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Quality Control Assurance and Reliability: Dr. C.Phaneendra Kiran

The document discusses control charts for attributes in quality control, detailing types such as p charts, np charts, c charts, and u charts, which are used to analyze discrete data. It explains the construction and interpretation of these charts, emphasizing the importance of understanding control limits and the implications of points plotted outside these limits. Additionally, it highlights the advantages of attribute control charts over variable control charts and their applications in various industries.

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mohimran2002
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7 views49 pages

Quality Control Assurance and Reliability: Dr. C.Phaneendra Kiran

The document discusses control charts for attributes in quality control, detailing types such as p charts, np charts, c charts, and u charts, which are used to analyze discrete data. It explains the construction and interpretation of these charts, emphasizing the importance of understanding control limits and the implications of points plotted outside these limits. Additionally, it highlights the advantages of attribute control charts over variable control charts and their applications in various industries.

Uploaded by

mohimran2002
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Quality Control

Assurance and
Reliability
Dr. C.Phaneendra Kiran
Ph.D
BITS Pilani Department of Mechanical Engineering
BITS Pilani Hyderabad Campus
Pilani Campus
Chapter 8
(Lecture No: 12)
BITS Pilani
Control Charts for Attributes
Pilani Campus
Control Charts

There are two types of control charts that we deal with.

 Variables Control Charts


These charts are applied to data that follow a continuous
distribution.

 Attributes Control Charts


These charts are applied to data that follow a discrete
distribution.

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Attributes Data

Data that can be classified into one of several categories or


classifications is known as attribute data.

Classifications such as conforming and nonconforming are


commonly used in qualitycontrol.

Another example of attributes data is the count of defects

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Types of attributes control
chart
p chart
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 chart
This chart shows the number of nonconforming. Almost
the same as the p chart.
c chart
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. BITS Pilani, Pilani Campus
Control Charts for Fraction
Nonconforming

Fraction nonconforming is the ratio of the number of


nonconforming items in a population to the total number of
items in that population.

Control charts for fraction nonconforming are based on the


binomial distribution.

A quality characteristic follows a binomial distribution if:


 All trials are independent.
 Each outcome is either a “success” or “failure”
 The probability of success on any trial is given as p. The probability of a failure is 1-p
 The probability of a success is constant

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Binomial distribution

where L is the “distance” of the of the


control limits from the centre line,
expressed in standard deviation units.

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P Chart

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p-Chart construction for constant
subgroup size

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Trial and Revised Control
Limits

 Control limits that are based on a preliminary set of


data can often be referred to as trial control limits.

 The quality characteristic is plotted against the trial


limits, if any points plot out of control, assignable
causes should be investigated and points removed.

With removal of the points, the limits are then


recalculated.

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Example

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Sol:

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Interpretation of Points on the Control
Chart for Fraction Nonconforming

 Care must be exercised in interpreting points that plot below the lower
control limit.

 They often do not indicate a real improvement in process quality.

They are frequently caused by errors in the inspection process or improperly


calibrated test and inspection equipment.

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Example

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Sol:

The control chart is shown below.

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Sol:

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Sol:

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Sol:

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Sol:

The revised center line and control limits are shown on the
control chart in Fig. . Note that we have not dropped samples
15 and 23 from the chart, but they have been excluded from
the control limit calculations, and we have noted this directly
on the control chart. This annotation of the control chart to
indicate unusual points, process adjustments, or the type of
investigation made at a particular point in time forms a useful
record for future process analysis and should become a
standard practice in control chart usage.

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Design of the Fraction Nonconforming
Control Chart (np Chart)

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Example on np chart

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Sol:

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Control charts for variable
sample size

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Consider the following example
&Variable-width control limits:

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Sol:

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Control limit based on
average sample size

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Sol:

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The Standardized Control
Chart.
The third approach to dealing with variable sample size is to
use a standardized control chart, where the points are
plotted in standard deviation units. Such a control chart has
the center line at zero, and upper and lower control limits of
+3 and −3, respectively. The variable plotted on the chart is

where p (or if no standard is given) is the process fraction nonconforming in the


in-control
state

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BITS Pilani, Pilani Campus
Sol:

BITS Pilani, Pilani Campus


Control Charts for Nonconformities
(Defects) – c Chart

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Example

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Sol:

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Control Chart for Nonconformities per
unit (u chart)

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Example

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Sol:

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Indications that special causes of
variations are present

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u Chart – variable width control
limit

In a textile finishing plant, dyed cloth inspected for the occurrence


of defects per 50 m2. The data on 10 rolls of cloth are shown in
the table.

Set up a control chart for nonconformities per unit.

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Sol:

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Application of Control Charts

• The control chart, though originally developed for quality


control in manufacturing, is applicable to all sorts of
repetitive activities in any kind of organization.

• They can be used for services as well as products, for


people, machines, cost, and so on.
For example, we can plot errors on engineering drawings,
errors on plans and documents, and errors in computer
software as c or u charts.

• Sometimes, the quality control engineer has a choice


between variable control charts and attribute control charts.

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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.

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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.

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Review

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Example
• What is the difference between a defect and
defective?
• The following tabulation gives defects
observed in an aircraft sub assembly
operation and shows the number of units
produced on each day during a week.
Prepare an U-chart for this. Assume U’=4.2

Mon Tue Wed Thurs Fri Sat

n 5 5 5 5 4 5

c 19 25 15 29 36 27
Sol:

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Example

The upper and lower control limits for a p chart are: LCL = 0
and UCL = 0.20. Determine the minimum possible sample
size n that is compatible with this control chart

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Sol:

Solution:

p = 0.5(UCL + LCL) = 0.5(.20 + 0) = 0.10

LCL = p - 3 p(1− p) / n = 0

Therefore, p = 3 p(1− p) / n
0.10 = 3 0.10( 0.90 ) / n
(0.10)2 = 0.01 = 32 (0.10)(0.90)/n = 0.81/n
n = 0.81/0.01 = 81

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