09 Lot-By-lot Acceptance Sampling For Attributes

Quality Control
Chapter 9- Lot-by-Lot Acceptance Sampling By Attributes

PowerPoint presentation to accompany Besterfield Quality Control, 8e
PowerPoints created by Rosida Coowar
Besterfield: Quality Control, 8th ed..
2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved
Outline
Fundamental Aspects Statistical Aspects Sampling Plan Design
Learning Objectives
When you have completed this chapter you should be able to:
Know the advantages and disadvantages of
sampling; the types of sampling plans and selection factors; criteria for formation of lots; criteria for sampling selection; and decisions regarding rejected lots.
Determine the OC Curve for a single sampling plan.
Learning Objectives-contd.
Determine the equations needed to graph the OC
Curve for a double sampling plan.

Know the properties of OC Curves. Know the consumer-producer relationships of risk,
AQL, and LQ.
Learning Objectives-contd.
Determine the AOQ curve and the AOQL for a single
sampling plan.
Determine single sampling plans for stipulated
producers risk and for stipulated consumers risk.
Fundamental Aspects
Acceptance Sampling is a form of inspection applied to lots or batches of items before or after a process to judge conformance to predetermined standards.
Acceptance Sampling
Acceptance Sampling is very useful when:
Large numbers of items must be processed in a
short amount of time.

The cost of passing defectives is low.
Fatigue/boredom is caused by inspecting large
numbers of items.
Acceptance Sampling
Acceptance Sampling is very useful when:
Destructive testing is required
Acceptance Sampling
Three important aspects of sampling: Involves random sampling of the entire lot Accept and Reject Lots (does not improve
the quality) Lot Sentencing

Audit Tool Three approaches to lot sentencing: Accept with no inspection
100% inspection
Acceptance Sampling
Besterfield: Quality Control, 8th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved
Acceptance Sampling
Advantages
Less expensive Reduced damage Reduces the amount of inspection error Disadvantages
Risk of accepting bad lots and rejecting
good lots
Less information generated
Requires planning and documentation

Sampling Plans
Sampling Plans specify the lot size, sample size,
number of samples and acceptance/rejection criteria. Sampling plans involve: Single sampling Double sampling Multiple sampling
Lot
Random sample
Sampling Plans
Single Sampling Plan
N = lot size
n = sample size C=acceptance number If c or less non-conforming units are found in the sample, the lot is accepted, else it is rejected.
Single Sampling Plan

A single sampling plan is one where: A representative sample of n items is drawn from a lot size of N items Each item in the sample is examined and classified as good/defective If the number of defective exceeds a specified rejection number (c) the whole lot is rejected; otherwise the whole lot is accepted
Double Sampling Plan

A Double Sampling Plan allows to take a second sample if the results of the original sample are inconclusive.
Specifies the lot size, size of the initial sample, the
accept/reject/inconclusive criteria for the initial sample (N, n1, c1 (Ac), r1(Re)) Specifies the size of the second sample and the acceptance rejection criteria based on the total number of defective observed in both the first and second sample (n2,c2,r2)

Lot First Random sample
Accept Lot
First sample inconclusive, take second sample
Reject Lot
C1
r1
Compare number of defective found in the first random sample to C1 and r1 and make appropriate decision.

Lot
First Random sample
Second Random sample
Accept Lot
Reject Lot
C2 Compare the total number of defective in both lots to C2 and make the appropriate decision

A Multiple Sampling Plan is similar to the double sampling plan in that successive trials are made, each of which has acceptance, rejection and inconclusive options.
Which Plan you choose depends on:

of items in each sample
Cost and time Number of samples needed and number
Lot Formation
Considerations before inspection:
Lots should be homogeneous Larger lots are more preferable than
smaller lots Lots should be conformable to the materials-handling systems used in both the vendor and consumer facilities
Random Sampling
Units selected for inspection should be
chosen at random If random samples are not used, bias can be introduced If judgment methods are used to select the sample, the statistical basis of the acceptance-sampling procedure is lost
Statistical Aspects
The Operating Characteristic Curve:
Measures the performance of an
acceptance sampling plan Plots the probability of accepting the lot versus the lot fraction defective Shows the probability that a lot submitted with a certain fraction defective will be either accepted or rejected
Acceptable Quality Level (AQL)

The AQL is a percent defective that is the base line requirement for the quality of the producer's product. The producer would like to design a sampling plan such that there is a high probability of accepting a lot that has a defect level less than or equal to the AQL.
Lot Tolerance Percent Defective

The Lot Tolerance Percent Defective LTPD or LQ is a designated high defect level that would be unacceptable to the consumer. The consumer would like the sampling plan to have a low probability of accepting a lot with a defect level as high as the LTPD.
Type I Error (Producers Risk)

This is the probability, for a given (n,c) sampling plan, of rejecting a lot that has a defect level equal to the AQL. The producer suffers when this occurs, because a lot with acceptable quality was rejected. The symbol is commonly used for the Type I error and typical values for range from 0.2 to 0.01.
Type II Error (Consumers Risk)

This is the probability, for a given (n,c) sampling plan, of accepting a lot with a defect level equal to the LTPD. The consumer suffers when this occurs, because a lot with unacceptable quality was accepted. The symbol is commonly used for the Type II error and typical values range from 0.2 to 0.01.
Operating Characteristic Curve

This curve plots the probability of accepting the lot (Y-axis) versus the lot fraction or percent defectives (X-axis). The
OC curve is the primary tool for displaying and investigating the properties of a Lot Acceptance Sampling Plan.
OC Curves
There are two types of OC curves: Type A Gives the probability of acceptance of an individual lot coming from finite production Type B Gives the probability of acceptance for lots coming from a continuous production
OCCs for Single Sampling Plans

An Operating Characteristic Curve (OCC) is a probability curve for a sampling plan that shows the probabilities of accepting lots with various lot quality levels (% defectives).
1
Probability of accepting lot
0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 .05
Under this sampling plan, if the lot has 3% defective . the probability of accepting the lot is 90% . the probability of rejecting the lot is 10%
If the lot has 20% defective . it has a small probability (5%) of being accepted . the probability of rejecting the lot is 95%
.10
.15
.20
Lot quality (% defective)
OCC, AQL and Producers Risk

1 0.9
Producers Risk = probability acceptable lot is rejected
0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 .05 .10 .15 .20
AQL - percentage level of defects at which a customer is willing to accept
Acceptable Lot
OCC, LTPD and Consumers Risk

1 0.9
0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 .05 .10 .15 .20
LTPD - upper limit on the percentage of defectives that a customer is willing to accept.
Consumers Risk = probability unacceptable is accepted
Unacceptable Lot
OCC for Double Sampling Plan

Inspect a sample of 150 from lot of 2400 If 1 or less Nonconforming units accept lots and stop If 4 or more Nonconforming units the lot is not accepted and stop
If 2 or 3 nonconforming units, inspect a second sample of 200
If 5 or less Nonconforming units On both samples, Accept the lot
If 6 or more Nonconforming units On both samples The lot is not accepted
Figure 9-5 Graphical description of the double sampling plan: N=2400,n1=150,c1=1 r1=4, n2=200, c2=5, and r2=6
OCC for a Multiple Sampling Plan
Average Outgoing Quality (AOQ)

A common procedure, when sampling and testing is non-destructive, is to 100% inspect rejected lots and replace all defectives with good units. In this case, all rejected lots are made perfect and the only defects left are those in lots that were accepted.
Average Outgoing Quality

The Average Outgoing Quality (AOQ) is the average of rejected lots (100% inspection) and accepted lots ( a sample of items inspected)
N -n AOQ = Pac * p( ) where N Pac = Probability of accepting a lot p = Fraction defective n = sample size N = Lot size
AOQ and Acceptance Sampling

15 lots 2% nonconforming N=3000 Producer n=89 c=2 4 lots 2% nonconforming 4 lots 0% nonconforming 11 lots 2% nonconforming Consumer
Figure 9-15 How acceptance Sampling works
AOQ and Acceptance Sampling

Total Number
11 lots2% Nonconforming 4(3000)(0.98)=11,7 60 0% Nonconforming 44,760 4 lots0
Number Nonconforming
33,000(0.02)=660
11(3000)=33,000
660
Percent Nonconforming (AOQ) = 660/44,760 X 100 =1.47%
Figure 9-15 contd.

Average Quality of Inspected Lots

Typically the term (N-n)/N is very close to 1; therefore, the equation most often used is:
AOQ = Pac * p where Pac = Probability of accepting a lot p = Fraction defective
Average Outgoing Quality Level

A plot of the AOQ (Y-axis) versus the incoming lot p (X-axis) will start at 0 for p = 0, and return to 0 for p = 1 (where every lot is 100% inspected and rectified). In between, it will rise to a maximum. This maximum, which is the worst possible long term AOQ, is called the Average Outgoing Quality Level AOQL.
Average Total Inspection (ATI)

When rejected lots are 100% inspected, it is easy to calculate the ATI if lots come consistently with a defect level of p. For a LASP (n,c) with a probability pa of accepting a lot with defect level p, we have: ATI = n + (1 - pa) (N - n) where N is the lot size.
Average Sample Number (ASN)

For a single sampling (n,c) we know each and every lot has a sample of size n taken and inspected or tested. For double, multiple and sequential plans, the amount of sampling varies depending on the number of defects observed.
Average Sample Number (ASN)

For any given double, multiple or sequential plan, a long term ASN can be calculated assuming all lots come in with a defect level of p. A plot of the ASN, versus the incoming defect level p, describes the sampling efficiency of a given plan scheme.
ASN = n1 + n2 (1 P1) for a double sampling plan.
Sampling Plan Design

Suppose is known and the AQL is also known then :
Sampling plan with stipulated producers
risk Sampling plan with stipulated consumers risk Sampling plan with stipulated producers and consumers risk
can be designed.

Stipulated Producers Risk
AQL = 1.2% Pa=0.95 P0.95= 0.012 Assume values for C, find np0.95 for this c value, calculate n
= 0.05

Stipulated Consumers Risk
LQ = 6.0% Pa=0.10 P0.10= 0.060 Assume values for C, find np0.95 for this c value, calculate n
= 0.10

Stipulated Producers and Consumers
risk = 0.10 = 0.10 AQL=0.9 LQ= 7.8 Find the ratio of P0.10/P0.95. From table 9-4 C is between 1 and 2. Find n for c =1 and n for c =2 .

Have 4 plans. Select plan based on:
Lowest sampling size

Greatest sampling size Plan exactly meets consumers
stipulation and is as close as possible to producers stipulation Plan exactly meets producers stipulation and is as close as possible to consumers stipulation

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Quality Control

Chapter 9- Lot-by-Lot Acceptance Sampling By Attributes

PowerPoints created by Rosida Coowar

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Curve for a double sampling plan.

AQL, and LQ.

Besterfield: Quality Control, 8th ed..

producers risk and for stipulated consumers risk.

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

short amount of time.

Fatigue/boredom is caused by inspecting large

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

the quality) Lot Sentencing

Risk of accepting bad lots and rejecting

Requires planning and documentation

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Single Sampling Plan

Besterfield: Quality Control, 8th ed..

Double Sampling Plan

Besterfield: Quality Control, 8th ed..

Double Sampling Plan

First sample inconclusive, take second sample

Double Sampling Plan

Second Random sample

Double Sampling Plan

Which Plan you choose depends on:

Cost and time Number of samples needed and number

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

Acceptable Quality Level (AQL)

Besterfield: Quality Control, 8th ed..

Lot Tolerance Percent Defective

Besterfield: Quality Control, 8th ed..

Type I Error (Producers Risk)

Besterfield: Quality Control, 8th ed..

Type II Error (Consumers Risk)

Besterfield: Quality Control, 8th ed..

Operating Characteristic Curve

Besterfield: Quality Control, 8th ed..

Besterfield: Quality Control, 8th ed..

OCCs for Single Sampling Plans

Probability of accepting lot

Lot quality (% defective)

Besterfield: Quality Control, 8th ed..

OCC, AQL and Producers Risk

Producers Risk = probability acceptable lot is rejected

Probability of accepting lot

AQL - percentage level of defects at which a customer is willing to accept

Lot quality (% defective)

OCC, LTPD and Consumers Risk

Probability of accepting lot

Consumers Risk = probability unacceptable is accepted

Lot quality (% defective)

OCC for Double Sampling Plan

Besterfield: Quality Control, 8th ed..