Control Charts
Basics
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Control Charts
Definition:
- A statistical tool to determine if a process is in
control.
History of Control Charts
Developed in 1920’s
By Dr. Walter A. Shewhart
Shewhart worked for Bell Telephone Labs
Two Types of Control Charts
Variable Control Charts
Attribute Control Charts
Variable Control Charts
Deal with items that can be measured .
Examples
1) Weight
2) Height
3) Speed
4) Volume
Types of Variable Control Charts
X-Bar chart
R chart
MA chart
Variable Control Charts
X chart: deals with a average value in a process
R chart: takes into count the range of the values
MA chart: take into count the moving average of a
process
Attribute Control Charts
Control charts that factor in the quality attributes of a
process to determine if the process is performing in or
out of control.
Types of Attribute Control Charts
P chart
C Chart
U Chart
Attribute Control Charts
P Chart: a chart of the percent defective in each
sample set.
C chart: a chart of the number of defects per unit in
each sample set.
U chart: a chart of the average number of defects in
each sample set.
Reasons for using Control Charts
Improve productivity
Make defects visible
Determine what process adjustments need to be
made
Determine if process is “in” or “out of control
Real World Use of Control Charts
Example from “Managing Quality” by Foster.
The Sampson company develops special
equipment for the United States Armed Forces.
They need to use control charts to insure that they
are producing a product that conforms to the
proper specifications. Sampson needs to produce
high tech and top of the line products, daily so
they must have a process that is capable to
reduce the risks of defects.
How Will Using Control Charts help your Company?
Possible Goals when using Control Charts in your
Company:
Line reengineering
Increased Employee motivation
Continually improve of your process
Increased profits
Zero defects
Control Chart Key Terms
Out of Control: the process may not performing
correctly
In Control: the process may be performing correctly
UCL: upper control limit
LCL: lower control limit
Average value: average
Process is OUT of control if:
One or multiple points outside the control limits
Eight points in a row above the average value
Multiple points in a row near the control limits
Process is IN control if:
The sample points fall between the control limits
There are no major trends forming, i.e.. The points vary,
both above and below the average value.
Calculating Major Lines in a
Control Chart
Average Value: take the average of the sample
data
UCL: Multiply the Standard deviation by three.
Then add that value to the Average Value.
LCL: Multiply the Standard deviation by three.
Then subtract that value from the Average
Value.
Examples of Control Charts
Examples of Control Charts
Control Charts
The following control chart shows the improvement of
a process. The standard deviation decreases as the
process becomes more capable.
Example of Control Charts
How to Calculate the standard
deviation
P chart:
P= percent or rate
N= number of trails
How to Calculate the standard
deviation
C chart:
X= the average
How to Calculate the control
limits
X-bar Chart:
Lower Control Limit:
Mean – 3*sigma
n(1/2)
Center Line:
Process mean
Upper Control Limit:
Mean + 3*sigma
n(1/2)
How to Calculate the control
limits
R chart:
Lower Control Limit:
R-Bar – 3*d3*sigma
Center Line:
R-Bar
Upper Control Limit:
R-Bar + 3*d3*sigma
Sample Size
The sample set of data should be greater than 28.
The data should have been collected uniformly
The data should contain multiple capable points of
data, or the information is incorrect.
Example
First Step: Determine what type of data you are working with.
Second Step: Determine what type of control chart to use with
your data set.
Third Step: Calculate the average and the control limits.
Example
The following slides contain data and questions for
your practice with control charts. Please take the
process step by step and look back to previous slides
for help.
Problem
You have gathered a sample set of data for your
company. The data is in the form of percents.
Your company wants your recommendation, is
the process in control.
What type of control chart should you use?
(Variable or Attribute)
Problem
What type of specific control chart should you use
with that type of sample set? (X-bar, R-chart, MA-
chart, P-chart, R-chart, or U-chart)
Problem
Now that you have determined the control chart to
use, you have to calculate the average and standard
deviation. Use the data on the following slide. Take
notice to the amount of sample data. (n>28)
Sample Data
Day Percent Day Percent
1 .056 15 .068
2 .078 16 .038
3 .064 17 .077
4 .023 18 .068
5 .067 19 .053
6 .078 20 .071
7 .067 21 .037
8 .045 22 .052
9 .034 23 .072
10 .045 24 .047
11 .062 25 .042
12 .051 26 .051
13 .070 27 .064
14 .039 28 .071
Example
Now that you have calculated the three important lines for the
control chart, plot the data and determine if the process is
capable. (i.e. The data falls mostly inside the UCL, and the LCL)
Final Step
Make a recommendation to your company.
The process is capable
The process is not capable
The following errors were found.
The process needs improv ement
The v ariations are normal in the system and we must accept
them.
Control Charts Review
What have we learned?
Control Charts are a useful way to determine the
capability of a process.
The different types of control charts.
How to calculate the control limits for a control chart.
Works Cited
“Control Charts as a tool in SQC.” Internet.
http://deming.eng.clemson.edu/pub/tutorials/qctools/ccmain1.htm . 31 January 2001.
Foster, S. Thomas. Managing Quality. Upper Saddle River: Prentice Hall, Inc. 2001.
“Generating and Using Control Charts.” Internet. http://www.hanford.gov/safety/upp/spc.htm. 31
January 2001.
“Quality and Statistical Process Control.” Internet.
http://www.systma.com/tqmtools/ctlchtprinciples.html. 12 February 2001.
“Statistical Thinking Tools-Control Charts for the Average.” Internet.
http://www.robertluttman.com/yms/Week5/page6.htm . 12 February 2001.
