Quality Management Tools

Presented by
Dr. Tien Minh Do
Department of Industrial Management
School of Economics and Management
University of Science and Technology
 Control chart
• Some statistic characteristics:
- Mean value
Where:
- Mean value of the sample
- ith data value in the sample
n – Sample size

Product Product 1 Product 2 Product 3 Product 4 Product 5 Product 6 Product 7 Product 8 Product 9 Product 10
Weight (kg) 49.5 49.9 50.1 50.5 50.3 49.8 50.2 49.9 50.4 50.0
 Control chart
• Some statistic characteristics:
- Data range R = Xmax – Xmin
Where:
R – Data range of the sample
Xmax – Maximum value of data in the sample
Xmin – Minimum value of data in the sample

Product Product 1 Product 2 Product 3 Product 4 Product 5 Product 6 Product 7 Product 8 Product 9 Product 10
Weight (kg) 49.5 49.9 50.1 50.5 50.3 49.8 50.2 49.9 50.4 50.0
 Control chart
• Some statistic characteristics:
- Standard deviation
Where:
s – Standard deviation of the sample
- Mean value of the sample
Xi – ith data value in the sample
n - Sample size

Product Product 1 Product 2 Product 3 Product 4 Product 5 Product 6 Product 7 Product 8 Product 9 Product 10
Weight (kg) 49.5 49.9 50.1 50.5 50.3 49.8 50.2 49.9 50.4 50.0

𝒔=
√
( 𝟒𝟗.𝟓− 𝟓𝟎.𝟏 )𝟐+(𝟒𝟗.𝟗−𝟓𝟎.𝟏)𝟐+ ( 𝟓𝟎.𝟏−𝟓𝟎 .𝟏 )𝟐 + ( 𝟓𝟎.𝟓−𝟓𝟎.𝟏 )𝟐 + ( 𝟓𝟎.𝟑−𝟓𝟎.𝟏 )𝟐+ ( 𝟒𝟗.𝟖− 𝟓𝟎.𝟏 )𝟐+(𝟓𝟎.𝟐−𝟓𝟎.𝟏)𝟐+ ( 𝟒𝟗.𝟗−𝟓𝟎 .𝟏 )𝟐 + ( 𝟓𝟎.𝟒− 𝟓𝟎.𝟏 )𝟐 + ( 𝟓𝟎 .𝟎−𝟓𝟎 .𝟏 )𝟐
𝟏𝟎−𝟏

S = 0.09
 Control chart
• What is 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 (CL) for the average, an upper line
for the upper control limit (UCL) and a lower line for the lower control limit
(LCL). These lines are determined from historical data as follows:
CL = Process’ mean value
UCL = 3s above CL
LCL = 3s under CL
- By comparing current data to these lines, conclusions about whether the
process variation is consistent (under control) or is unpredictable (out of
control, affected by special causes of variation) could be drawn
 Control chart (Continued)
• Classification of control charts: There are two following main types of control
charts:
- The control charts for variable data (countable data ) are used in pairs. This type
of chart includes: -R and -s charts.

- The top chart ( chart) monitors the average, or the centering of the
distribution of data from the process.

- The bottom charts (R and s charts) monitors the range, or the width of the
distribution.
 Control chart (Continued)
• Classification of control charts: There are two following main types of control
charts:
- The control charts for attribute data (uncountable data) are used singly. This
type of chart consists of p, pn, c and u charts

- p chart monitors process by controlling the non-conforming fraction. In this

case, sample size may change overtime.

- pn chart monitors process by controlling number of non-conforming

products (or defects). In this case, sample size is constant overtime.

- c chart monitors number of errors per unit of product or number of defects

per sample. In this case sample must be constant overtime.

- u chart monitors number of errors per unit of product or number of defects per
sample in the case that the sample size changes overtime.
 Control chart (Continued)
• When to use a control chart
- When controlling ongoing processes by finding and correcting problems as they
occur.

- When predicting the expected range of outcomes from a process.

- When determining whether a process is stable (in statistical control).

- When analyzing patterns of process variation from special causes (non-routine

events) or common causes (built into the process).

- When determining whether the quality improvement project should aim to

prevent specific problems or to make fundamental changes to the process.
 Control chart (Continued)
• Basic procedure for process control chart
- Choose the appropriate control chart. It depends on what to be controlled in the
process and then what data (variable or attribute) to be collected

- Determine the appropriate time period for collecting and plotting data. It
depends on production speed and accepted level of defect.

- Collect data. At least 20 subgroup of data should be collected to make sure the
process is stable.

- Calculate CL, UCL and LCL based on , R and s to construct the control chart

- Look for “out-of-control signals” on the control chart. When one is identified,
mark it on the chart
 Control chart (Continued)
• Basic procedure for process control chart
- Out-of-control signals:
 A single point outside the control limits. In Figure 1, point sixteen is above the
UCL (upper control limit).
 Two out of three successive points are on the same side of the centerline and
farther than 2 σ from it. In Figure 1, point 4 sends that signal.
 Four out of five successive points are on the same side of the centerline and
farther than 1 σ from it. In Figure 1, point 11 sends that signal.
 A run of eight in a row are on the same side of the centerline. Or 10 out of 11, 12
out of 14 or 16 out of 20. In Figure 1, point 21 is eighth in a row above the
centerline.
 Control chart (Continued)
• Basic procedure for process control chart
- Continue to plot data as they are generated. As each new data point is plotted,
check for new out-of-control signals.

- When a new control chart is started, the process may be out of control. If so, the
control limits calculated from the first 20 points are conditional limits. When at
least 20 sequential points are collected from a period when the process is
operating in control, recalculate control limits.
 Control chart (Continued)
• chart
- The 𝑿 ̅-R chart is a method of looking at two different sources of variation. One
source is the variation in sample averages. The other source is the variation
within a sample.

- 𝑿 ̅-R chart actually consists of two charts. One chart is for sample averages ().
The other chart is for sample ranges (R).

• When to use 𝑿 ̅−𝑹 chart

- Data are variable

- Monitor variation in a process and detect changes in either the average or the
amount of variation in the process.

- Sample size 2 ≤ n ≤ 9
 Control chart (Continued)
• Steps in constructing chart
- Gather the data
a. Select the sample size (n). Typical sample sizes are 4 or 5.

b. Select the frequency (time interval) with which the data will be collected.
Data should be collected in the order in which it is generated (in most
cases).

c. Select the number of samples (k) to be collected before control limits are
calculated. It is advised that the calculation of initial control limits should
be started after ten samples, but recalculate the limits each time until
number of samples reach twenty.
 Control chart (Continued)
• Steps in constructing chart
- Calculate the overall process averages and control limits.
a. Calculate the average range ()

Where:
k - number of samples
- sample range ith

Where:
- maximum individual data in the sample i th
- minimum individual data in the sample i th

b. Calculate the control limits for the R chart

Where:
D4, D3: Control chart constants that depend on sample size (see the
table below)
 Control chart (Continued)
• Steps in constructing chart
- Calculate the overall process averages and control limits.
c. Calculate the overall process mean value ():

Where:
k – number of samples
- Mean value of the sample ith

Where:
n – Sample size
- individual data in the sample ith

d. Calculate the control limits for the chart

Where: A2 Control chart constant that depends on sample size (see the table
below)
 Control chart (Continued)
• Steps in constructing chart
- Plot the data
a. Select the scales for the x and y axes for both the and R charts.

b. Put on the R chart

c. Plot the individual sample ranges on the R chart and connect consecutive
points with a straight line

d. Put on the chart

e. Plot mean values (averages) of the individual samples on the chart and
connect consecutive points with a straight line
 Control chart (Continued)

Control chart constants

Subgroup
size
(n) A2 D3 D4
2 1.880 - 3.267
3 1.023 - 2.574
4 0.729 - 2.282
5 0.577 - 2.114
6 0.483 - 2.004
7 0.419 0.076 1.924
8 0.373 0.136 1.864
9 0.337 0.184 1.816
10 0.308 0.223 1.777
15 0.223 0.347 1.653
25 0.153 0.459 1.541
 Control chart (Continued)
• Exercise
- A tissue paper producing company wants to inspect the tissue cutting
process and decide whether the process is in statistical control by
inspecting machine direction tensile strength (MDTS) of the tissues.
- The measuring unit for the machine direction tensile strength is actually
grams/76mm-2plies. The target value is 937 grams/76mm-2plies and the
specification limits are as follows:
USL: 1060 grams/76mm-2plies.
LSL: 825 grams/76mm-2plies.
- Twenty five samples, each of size five, have been taken. (see Table below)
- You are required to construct - R charts for the process control.
 Control chart (Continued)
• Exercise
 Control chart (Continued)
Number of samples Individual value
• Exercise 1 932 937 945 934 938
2 934 925 942 940 940
3 940 931 956 944 948
4 948 941 929 939 953
5 945 938 961 954 958
6 950 944 942 953 947
7 926 954 958 929 930
8 932 929 946 930 941
9 936 944 929 947 938
10 939 947 937 930 933
11 929 938 949 938 935
12 969 945 941 940 941
13 966 952 932 941 939
14 963 939 925 957 950
15 951 956 955 949 953
16 947 944 947 943 956
17 945 961 919 954 959
18 924 940 955 940 936
19 955 929 966 951 949
20 944 943 933 930 941
21 956 941 939 950 942
22 972 939 940 939 957
23 942 937 968 951 946
24 945 943 952 940 938
25 932 928 963 957 944
 Control chart (Continued)
Number of samples Individual value R
• Exercise 1 932 937 945 934 938 937.2 13
2 934 925 942 940 940 936.2 17
3 940 931 956 944 948 943.8 25
4 948 941 929 939 953 942 24
5 945 938 961 954 958 951.2 23
= 943.74
6 950 944 942 953 947 947.2 11
= 23.68 7 926 954 958 929 930 939.4 32
8 932 929 946 930 941 935.6 17
9 936 944 929 947 938 938.8 18
10 939 947 937 930 933 937.2 17
11 929 938 949 938 935 937.8 20
12 969 945 941 940 941 947.2 29
13 966 952 932 941 939 946 34
14 963 939 925 957 950 946.8 38
15 951 956 955 949 953 952.8 7
16 947 944 947 943 956 947.4 13
17 945 961 919 954 959 947.6 42
18 924 940 955 940 936 939 31
19 955 929 966 951 949 950 37
20 944 943 933 930 941 938.2 14
21 956 941 939 950 942 945.6 17
22 972 939 940 939 957 949.4 33
23 942 937 968 951 946 948.8 31
24 945 943 952 940 938 943.6 14
25 932 928 963 957 944 944.8 35
 Control chart (Continued)
• Exercise
- With sample size n = 5 we have: D3 = 0, D4 = 2.114 and A2 = 0.577
- For R chart:
CLR =
UCLR =
LCLR =0

- For X chart:
CLX =
UCLX =
LCLX =
 Control chart (Continued)
• Exercise
 Construct a Control chart X-R based on following data
n = 5 : A = 0.577, D4 = 2.114 và D3 = 0
Mẫu x1 x2 x3 x4 x5
1 59.52 60.43 59.56 60.06 60.08
2 59.75 60.46 59.96 60.55 59.57
3 59.66 60.37 60.09 59.94 60.15
4 60.18 59.91 60.12 59.99 60.18
5 60.32 59.94 60.02 59.72 60.37
6 60.50 60.27 59.76 60.07 59.45
7 60.22 59.42 59.79 60.45 59.54
8 59.82 60.25 60.05 60.03 59.74
9 59.96 59.59 60.07 59.71 60.06
10 60.47 60.47 60.09 59.88 59.86
11 60.28 60.41 60.15 60.04 59.68
12 60.24 60.35 59.95 60.47 60.06
13 60.37 60.42 59.54 59.65 60.17
14 59.77 59.88 59.73 59.55 60.25
15 59.55 59.78 60.51 60.37 60.48
16 60.76 59.89 60.18 60.02 59.77
17 60.44 59.99 60.09 60.04 59.82
18 60.12 60.01 60.27 60.48 60.42
19 59.54 60.06 60.48 59.59 60.49
20 59.76 60.43 59.50 59.49 60.09