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ENGR 5312 QUALITY IMPROVEMENT

COURSE PROJECT
Nov 29, 2006

Submitted To
Dr Weihang Zhu

Submitted By
Ronak Goswami
Divyesh Patel
Mitesh Paghadal
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Sr. No. Topic Name Page No.

1 Abstract 2
2 Statement of Problem 4
3 What is a Control Chart? 4
4 Types of Control Charts 5
5 Steps in Setting up a Control Chart 7
6 Selecting the Subgroup Size 7
7 Selecting the Total Frequency of Taking Subgroups. 7
8 Collecting the Data 8
9 Determining the Control Limits 9
10 Continuation of the X bar and R Charts 12
11 Results and Suggestions 14
12 References 15

ABSTARCT

A control chart is a statistical tool used to distinguish between variation in a process

resulting from common causes and variation resulting from special causes. It presents a
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graphic display of process stability or instability over time. Every process has variation.
Some variation may be the result of causes which are not normally present in the process.
One goal of using a Control Chart is to achieve and maintain process stability. This
consistency is characterized by a stream of data falling within control limits based on plus
or minus 3 standard deviations (3 sigma) of the centerline.

In this project we will discuss the calculation of 3 sigma limits, which represents the
limits of variation that should be expected from a process in a state of statistical control.
In this project our aim is to achieve statistical control of the curetimes using X bar and R
charts. Toys are being produced in a company named Etcetra. The plastic material is first
molded and then trimmed to the required shape. The curetimes during the molding
process affect the edge quality of the Toys produced. The data collected will be used to
plot the control charts for variables to find out the stability of the process. We will check
that readings are really meeting with the specifications or not.

Statement of Problem

In this project our prime objective is to detect special (or assignable) causes of variation
in a process – by analyzing data from the past and the future. We are basically
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determining 3 sigma limits, which represents the limits of variation that should be
expected from a process in a state of statistical control. Knowing the meaning of “special
causes” is essential to understanding the control chart concept. In this project our aim is
to achieve statistical control of the curetimes using X bar and R charts. Toys are being
produced in a company named Etcetra. The plastic material is first molded and then
trimmed to the required shape. The curetimes during the molding process affect the edge
quality of the Toys produced. The data collected will be used to plot the control charts for
variables to find out the stability of the process. We will check that readings are really
meeting with the specifications or not

What is a Control Chart?

A control chart is a statistical tool used to distinguish between variation in a process

resulting from common causes and variation resulting from special causes. It presents a
graphic display of process stability or instability over time.
Every process has variation. Some variation may be the result of causes which are not
normally present in the process. This could be special cause variation. Some variation is
simply the result of numerous, ever-present differences in the process. This is common
cause variation. Control Charts differentiate between these two types of variation.
One goal of using a Control Chart is to achieve and maintain process stability. Process
stability is defined as a state in which a process has displayed certain degree of
consistency in the past and is expected to continue to do so in the future. This consistency
is characterized by a stream of data falling within control limits based on plus or minus 3
standard deviations (3 sigma) of the centerline. Control limits represent the limits of
variation that should be expected from a process in a state of statistical control. When a
process is in statistical control, any variation is the result of common causes that effect
the entire production in a similar way. Control limits should not be confused with
specification limits, which represent the desired process performance.

Types of Control Charts:

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There are two main categories of Control Charts, those that display attribute data, and
those that display variables data.
Variables Data: This category of Control Chart displays values resulting from the
measurement of a continuous variable. Examples of variables data are elapsed time,
temperature, and radiation dose. While these two categories encompass a number of
different types of Control Charts, there are three types that will work for the majority of
the data analysis cases you will encounter.
Attribute Data: This category of Control Chart displays data that result from counting
the number of occurrences or items in a single category of similar items or occurrences.
These “count” data may be expressed as pass/fail, yes/no, or presence/absence of a
defect.

Steps in Setting up a Control Chart:

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Selecting the subgroup size

Here we have selected the subgroup size as 4. Some assumption that we have taken into
considerations for that are as follows.
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1. As subgroup size increases, the control limits become closer to the central value, which
makes the control chart more sensitive to small variations in the process average.
2. As the subgroup size increases, the inspection cost per subgroup increases.
3. Because of the ease of computation a sample size of 4 is quite common in industry.
4. From a statistical basis a distribution of subgroup averages, X ’s nearly normal fro
subgroups or 4 or more even when the samples are taken from a non-normal universe.

Selecting the total frequency of taking subgroups.

There is no rule for the frequency of taking subgroups. The inconvenience of the factory
layout and the cost of talking subgroups must be balanced with the value of the data
obtained. In general, it is best to sample quite often at the beginning and reduce the
sampling frequency when the data permits. The use of table, which was obtained from
MIL-STD 414, can be a valuable aid in making judgments on the amount of sampling
required. If the process of slotting produce 4000 slots per day, from table, 60 inspections
are required. Therefore, with subgroup size of 4, 15 subgroups would be needed. We
could select frequency of 15 but it is necessary to collect a minimum of 25 subgroups of
data. As a fewer number of subgroups would not provide a sufficient amount of data for
the accurate computation of the control limits.

Sample Sizes (from MIL-STD 414, Normal Inspection, Level IV)

Lot Size Sample Size
66-110 10
111-180 15
181-300 25
301-500 30
501-800 35
801-1300 40
1301-3200 60
8001-22000 85

Collecting Data
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The next step is to collect the data. This step can be accomplished using the type of form
as shown wherein the data are recorded in a horizontal fashion, by recording the each
subgroup one below the other. An alternative method of recording data in vertical fashion
can also be used. Using a rational subgroup of four, an inspector obtains five subgroups
per day for 5 days using the period of time method. The samples are measured on the
form.
Following are the Curetime data of twenty-five samples, each of size four, have been
taken when the process is assumed to be in control.
Sample Observations
Mean Range
No. Cueretime 1 Cueretime 2 Cueretime 3 Cueretime 4
1 27.35 27.50 29.94 28.21 28.25 2.60
2 27.80 26.15 31.21 31.33 29.12 5.18
3 33.53 29.33 29.70 31.05 30.90 4.20
4 37.98 32.27 31.92 29.44 32.90 8.54
5 33.83 30.33 28.38 33.70 31.56 5.45
6 29.68 29.57 27.23 34.00 30.12 6.77
7 32.63 26.32 32.08 36.17 31.80 9.85
8 30.30 30.53 24.43 26.85 28.03 6.10
9 28.44 30.48 32.43 30.76 30.53 3.99
10 28.28 33.95 30.47 28.87 30.39 5.67
11 26.92 27.66 31.47 29.67 28.93 4.55
12 28.47 28.30 28.99 31.15 29.23 2.85
13 32.43 26.10 29.48 37.20 31.30 11.10
14 28.84 30.52 32.24 30.47 30.52 3.39
15 30.75 33.00 28.08 26.20 29.51 6.80
16 31.26 24.29 35.46 28.41 29.86 11.17
17 31.25 28.58 35.01 31.24 31.52 6.43
18 31.42 35.80 33.61 27.82 32.16 7.98
19 32.20 32.02 32.71 29.38 31.58 3.33
20 26.92 29.78 33.93 33.78 31.10 7.01
21 35.05 32.93 31.52 27.74 31.81 7.32
22 32.12 29.33 31.00 31.40 30.96 2.80
23 30.09 32.44 27.85 30.71 30.27 4.59
24 30.05 27.24 22.02 28.70 27.00 8.03
25 29.30 30.84 30.83 31.91 30.72 2.60
Means 30.40 5.93

Determining the trial control limits

- Calculate the mean ( X ) and range (R) for each sample
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Both the mean ( X ) and range (R) have already been calculated in table using following
formulas. These sample statistics will serve as indices of central tendency and dispersion
for the process.
X1  X 2  X 3  X 4
X =
n

R = X max - X min

Where: X 1 , X 2 …are individual measurements in a sample

n is the sample size

Calculation:

R = X max - X min = 29.94-27.35 = 2.60

- Calculate the process center line

The central values for the X and R charts are obtained using the formulas
m

X =
X
j 1
j
=
X 1  X 2  ...  X m
m
m
m

R =
R
j 1
j
=
R1  R2  ...  Rm
m
m
Where X = mean or average of the subgroup means
X j = mean of the jth subgroup
m = number of subgroups
R = mean or average of the subgroup ranges
R j = range of the jth subgroup

Calculation
From table by calculation we get
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m m

X =
Xj
j 1 R =
R
j 1
j

m m
= 760.07 = 148.30
25 25
= 30.40 = 5.93

- Calculate the trail control limits

Control limit indicate the amount of change sample averages and ranges would vary if
only common causes of variation were operating in a process. The control limits are
based upon the sample size and the amount of within sample variation reflected by the
sample ranges. Trial control limits for the charts can be calculated from the central value
by the formulas
Control Limit for the average chart
UCL x = X +A2 R
LCL x = X -A2 R
Control Limit for the range chart
UCL x = D 4 R
LCL x = D 3 R
Where A 2 , D 4 , D 3 are constant values based upon the sample size

Calculation
From the table B of appendix the values for the factors for a subgroup size n = 4 are A 2 =
0.729, D 4 = 2.282 and D 3 =0.
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UCL x = X + A 2 R = 30.40 + (0.729)*(5.93) = 34.72 Sec

LCL x = X - A 2 R = 30.40 - (0.729)*(5.93) = 26.08 Sec
UCL x = D 4 R = (2.282)*(5.93) = 13.53 Sec
LCL x = D 3 R = (0)*(5.93) = 0 Sec

- Plotting the Process center lines and control limits on the charts

Since both the X bar and the R chart exhibit control, the process can be taken to be in
control at the stated levels and the control limits can be adopted for use in on-line
statistical process control.
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Continuation of the X bar and R charts

Twelve additional samples of curetime data from the molding process were collected
from an actual production run. The data from these new samples are shown in table 2.

Observations
Sample
Cueretime Mean Range
No. Cueretime 2 Cueretime 3 Cueretime 4
1
1 31.66 29.78 31.88 33.91 31.81 4.13
2 34.46 25.18 37.77 39.21 34.16 14.03
3 41.34 39.55 29.56 32.57 35.75 11.79
4 29.47 25.38 25.04 24.00 25.97 5.47
5 25.47 34.85 30.19 31.62 30.53 9.38
6 46.25 34.71 41.41 44.63 41.75 11.54
7 35.45 38.83 33.09 31.63 34.75 7.20
8 34.55 33.86 35.19 42.32 36.48 8.45
9 43.44 37.36 38.86 39.25 39.73 6.07
10 37.05 42.47 35.90 38.22 38.41 6.57
11 38.57 39.07 32.22 33.20 35.77 6.85
12 27.03 33.64 26.63 42.79 32.52 16.16
Means 34.80 8.97

The X bar and the R charts are drawn with the new data with the same control limits
established before. They are shown below
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Charts show the average and range value for each subgroup plotted on the graph. Upper
control limit and lower control limits are presented by yellow lines and Green Lines
respectively while the center lines are by Pink lines.
Now looking at the charts we can say that there is some lack of control. Following
observations are made from the control charts:

X bar chart

 Six points fall above UCL.

 One point falls below LCL.
 One point falls on UCL.

R chart
 Two points fall above UCL.
 Eight consecutive points are above the center line

Results and Suggestion

This example describes the case in which the average values of the measured quality
definitely moved outside control-chart limits. Even though in such cases the actual
troubleshooting may encounter many difficulties, from a statistical view point these are
the simplest types of examples. In fact, when such cases are described in presenting the
advantages of control-chart techniques, the question is likely to be asked, “Would not the
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need for action have been just as clear from the tests as a matter of common sense even if
there had been no control chart? Just how did the control chart itself really help?”

This question implies that the tests would have been carried out and that their results
would have been conveniently available for analysis, regardless of whether or not a
control chart was used. This assumption is often contrary to the facts. Experiences shows
that the use of control chart sometimes leads to a more systematic program of testing and
measurement; it nearly always leads to a tabulation of test results in a way that makes
them more readily available as a basis for action.

But the control chart’s contribution to effective action in this particular case does not
depend on any stimulus that it may have given to more systematic procedures in making
and recording measurements of quality. The control chart provides a graphic presentation
of quality history that gives a clearer picture than could be obtained from any tabulation
of test data. Of course the primary contribution of the control chart to such
troubleshooting lies in the information given by the control limits. These provide rules for
action that are much more reliable than any so-called commonsense judgments. When the
control charts shows a long period of control followed by several points out of control,
the evidence is conclusive that there is a discoverable cause of variation. Moreover, the
limits provide a definite basis for judgment as to whether or not the cause of trouble has
been corrected.

References

1. Statistical Quality Control by Eugene L. Grant and Richard S. Leavenworth

2. http://www.balancedscorecard.org/files/control.pdf
3. http://www.qualitydigest.com/oct97/html/excel.html
4. Etcetra’s Manual
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