result in lower total inspection costs.
• Furthermore, in some situations, a double-sampling plan
has the psychological advantage of giving a lot a second
chance. This may have some appeal to the supplier.
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Inspect a random sample of
n1=50 from the lot
d1= number of observed
defective
Accept Reject
the lot the lot
d1+d2 ≤ c2=3 d1+d2 > c2=3
• This plan will operate as follows: If, at the completion of any stage of sampling,
the number of defective items is less than or equal to the acceptance number,
the lot is accepted.
• If, during any stage, the number of defective items equals or exceeds the
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rejection number, the lot is rejected; otherwise the next sample is taken
4.1.5 Sequential-Sampling Plans
• Sequential sampling is an extension of the double-sampling
and multiple-sampling concept.
• In sequential sampling, we take a sequence of samples from
the lot and allow the number of samples to be determined
entirely by the results of the sampling process.
• Sequential sampling can theoretically continue indefinitely,
until the lot is inspected 100%.
• In practice, sequential-sampling plans are usually truncated
after the number inspected is equal to three times the
number that would have been inspected using a
corresponding single-sampling plan.
• If the sample size selected at each stage is greater than one,
the process is usually called group sequential sampling. 43
• If the sample size inspected at each stage is one, the
procedure is usually called item-by-item sequential
sampling.
• The operation of an item-by-item sequential-sampling
plan is illustrated in Fig. 4.8.
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• To illustrate the use of these equations, suppose we wish
to find a sequential-sampling plan for which p1 = 0.01, α =
0.05, p2 = 0.06, and β = 0.10. Thus,
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• Therefore, the Limit lines are
XA = -1.22 + 0.28n (accept) and
XR = 1.57 + 0.028n (reject)
• For example, the calculations for n = 45 are
XA = -1.22 + 0.028n = -1.22 + 0.028(45) = 0.04 (accept)
XR = 1.57 + 0.028n = 1.57 + 0.028(45) = 2.83 (reject)
• Acceptance and rejection numbers must be integers,
so the acceptance number is the next integer less than
or equal to XA, and the rejection number is the next
integer greater than or equal to XR.
• Thus, for n = 45, the acceptance number is 0 and the
rejection number is 3. Note that the lot cannot be
accepted until at least 44 units have been tested. 48
4.1.6 Military Standard 105E (ANSI/ASQCZ1.4, ISO 2859)
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1. The preceding 10 lots have been on normal
inspection, and none of the lots has been rejected
on original inspection.
2. The total number of defectives in the samples
from the preceding 10 lots is less than or equal to
the applicable limit number specified in the
standard.
3. Production is at a steady rate; that is no difficulty
such as machine breakdowns, material shortages,
or other problems have recently occurred.
4. Reduced inspection is considered desirable by the
authority responsible for sampling.
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4. Reduced to normal. When reduced inspection is in effect,
normal inspection is instituted provided any of the following
four conditions are satisfied.
I. A lot or batch is rejected.
II. When the sampling procedure terminates with neither
acceptance nor rejection criteria having been met the lot or
batch is accepted, but normal inspection is reinstituted
starting with the next lot.
III. Production is irregular or delayed.
IV. Other conditions warrant that normal inspection be
instituted.
5. Discontinuance of inspection. In the event that 10 consecutive
lots remain on tightened inspection, inspection under the
provision of MIL STD 105E should be terminated, and action
should be taken at the supplier level to improve the quality of
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submitted lots.
A step-by-step procedure for using MIL STD 105E is as
follows:
1. Choose the AQL.
2. Choose the inspection level.
3. Determine the lot size.
4. Find the appropriate sample size code letter from
Table 4-3.
5. Determine the appropriate type of sampling plan to
use (single, double, multiple).
6. Enter the appropriate table to find the type of plan
to be used.
7. Determine the corresponding normal and reduced
inspection plans to be used when required. 58
• Table 4-3 presents the sample size code letters for
MIL STD 105E.
• Tables 4- 4, 4-5, and 4-6 present the single-
sampling plans for normal inspection, tightened
inspection, and reduced inspection, respectively.
• The standard also contains tables for double-
sampling plans and multiple-sampling plans for
normal, tightened, and reduced inspection.
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Table 4-3 Sample Size Code Letters (MIL STD 105E,
Table 1)
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• To illustrate the use of MIL STD 105E, suppose that a
product is submitted in lots of size N= 2000. The
acceptable quality level is 0.65%. We will use the
standard to generate normal, tightened, and reduced
single-sampling plans for this situation.
• For lots of size 2000 under general inspection level II,
Table 4-3 indicates that the appropriate sample size code
letter is K.
• Therefore, from Table 4-4, for single-sampling plans
under normal inspection, the normal inspection plan is n
= 125, c = 2.
• Table 4-5 indicates that the corresponding tightened
inspection plan is n = 125, c = 1.
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• If the normal inspection acceptance number is 1, 2, or 3,
the acceptance number for the corresponding tightened
inspection plan is reduced by one. (0, 1, or 2)
• If the normal inspection acceptance number is 5, 7, 10,
or 14, the reduction in acceptance number for tightened
inspection is two. (3, 5, 8, or 12)
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Table 4.4 Master Table for Normal Inspection for Single-Sampling ( MIL STD 105E, Table II-A)
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Table 4.5 Master Table for Tightened Inspection—Single-Sampling (MIL STD 105E, Table II-B)
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Table 4.6 Master Table for Reduced Inspection—Single-Sampling (MIL STD 105E, Table II-C)
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4.2 Other Acceptance Sampling Techniques
Acceptance Sampling by Variables
Advantages and Disadvantages of Variables Sampling
• The primary advantage of variables sampling plans is that
the same operating-characteristic curve can be obtained
with a smaller sample size than would be required by an
attributes sampling plan
• A second advantage is that measurement data usually
provide more information about the manufacturing
process or the lot than do attributes data. Generally,
numerical measurements of quality characteristics are
more useful than simple classification of the item as
defective or nondefective. 66
• A final point to be emphasized is that when
acceptable quality levels are very small, the sample
sizes required by attributes sampling plans are very
large. Under these circumstances, there may be
significant advantages in switching to variables
measurement.
• Perhaps the primary disadvantage is that the
distribution of the quality characteristic must be
known.
• The second disadvantage of variables sampling is
that a separate sampling plan must be employed
for each quality characteristic that is being
inspected. 67
Designing a Variables Sampling
Plan with a Specified OC Curve
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Figure 4-10 Nomograph for designing variables sampling
plans 69
4.2.2 MIL STD 414 (ANSI/ASQC Z1.9)
General Description of the Standard
• The focal point of this standard is the acceptable
quality level (AQL), which ranges from 0.04% to 15%.
• There are five general levels of inspection
• Level IV is designated as "normal."
• Inspection level V gives a steeper OC curve than
level IV.
• As with the attributes standard, MIL STD 105E,
sample size code letters are used, but the same code
letter does not imply the same sample size in both
standards. 70
• Provision is made for normal, tightened, and reduced inspection.
• Figure 4-11 presents the organization of the standard.
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Table 4. 8 Master Table for Normal and Tightened Inspection for Plans Based on
Variability Unknown (Standard Deviation Method) (Single-Specification
Limit—Form 1)(MIL STD 414, Table B.1)
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