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University of Hail College of Engineering

ISE 320 - Quality Control and Industrial Statistics

Chapter 3
Control Charts for Variables

Prof. Mohamed Aichouni

Lectures notes adapted from: PowerPoint presentation to accompany

Besterfield, Quality Improvement, 9th edition

Course Webpage: faculty.uoh.edu.sa/m.aichouni/ise320-quality/

variation
• The variation concept is a law of nature in that no
two natural items are the same.
‰ The
Th variation
i ti may b
be quite
it llarge and
d easily
il
noticeable
‰ The variation may be very small. It may appear that
items are identical; however, precision instruments
will show difference
‰ The
Th ability
bilit to
t measure variation
i ti isi necessary before
b f
it can be controlled

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Variations in Manufacturing Products

There are three categories of variation in piece part
production:

1. Within-piece variation: variations in surface.

2. Piece-to-piece variation: Among pieces produced at
the same time
3. Time-to-time variation: Difference in product
produced at different times of the day

Process Variations Causes

1. Common causes are ever-present in the process;
========= Natural Variations

2. Special causes are intermittent effects that must

be investigated immediately.
========= Assignable Causes Variations

• Management and quality professionals (YOU)

should help manufacturing people to identify
and remove special causes and reduce the
occurrence of common causes in the process..

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Process Variation
Process Variability
Variations due to:

Natural Causes: Special Causes:

Temperature variation• Machine is breaking•
Material variation• Untrained operative•
Customer differences• Machine movement•
Operator performance• Process has changed•

Must be monitored Early and visible

warning required

Sources of Variation in Processes

Sources of Variation in production processes:

Measurement
Operators Methods
Materials Instruments

INPUTS PROCESS OUTPUTS

Tools Human
Machines Environment Inspection
Performance
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Sources of Variation in Manufacturing

Sources of variation are:
Machines and Equipment: Methods
• Toolwear
• Machine vibration
Environment
• Electrical fluctuations etc.
• Temperature
Material • Light
• Tensile strength • Radiation
• Ductility • Humidity etc.
• Thickness
Operator / Man
• Porosity etc.
• Personal problem
Measurements • Physical problem etc.
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Control Charts
Of all the quality tools for analyzing data, the control
chart is the most useful. No other tool captures
the voice of your process better.
Control charts are used to determine whether your
process is operating in statistical control.
Until it is, any improvement efforts are, at best,
mere process tampering.
Basically, a control chart is a run chart (described
earlier) that includes statistically generated upper
and lower control limits.
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Control Charts
The control chart is a
means of visualizing Special causes variation
the variations that
occur in the process
data and its
components. Natural (common causes )variation

It shows
h whether
h th theth
process is in a stable Figure 1 Example of a control chart
state (in statistical
control) or out of
statistical control. 9

Control Charts

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Control Charts Types

Continuous Categorical or Discrete
Numerical Data Control Numerical Data
Charts

Variables Attributes
Charts Charts

R s X P C
Chart Chart Chart Chart Chart

Other Charts:
ImR, EWMA, CUSUM..
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Control Charts

Figure 2 - Example of a method of reporting inspection results 12

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Use of Variable Control Charts in

Manufacturing

The objectives of the variable control charts are:

9 For process improvement
9 To determine the process capability.
9 For decisions regarding product specifications
9 For current decisions on the production process
9 For current decisions on recently produced items

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Variable Control Charts Interpretation

control charts help to determine if the process is :
(a) in statistical control ; or (b) out of statistical control.

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Control Chart Techniques

Procedure for establishing a pair of control charts for
the average Xbar and the range R:
1. Select the quality characteristic
2. Choose the rational subgroup
3. Collect the data
4. Determine the trial center line and control limits
5. Establish the revised central line and control limits
6. Achieve the objective

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Quality Characteristic

• Variable - a single quality characteristic

that can be measured on a numerical
scale.
• When working with variables, we
should monitor both the mean value of
the characteristic and the variability
associated with the characteristic.

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Quality Characteristic
The Quality characteristic must be measurable.
It can expressed in terms of the seven basic units:
1. Length

2. Mass

3. Time

4. Electrical current

5 Temperature
5.

6. Substance

7. Luminosity

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Control Charts for x and R

Notation for variables control charts
• n - size of the sample (sometimes called a
subgroup) chosen at a point in time
• m - number of samples selected
• x i = average of the observations in the ith
sample (where i = 1, 2, ..., m)
• x = grand average or “average
average of the
averages (this value is used as the
center line of the control chart)

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Control Charts for x and R

Notation and values

• Ri = range of the values in the ith
sample
Ri = xmax - xmin
• R = average g range
g for all m samples
p
• μ is the true process mean
• σ is the true process standard deviation

Control Charts for x and R

Statistical Basis of the Charts

• Assume the quality characteristic of interest is
normally distributed with mean μ, and standard
deviation, σ.
• If x1, x2, …, xn is a sample of size n, then he average
of this sample is x1 + x 2 + L + x n
x=
n
• x is normally distributed with mean, μ, and standard
deviation, σ =σ/ n
x

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Control Charts for x and R

Control Limits for the x chart

UCL x = x + A2 R
Center Line = x
LCL x = x − A2 R
• A2 is found in constants for various values of
n.

Control Charts for x and R

Control Limits for the R chart

UCL R = D 4 R
Center Line = R
LCL R = D3 R

• D3 and D4 are constants for various values of

n.

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Control Charts Constants

Control Charts for x and s

• The sample standards deviation can be a
more accurate estimation of the process
variability process, especially if the sample
size n>10.

• In this case control charts for Xbar and S can

be used to monitor the process.

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Control Charts for x and s

• Construction of the control charts for Xbar
and S follows the same procedure as for the
Xbar-R charts.
UCL s = B 4 s
• Control Limits for s chart are:
CenterLine = s
LCL s = B 3 s
• Control Limits for Xbar chart:
UCL= x + A3s
• A3, B3, B4 are constants Center Line= x
LCL= x − A3s

Example of x -R control charts

A component part for a jet
aircraft engine is
manufactured by an
investment casting
process.
The vane opening on this
casting is an important
functional parameter of the
part.
We will illustrate the use of
Xbar and R control charts
to assess the statistical
stability of this process.

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Example of x -R control charts

Determine the
mean and the
range for
each sample.

Determine the
grand
average of the
means and
the average of
the ranges.

Example of x -R control charts

Calculate the control limits for the R chart:

UCL R = D 4 R = 12 .27
Center Line = R = 5 .80
LCL R = D3 R = 0

Calculate the control limits for the Xbar chart:

UCL x = x + A2 R = 36 .67
Center Line = x = 33 .32
LCL x = x − A2 R = 29 .97

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Example of x -R control charts

The process is Out of
statistical
t ti ti l control;
t l
It is not stable.
Special causes should
be investigated using
cause and effect
diagram and other
quality tools.

Other Control Charts for

variables
1. Individual Moving Range Charts
2. Exponentially Weighted Mean Average
(EWMA) charts
3. Cumulative Sum (CUSUM) chart.

Student should search on the net for the use of these

charts

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Control Charts Selection

Source: Aichouni (2007), Quality Control.

Additional
Examples
Example 4-1
The strength of a metallic
wire in a production
process is given for 20
samples .
Study the stability of the
p
production pprocess usingg
the Xbar-R charts.

Use both hand calculations and

Minitab to produce the control
charts.

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Additional
Examples
Example 4-2
The thickness of a metal part
in the manufacturing
process of a car is given
for 25 samples .
Study the stability of the
p
production p
process using g
the Xbar-s charts.

Use Minitab to produce the control

charts.

Conclusion Lecture Finished

"Quality control truly

Any No
begins
g and ends Question?
with education",
K. Ishikawa (1990). Yes
Ask questions

Teachers answers

Train your self (Google, YouTube,

course webpage

End
(See you next lecture)

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