STATISTICAL PROCESS CONTROL

& VARIABLES CONTROL CHART

Dosen
Yohanes Dicka Pratama

Fakultas Sains dan Teknologi

Universitas Katolik Musi Charitas
Palembang
Introduction

• If a product is to meet or exceed customer

expectations, generally it should be produced
by a process that is stable or repeatable.
• More precisely, the process must be
capable of operating with little variability
around the target or nominal dimensions
of the product’s quality characteristics.
Introduction

Statistical process control (SPC) is a powerful

collection of problem-solving tools useful in
achieving process stability and improving
capability through the reduction of variability.
Chance and Assignable Causes
Statistical Basic of The Control Chart
Statistical Basic of The Control Chart

The most important use of control chart is to improve the

process “most process do not operate
in state of statistical control and
consequently the routine and attentive
use of control chart will identify assignable
causes. If these causes can be eliminated
from these process, variability will be reduced
and the process will be improved”.
OCAP = Out of Control
Action Plan
Statistical Basic of The Control Chart

There are at least five reasons for popularity of

control chart:
• Control charts are a proven technique for improving
productivity.
• Control charts are effective in defect prevention.
• Control charts prevent unnecessary process
adjustment.
• Control charts provide diagnostic information.
• Control charts provide information about process
capability.
Choice of Control Limits

Specifying the control limits is one of the critical

decisions that must be made in designing a control
chart.
Type I Error
that is, the risk of a point falling beyond the control limits,
indicating an out-of-control condition when no assignable
cause is present.

Type II Error.
that is, the risk of a point falling between
the control limits when the process is really out of control
The Operating Characteristic (OC) Curve

The ability of the x bar and R charts to detect

shifts in process quality is described by their OC
curve.

The risk is the probability

of not detecting such a shift.
Sample Size & Sampling Frequency

In designing a control chart, we must specify

both the sample size and the frequency of
sampling.
• In general, large samples will make it easier to
detect small shifts in the process.
• The most desirable situation from the point of
view of detecting shifts would be to take
samples very frequently.
Sample Size & Sampling Frequency
Sample Size & Sampling Frequency

Average run length (ARL) and average time to

signal (ATS).

for in control ARL, and

for out of control ARL.

for average time to signal

Rational Subgroups

Two general approaches to constructing rational

subgoups are used:
• The snapshot approach to rational subgroup,
this approach is used when the primary purpose
is to detect process shift.
Rational Subgroups

• The random sample approach to rational

subgroup, this approach is used if the process
shift out of control state then back in control
again in the sample.
Rational Subgroups

• There are other bases for forming rational

subgroups.
A logical approach to rational subgrouping here is
to apply control chart techniques to the output
for each individual machine, different work
station, different operator, and so forth.
Analysis of Patterns on Control Charts
Analysis of Patterns on Control Charts

The ability to interpret a particular patterns in

terms of assignable causes requires experience
and knowledge of the process.
Analysis of Patterns on Control Charts

Additional information on the interpretation of

pattern on control chart is in the Western
Electric Statistical Quality Control Handbook:
• Cyclic Pattern
Such pattern on control chart may result from
systematic environmental changes such as
temperature, operator fatique, regular rotation
operator or machine, fluctuation in voltage, or
other variable in production equipment.
Analysis of Patterns on Control Charts

• Mixture Pattern
Mixture result from “over-control” where the
operators make process adjustments too often
or output product from several source.
Analysis of Patterns on Control Charts

• A Shift in Process Level

These shift may result from the introduction of new
worker; changes in methods, raw material, or machines;
or a change in either the skill, attentiveness, or
motivation of the operator.
Analysis of Patterns on Control Charts

• A Trend
Trends are usually due to a gradual wearing out
deterioration of a tool or some other critical process
component.
Analysis of Patterns on Control Charts

• Stratification
One potential cause of stratification is incorrect
calculation of control limits. This pattern may also
result when the sampling process collects one or more
unit from several different underlying distribution
within each subgroup.
Control Chart for Variable

When dealing with a quality characteristic that is

variable, it is usually necessary to monitor both the
mean value of the quality characteristic and its
variability.
Control Chart for Variable

Control Chart of Mean

Standard Deviation
Estimated

Control Chart of variability

Control Chart for Variable

Phase I Application of x bar and R Chart

In Phase I control chart usage, when preliminary
samples are used to construct x bar and R charts, it is
customary to treat the control limits obtained from
equations (6.4) and (6.5) as trial control limits.
• R Chart:

• X Bar Chart:
Control Chart for Variable
Control Chart for Variable

Phase II Application of x bar and R Chart

Once a set of reliable control limits is established, we
use the control chart for monitoring future
production.
Control Chart for Variable
Control Chart for Variable

X Bar Chart

R Chart
Control Chart for Variable

A Tier Chart
Control Chart for Variable

Control Limits, specification limits, and Natural Tolerance limits

Control Chart for Variable

Changing Sample Size on the X Bar and R Charts

Control Chart for Variable

Chart Based on Standard Values

When it is possible to specify standard value for the process
mean and standard deviation, we may use these standard to
establish the control chart for X Bar and R without analysis of
past data.

X Bar Chart R Chart

Control Chart for Variable

Control Chart for X bar and s

Generally, X bar and s chart preferable to their
more familiar counterparts, X bar and s charts,
when either:
• The sample size n is moderately large, say n > 10
or 12
• The sample size n is variable.
Control Chart for Variable

Construction and Operation X bar and s Charts

The parameter of If no standard is Then the X Bar
the s chart with a given, then it must chart parameter
standard value σ be estimated by become:
given: analyzing past data
S Chart:

X Bar Chart:

Estimated of σ:
Control Chart for Variable

X Bar Chart: S Chart:

Exercise !!!

Find:
a. S chart
b. X bar chart
c. Estimates σ
d. Non-Conforing
Product (If
Spesification 70 –
79 mm)
Control Chart for Variable

The 𝑠 2 Control Chart

Most quality engineers use either the R or s
chart to monitor variability, some practitioners
recommend a control chart based directly on the
sample variance. The parameters for 𝑠 2 control
chart are:
Control Chart for Variable

The Shewhart Control Chart for Individual Measurement

There are many situation in which the sample size used
for process monitoring is n=1, some examples of these
situation are as follows:
• Automated inspection and measurement technology is
used and every unit manufactured is analyzed so there is
no basis for rational subgrouping.
• Data comes available relatively slowly and it is
inconvenient to allow samples sizes of n > 1 to accumulate
before analysis.
Control Chart for Variable

The Shewhart Control Chart for Individual Measurement

• Repeat measurement on the process differ only because
of laboratory or analysis error, as in many chemical
process.
• Multiple measurement are taken on the same unit of
product.
• In the process plant, such paper making measurement on
some parameter such as coating thickness across the roll
will differ very little and produce a standard deviation
that is too small.
Control Chart for Variable

The Shewhart Control Chart for Individual

Measurement
In many applications of the individuals control
chart, we use the moving range two successive
observations as the basis of estimating the
process variability.
Control Chart for Variable

Set up the control

chart for individual
observation for these
data !!!!