Control Chart for
Attributes
Ts Dr rosniza binti hamzah
At the end of the course, students should be able to…
Describe, explain and illustrate control chart for
attributes. Develop the control charts- able to
calculate control limits, input data, analyse data
trend. Use statistical softwares to carry out some of
these function.
Introduction
Many quality characteristics cannot be
conveniently represented numerically.
In such cases, each item inspected is classified
as either conforming or nonconforming to
the specifications on that quality characteristic.
Quality characteristics of this type are called
attributes.
Examples are nonfunctional semiconductor
chips, warped connecting rods, etc,.
Types of Control Charts
Control Charts for Variables Data
X and R charts: for sample averages and ranges.
X and s charts: for sample means and standard deviations.
Md and R charts: for sample medians and ranges.
X charts: for individual measures; uses moving ranges.
Control Charts for Attributes Data
p charts: proportion of units nonconforming.
np charts: number of units nonconforming.
c charts: count of nonconformities.
u charts: count of nonconformities per unit.
Type of Attribute Charts
p charts
This chart shows the fraction of nonconforming or defective product
produced by a manufacturing process.
It is also called the control chart for fraction nonconforming.
np charts
This chart shows the number of nonconforming. Almost the same as
the p chart.
c charts
This shows the number of defects or nonconformities produced by a
manufacturing process.
u charts
This chart shows the nonconformities per unit produced by a
manufacturing process.
p charts
In this chart, we plot the percent of
defectives (per batch, per day, per machine,
etc.).
However, the control limits in this chart are
not based on the distribution of rate events
but rather on the binomial distribution (of
proportions).
Formula
Fraction nonconforming:
p = (np)/n
where p = proportion or fraction nc in the
sample or subgroup, n = number in the
sample or subgroup, np = number nc in the
sample or subgroup.
Example
During the first shift, 450 inspection are made of book-
of the month shipments and 5 nc units are found.
Production during the shift was 15,000 units. What is
the fraction nc?
p = (np)/n = 5/450 = 0.011
The p, is usually small, say 0.10 or less.
If p > 0.10, indicate that the organization is in serious
difficulty.
p-Chart contruction for constant
subgroup size
Select the quality characteristics.
Determine the subgroup size and method
Collect the data.
Calculate the trial central line and control
limits.
Establish the revised central line and control
limits.
Achieve the objective.
Select the quality characteristics
The quality characteristic?
A single quality characteristic
A group of quality characteristics
A part
An entire product, or
A number of products.
Determine the subgroup size and
method
The size of subgroup is a function of the proportion
nonconforming.
If p = 0.001, and n = 1000, then the average number nc,
np = 1. Not good, since a large number of values would
be zero.
If p = 0.15, and n = 50, then np = 7.5, would make a
good chart.
Therefore, the selection subgroup size requires some
preliminary observations to obtain a rough idea of the
proportion nonconforming.
Collect the data
The quality technician will need to collect
sufficient data for at least 25 subgroups.
The data can be plotted as a run chart.
Since the run chart does not have limits, its is
not a control chart.
Calculate the trial central line and
control limits
The formula:
p (1 p )
UCL p 3
n
p(1 p )
LCL p 3
n
np = average of p for many subgroups
p = number inspected in a subgroup
n
n
p
np
138
0.018
Sub-
group
Number
Inspected
np p
n 7500
Number n
1 300 12 0.040
2 300 3 0.010
0.018(1 0.018) 3 300 9 0.030
UCL 0.018 3
300 4 300 4 0.013
0.041 5 300 0 0.0
6 300 6 0.020
7 300 6 0.020
0.018(1 0.018) 8 300 1 0.003
LCL 0.018 3
300 19 300 16 0.053
0.005 0.0
25 300 2 0.007
Total 7500 138
Negative value of LCL is possible in a theoritical result, but
not in practical (proportion of nc never negative).
p Chart
0.053
p
0.04 UCL
0.03
0.02
p-bar
0.01
LCL
0
5 10 15 20 25
Subgroup
Establish the revised central line and
control limits
Determine the standard or reference value for
the proportion nc, po.
pnew
np np d
n n d
where npd = number nc in the discarded subgroups
nd = number inspected in the discarded subgroups
Revised control limits
138 16
po pnew pnew
7500 300
0.017
0.017(1 0.017)
po (1 po ) UCL 0.017 3
UCL po 3 300
n 0.039
po (1 po ) 0.017(1 0.017)
LCL po 3 LCL 0.017 3
300
n
0.005 0.0
where po is central line
Achieve the objective
The first 5 steps are planning (p304-308).
The last step involves action and lead to the
achievement of the objective.
The revised control limits were based on data
collected in May.
For June, July, August? See Fig 8-3, p.310
Quality improved?
Analysis of June results shows the quality
improved.
Using June data, a better estimation of
proportion nc is obatained.
The new value: po = 0.014, UCL = 0.036
Data from July are used to determine CL &
UCL for August.
np Chart
The np chart is almost the same as the p chart.
Central line = npo
UCL npo 3 npo (1 po )
If po
LCL npo it3must
is unknown, npbe (1
determined
p ) by
collecting data, calculatingo UCL, LCL.
o
Example
Subgroup n np UCL np -bar LCL
1 300 3 12.0 5.24 0.0
2 300 6 12.0 5.24 0.0
3 300 4 12.0 5.24 0.0
4 300 6 12.0 5.24 0.0
5 300 20 12.0 5.24 0.0
21 300 2 12.0 5.24 0.0
22 300 3 12.0 5.24 0.0
23 300 6 12.0 5.24 0.0
24 300 1 12.0 5.24 0.0
25 300 8 12.0 5.24 0.0
c Chart
The procedures for c chart are the same a s
those for the p chart.
If count of nonconformities, co, is unknown, it
must be found by collecting data, calculating
UCL & LCL.
UCL c 3 c LCL c 3 c
= average count of nonconformities
c
c
g
Example c
c 141
5.64
UCL 5.64 3 5.64 12.76
g 25
ID Number Subgroup c UCL c -bar LCL
MY102 1 7 12.76 5.64 0 LCL 5.64 3 5.64
MY113 2 6 12.76 5.64 0
MY121 3 6 12.76 5.64 0 1.48 0
MY125 4 3 12.76 5.64 0
MY132 5 20 12.76 5.64 0
MY143 6 8 12.76 5.64 0
MY150 7 6 12.76 5.64 0
MY152 8 1 12.76 5.64 0
MY164 9 0 12.76 5.64 0
MY166 10 5 12.76 5.64 0
MY172 11 14 12.76 5.64 0
MY267 22 4 12.76 5.64 0
MY278 23 14 12.76 5.64 0
MY281 24 4 12.76 5.64 0
MY288 25 5 12.76 5.64 0
c-Chart
25
20
c
UCL
Count of Nonconformities
c-bar
15 LCL
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Subgroup Num ber
Revised
Out-of-control: sample no. 5, 11, 23.
c cd 141 20 14 14
cnew 4.23
g gd 25 3
UCL co 3 co 4.23 3 4.23 10.40
LCL co 3 co 4.23 3 4.23 1.94 0
u Chart
The u chart is mathematically equivalent to the c
chart.
u
c
u
c
n n
u u
UCL u 3 LCL u 3
n n
Example c 3389
u 1.20
n 2823
ID Number Subgroup n c u UCL u -Bar LCL
30-Jan 1 110 120 1.091 1.51 1.20 0.89
31-Jan 2 82 94 1.146 1.56 1.20 0.84
1-Feb 3 96 89 0.927 1.54 1.20 0.87
2-Feb 4 115 162 1.409 1.51 1.20 0.89
3-Feb 5 108 150 1.389 1.52 1.20 0.88
4-Feb 6 56 82 1.464 1.64 1.20 0.76
28-Feb 26 101 105 1.040 1.53 1.20 0.87
1-Mar 27 122 143 1.172 1.50 1.20 0.90
2-Mar 28 105 132 1.257 1.52 1.20 0.88
3-Mar 29 98 100 1.020 1.53 1.20 0.87
4-Mar 30 48 60 1.250 1.67 1.20 0.73
For January 30:
c 120
u Jan 30 1.09
n 110
1.20
UCLJan 30 1.20 3 1.51
110
1.20
LCLJan 30 1.20 3 0.89
110
Nonconformity Classification
Critical nonconformities
Indicate hazardous or unsafe conditions.
Major nonconformities
Failure
Minor nonconformities
Control Charts for Variables vs.
Charts for Attributes
Sometimes, the quality control engineer has
a choice between variable control charts and
attribute control charts.
Advantages of attribute control charts
Allowing for quick summaries, that is, the engineer
may simply classify products as acceptable or
unacceptable, based on various quality criteria.
Thus, attribute charts sometimes bypass the need
for expensive, precise devices and time-consuming
measurement procedures.
More easily understood by managers unfamiliar with
quality control procedures.
Advantages of variable control charts
More sensitive than attribute control charts.
Therefore, variable control charts may alert us to
quality problems before any actual "unacceptables"
(as detected by the attribute chart) will occur.
Montgomery (1985) calls the variable control charts
leading indicators of trouble that will sound an alarm
before the number of rejects (scrap) increases in the
production process.
THE END
