Statistical Quality Control
Three SQC Categories
◼ Statistical quality control (SQC) is the term used to describe
the set of statistical tools used by quality professionals
◼ SQC encompasses three broad categories of;
◼ Descriptive statistics
◼ e.g. the mean, standard deviation, and range
◼ Statistical process control (SPC)
◼ Involves inspecting the output from a process
◼ Quality characteristics are measured and charted
◼ Helpful in identifying in-process variations
◼ Acceptance sampling used to randomly inspect a batch of goods to
determine acceptance/rejection
◼ Does not help to catch in-process problems
Sources of Variation
◼ Equipment
◼ • Tool wear, machine vibration, …
◼ Material
◼ • Raw material quality
◼ Environment
◼ Temperature, pressure, humidity
◼ Operator
◼ Operator performance- physical & emotional
Variation exists in all processes.
Categories of Variation
◼ Variation can be categorized as either;
◼ Chance or Common or Random causes of variation, or
◼ Random causes that we cannot identify
◼ Unavoidable
◼ e.g. slight differences in process variables like diameter, weight, service
time, temperature
◼ Assignable or Special causes of variation
◼ Causes can be identified and eliminated
◼ e.g. poor employee training, worn tool, machine needing repair
Therefore, the main objective of a control chart is to detect
ASSIGNABLE CAUSES
Traditional Statistical Tools
◼ Descriptive Statistics
include n
◼ The Mean- measure of central
tendency x i
x= i =1
n
◼ The Range- difference
between largest/smallest
(x )
observations in a set of data n
2
i −X
◼ Standard Deviation
measures the amount of data σ= i =1
dispersion around mean n −1
◼ Distribution of Data shape
◼ Normal or bell shaped or
◼ Skewed
Distribution of Data
◼ Normal distributions ◼ Skewed distribution
Control Charts
• Introduced in 1926 by WALTER SHEWART, who concluded that a
distribution can be transformed into normal shape by estimating
mean and standard deviation.
• Control chart is a device which specifies the state of statistical
control. Control chart detects the variation in processing and warns if
there is any deviation from the specified tolerance limits.
• The purpose of using control chart is to stabilize process by keeping
it under control and carrying out necessary adjustments.
Control Charts - Advantages
• A control chart indicate whether the process is in control or out of
control.
• It determines the process variability and detects unusual variations
in a process.
• It ensures product quality level.
• It warns in time and if process is rectified at that time percentage of
rejection can be reduced.
• It provides information about selection of process and setting up of
tolerance limits.
SPC Methods-Control Charts
◼ Control Charts show sample data plotted on a graph with CL,
UCL, and LCL
◼ Control chart for variables are used to monitor characteristics
that can be measured, e.g. length, weight, diameter, time
◼ Control charts for attributes are used to monitor characteristics
that have discrete values and can be counted, e.g. % defective,
number of flaws in a shirt, number of broken eggs in a box
Control Charts for Variables
◼ Use x-bar and R-bar
charts together
◼ Used to monitor
different variables
◼ X-bar & R-bar Charts
reveal different
problems
◼ In statistical control on
one chart, out of control
on the other chart? OK?
Control Charts for Variables
◼ Use x-bar charts to monitor the changes in
the mean of a process (central tendencies)
◼ Use R charts to monitor the range or
dispersion or variability of the process
◼ S chart: take into count the standard
deviation of a process
◼ System can show acceptable central
tendencies but unacceptable variability or
◼ System can show acceptable variability but
unacceptable central tendencies
Control Charts for Attributes i.e. discrete events
❑ Use a P-Chart for yes/no or good/bad
decisions in which defective items are
clearly identified
❑ Use a C-Chart for more general counting
when there can be more than one defect
per unit
◼ Number of flaws or stains in a carpet sample cut from a
production run
◼ Number of complaints per customer at a hotel
Control Charts for Attributes
◼ 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.
Out of control conditions indicated by:
Skewed distribution
Data Point out of limits
Acceptance Sampling
◼ Definition: the third branch of SQC refers to the
process of randomly inspecting a certain number of
items from a lot or batch in order to decide whether to
accept or reject the entire batch
◼ Different from SPC because acceptance sampling is
performed either before or after the process rather
than during
◼ Sampling before typically is done to supplier material
◼ Sampling after involves sampling finished items before shipment
or finished components prior to assembly
◼ Used where inspection is expensive, volume is high, or
inspection is destructive
Acceptance Sampling Plans
◼ Goal of Acceptance Sampling plans is to determine the criteria
for acceptance or rejection based on:
◼ Size of the lot (N)
◼ Size of the sample (n)
◼ Number of defects above which a lot will be rejected (c)
◼ Level of confidence we wish to attain
◼ There are single, double, and multiple sampling plans
◼ Which one to use is based on cost involved, time consumed, and cost of
passing on a defective item
◼ Can be used on either variable or attribute measures, but more
commonly used for attributes
Implications for Managers
◼ How much and how often to inspect?
◼ Consider product cost and product volume
◼ Consider process stability
◼ Consider lot size
◼ Where to inspect?
◼ Inbound materials
◼ Finished products
◼ Prior to costly processing
◼ Which tools to use?
◼ Control charts are best used for in-process production
◼ Acceptance sampling is best used for inbound/outbound
SQC in Services
◼ Service Organizations have lagged behind
manufacturers in the use of statistical quality control
◼ Statistical measurements are required and it is more
difficult to measure the quality of a service
◼ Services produce more intangible products
◼ Perceptions of quality are highly subjective
◼ A way to deal with service quality is to devise
quantifiable measurements of the service element
◼ Check-in time at a hotel
◼ Number of complaints received per month at a restaurant
◼ Number of telephone rings before a call is answered
◼ Acceptable control limits can be developed and charted
