MBA in Advanced Construction Management

Construction Quality
Management
Course Code: 247002CQM
Session No: 18
Title: Types of Control Charts
Course Content
Recap!!
Sources of Variation
• Common causes of variation
in Production and Service Processes
– Random causes that we cannot identify
– Unavoidable
– Cause slight differences in process variables
like diameter, weight, service time,
temperature, etc.
• Assignable causes of variation
– Causes can be identified and eliminated
– Typical causes are poor employee training,
worn tool, machine needing repair, etc.
Measuring Variation: The Standard Deviation
Small vs. Large Variation
Process
• A measure ofCapability
the ability of a
process to meet preset design
specifications:
– Determines whether the process can
do what we are asking it to do
• Design specifications (tolerances):
– Determined by design engineers to
define the acceptable range of
individual product characteristics (e.g.:
physical dimensions, elapsed time,
etc.)
– Based upon customer expectations &
how the product works (not statistics!)
Relationship between Process Variability and Specification Width
Three Sigma Capability
• Mean output +/- 3 standard deviations falls within the design specification
• It means that 0.26% of output falls outside the design specification and is unacceptable.
• The result: a 3-sigma capable process produces 2600 defects for every million units produced
Six Sigma Capability
• Six sigma capability assumes the
process is capable of producing
output where the mean +/- 6
standard deviations fall within the
design specifications
• The result: only 3.4 defects for
every million produced
• Six sigma capability means smaller
variation and therefore higher
quality
Setting Control Limits
Types of Control Charts

• Control chart for • Control charts for

variables are used to attributes are used to
monitor characteristics that monitor characteristics that
can be measured, e.g. have discrete values and can
length, weight, diameter, be counted, e.g. % defective,
time, etc. number of flaws in a shirt,
number of broken eggs in a
box, etc.
Control Charts for Variables
• Mean (x-bar) charts
– Tracks the central tendency (the average value
observed) over time
• Range (R) charts:
– Tracks the spread of the distribution over time
(estimates the observed variation)
x-bar and R charts
monitor different parameters!
Control Charts for Variables
Control Charts for Variables
Example: X-bar Charts
Example: X-bar Charts
Example: X-bar Charts
Example: X-bar Charts (Practice Problem)
Example: X-bar Charts
Example: X-bar Charts
Example: X-bar Charts
Example: X-bar Charts
Solve X-bar charts!!
In a residential complex project, quality of M25 grade concrete is assessed by measuring the compressive
strength of concrete after 28 days of standard curing. Quality of concrete is established by average
compressive strength of three cubes (150mm x 150mm x 150mm each) drawn from each batch of
concrete poured.

Concrete is produced in a nearby batching plant used for a recently completed project. From the test
results of the completed project, it is established that the characteristic compressive strength of M25
grade concrete varies with a standard deviation of 3.00 MPa.

The test results for ten successive samples, from the new project, are shown in the table below. Develop
control limits of three standard deviations to interpret the status of concreting process.
X-bar charts!!
Sample
number Compressive Strength (MPa)
Cube 1 Cube 2 Cube 3
1 27.36 32.05 30.25
2 29.56 28.36 31.58
3 32.14 30.20 25.46
4 28.00 29.11 29.89
5 26.24 35.23 32.98
6 29.36 30.25 30.58
7 32.63 30.59 34.78
8 31.26 33.41 32.85
9 29.11 35.47 33.68
10 32.65 30.54 25.42
An Alternative Method for the X-bar Chart Using
R-bar and the A2 FactorSample Size x-Chart Factors for R-Chart
Factor for

(n) A2 D3 D4
2 1.88 0.00 3.27

Use this method when 3 1.02 0.00 2.57

4 0.73 0.00 2.28
sigma for the process 5 0.58 0.00 2.11
distribution is not known. 6 0.48 0.00 2.00
7 0.42 0.08 1.92
Use factor A2 from Table 6.1 8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
Control Charts for Variables
Control Chart for Variables
R- bar charts (Range Charts) Steps
Step 1: Calculate the Range of Each Sample and Average Range
r 1+ r 2+r 3 … …+𝑟𝑘
!!!Don’t confuse with mean, this
R= is range!!!
k
Step 2: Calculate the UCL And LCL for x-bar charts R1= (Largest dataset- Smallest
Dataset)

UC Lx = x+ A 2 R Here is the mean

Step 3: Calculate the UCL And LCL for R charts

UCL = D 4 R
X-bar and R or S Control
Charts
• xControl Chart (from R):

R Chart:
Example R charts

Calculate the Range of Each Sample and Average Range

Time 1 Time 2 Time 3

Observation 15.8 16.1 16.0

1
Observation 16.0 16.0 15.9
2
Observation 15.8 15.8 15.9
3
Observation 15.9 15.9 15.8
4
Example R charts

Calculate the Range of Each Sample and Average Range

Time 1 Time 2 Time 3
Observation 15.8 16.1 16.0
1
Observation 16.0 16.0 15.9
2
Observation 15.8 15.8 15.9
3
Observation 15.9 15.9 15.8
4
0.2+
Sample𝑹= 0.2
0.3+ 0.2
0.3 =.233
0.2
ranges (R) 𝟑
Example R charts
Calculate CL, UCL, LCL Sample Size
Factor for x-Chart Factors for R-Chart

(n)
A2 D3 D4
• Calculate the mean
2 1.88 0.00 3.27
3 1.02 0.00 2.57
4 0.73 0.00 2.28
5 0.58 0.00 2.11
6 0.48 0.00 2.00
• Calculate the UCL and LCL for x-bar 7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
Example R charts
Calculate CL, UCL, LCL for R-charts
Sample Size
Factor for x-Chart Factors for R-Chart

(n)
A2 D3 D4
2 1.88 0.00 3.27
3 1.02 0.00 2.57
4 0.73 0.00 2.28
5 0.58 0.00 2.11
6 0.48 0.00 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
Control Chart for Range (R-Chart)
Center Line and Control Limit
Factor for x-Chart Factors for R-Chart
calculations: Sample Size
(n)
A2 D3 D4
2 1.88 0.00 3.27
3 1.02 0.00 2.57
4 0.73 0.00 2.28
5 0.58 0.00 2.11
6 0.48 0.00 2.00
7 0.42 0.08 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78
11 0.29 0.26 1.74
12 0.27 0.28 1.72
13 0.25 0.31 1.69
14 0.24 0.33 1.67
15 0.22 0.35 1.65
Example: R-bar Charts – Practice Problem
Example: R-bar Charts
Example: R-bar Charts
Example: R-bar Charts
Example: R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts – Practice
Problem
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
Example: X-bar and R-bar Charts
•.

Control Charts for Attributes

• Use P-Charts for quality characteristics that are discrete and involve
yes/no or good/bad decisions
– Percent of broken eggs in a carton
– Percentage of defective concrete blocks in a batch (e.g., cracked or chipped blocks).
– Percentage of bricks with dimensional defects in a pallet

• Use C-Charts for discrete defects 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 potholes per kilometer on a newly laid road.
– Number of spalling locations per square meter of a retaining wall
Control Charts for Attributes
Control Charts for Attributes
Example P-chart
A Quality Control Manager for a concrete block manufacturing company has inspected
the number of defective concrete blocks in five random samples with 20 blocks in each
sample. The table below shows the number of defective concrete blocks in each sample
of 20 blocks
Sample Sample Size Number
(n) Defective

1 20 3

2 20 2

3 20 1

4 20 2

5 20 1
Example P-chart
Step 1:
Calculate the Percent defective of Each Sample and the Overall Percent Defective
(P-Bar)
Sampl Number Sample Percent
e Defectiv Size Defective
e
1 3 20 .15
2 2 20 .10
3 1 20 .05
4 2 20 .10
5 1 20 .05
Total () 9 100 .09
Example P-chart

Step 2: Calculate the Standard Deviation of P.

σ p=
√
p(1− p) (.09)(.91)
n
=
20 √
=0.064
Example P-chart
Step 3: Calculate CL, UCL, LCL
 Center line (p bar):

CL= p=.09 Process under control

 Control limits for ±3σ limits:

UCL=p+z ( σ p ) =.09+3(.064)=.282
Example: P-charts
Example: P-charts
Example: P-charts
Example: P-charts
Example: P-charts
Control Charts for Attributes
Example: C-charts
Example: C-charts
Example: C-charts
Example: C-charts
Example: C-charts
Thank you!!!!