08 Acceptance Sampling Plans - Ppm's

Six Sigma
Green Belt Training

Acceptance Sampling
Recognize
2007 American Society for Quality. All Rights Reserved.
Define
Measure
Analyze
Improve
Control
What We Will Learn
1. What is Acceptance Sampling?

2. Definitions of Key Terms.
3. How to create variable data acceptance sampling plans.
4. How to apply variable data acceptance sampling plans.
5. How to create attribute data acceptance sampling plans.
6. How to apply attribute data acceptance sampling plans.
Recognize
Define
Measure
Analyze
Improve
Control
Page 2 Creating Sampling Plans 2.1
2007 American Society for Quality.

All Rights Reserved.
What is Acceptance Sampling?

The application of specific
sampling plans to a designated
lot or sequence of lots.
Provides accept/reject
criteria for lots of material.
May be used in a program of
acceptance control to achieve
better quality at lower cost,
improved control and increased
productivity.
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Control

Definitions
Acceptable Quality Level (AQL)
The poorest level of quality
from a supplier's process that
would be considered
acceptable as a process
average. You want to design a
sampling plan that accepts a
particular lot of product at the
AQL most of the time.
Operating Characteristic (OC) Curve

1.5
Rejectable Quality Level (RQL)
1.0
The poorest level of quality that

the consumer is willing to
tolerate in an independent lot.
You want to design a sampling
plan that rejects a particular lot
of product at the RQL most of
the time. Also commonly known
as lot tolerance percent
defective (LTPD) and limiting
quality (LQ).
Probability of Acceptance
AQL
0.8
0.6
0.4
RQL
0.2
0.0
0
4
6
Lot Percent Defective
10
Source: Minitab Help

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Definitions, Continued
Average outgoing quality (AOQ) curve
Approximates the relationship between
the quality of the incoming material and
the quality of the outgoing material,
assuming that rejected lots will be
100% inspected and defective items will
be reworked and inspected again
(rectifying inspection).
1.6
AOQ (Percent Defective)
Average Outgoing Quality (AOQ) Curve

1.8
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
0
4
6
Incoming Lot Percent Defective
10
Average total inspection (ATI) curve
Average Total Inspection (ATI) Curve

1000
Average Total Inspection
Approximates the relationship between

the quality of the incoming material and
the number of items that need to be
inspected, assuming that rejected lots
will be 100% inspected and defective
items will be reworked and inspected
again (rectifying inspection).
800
600
400
200
4
6
Lot Percent Defective
10
Source: Minitab Help

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Acceptance Sampling Plans for

Variable Data
We must know:
1. Specification limits
2. Acceptable Quality Level
3. Reject Quality Level
Knowledge of the process standard deviation can

dramatically reduce the size of the acceptance
sample.
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Control

Example
Pressure Release Valves are specified as 75 10 PSI.

AQL = 50 PPM
RQL = 200 PPM
Standard deviation is unknown
Recognize
Define
Measure
Analyze
Improve
Control

Creating the Sampling Plan

Stat>Quality Tools>Acceptance Sampling by
Variables>Create Compare
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Define
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Control

Creating the Plan
Copy this number for

use in the next step.
Generated Plan(s)
Sample Size
546
Critical Distance (k Value)
3.69358
Maximum Standard Deviation (MSD)
2.58654
Z.LSL = (mean - lower spec)/standard deviation

Z.USL = (upper spec - mean)/standard deviation
Accept lot if standard deviation <= MSD, Z.LSL >= k and Z.USL >= k; otherwise
reject.
Defectives
Probability
Probability
Per Million
Accepting
Rejecting
AOQ
ATI
50
0.951
0.049
21.6
568.4
200
0.102
0.898
9.3
953.7
Average outgoing quality limit (AOQL) = 27.6 at 85.6 defectives per million.
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The Graphs
Acceptance Region Plot
0.75
0.50
0.25
0.00
1.8
The maximum
compliant
process standard
deviation would
be 2.587 if the
process is
centered on the
target. As the
process moves
from the center
the acceptable
standard
deviation
becomes smaller.
1.2
0.6
0.0
100
200
300
400
65
75
80
85
Sample Mean
Average Total Inspection (ATI) Curve
30
20
10
0
0
70
Lot Defectives Per Million
AOQ (Defectives Per Million)
2.587
2.4
Sample StDev
1.00
100
200
300
400
1000
900
800
700
600
0
Incoming Lot Defectives Per Million
100
200
300
400
Sample Size = 546, Critical Distance = 3.69358
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Making the Decision
Paste the k value here.
Data: Valves.MTW
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Define
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Control

Making the Decision
Acceptance Sampling by Variables - Accept/Reject Lot
Make Accept or Reject Decision Using Valves
Sample Size
550
Mean
74.9077
Standard Deviation
2.42923
Lower Specification Limit (LSL)
65
Upper Specification Limit (USL)
85
Z.LSL
4.07853
Z.USL
4.15452
3.69358
2.58654
Decision:
Recognize
Define
Accept lot.
Measure
Analyze
Improve
Control

Create a Plan it the Standard Deviation is

Known
Pressure Release Valves are specified as

75 10 PSI.
AQL = 50 PPM
RQL = 200 PPM
Historic standard deviation is 2 PSI
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Measure
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Control

The Graphs
1.0
0.6
45
30
15
0
0
200
300
400
Average Total I nspection (ATI ) Curve
0.4
0.2
0.0
0
100
200
300
1000
800
600
400
200
400
Define
Measure
Analyze
100
200
300
400
Sample Size = 70, Critical Distance = 3.69363
Recognize
100
0.8
60
Improve
Note the large decrease in sample size

when the standard deviation is known.
Control

The Plan
Generated Plan(s)
Sample Size
70
3.69363
Z.LSL = (mean - lower spec)/historical standard deviation

Z.USL = (upper spec - mean)/historical standard deviation
Accept lot if Z.LSL >= k and Z.USL >= k; otherwise reject.
Defectives
Probability
Probability
Per Million
Accepting
Rejecting
AOQ
ATI
50
0.950
0.050
44.2
116.2
200
0.099
0.901
18.5
907.5
Average outgoing quality limit (AOQL) = 56.2 at 84.7

defectives per million.
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The Decision
Data: Valves
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Control

The Decision
Make Accept or Reject Decision Using Lot 2
Sample Size
70
Mean
75.1323
Historical Standard Deviation
Lower Specification Limit (LSL)
65
Upper Specification Limit (USL)
85
Z.LSL
5.06613
Z.USL
4.93387
3.69358
Decision:
Recognize
Define
Accept lot.
Measure
Analyze
Improve
Control

Creating an Attribute Acceptance

Sampling Plan
You have been assigned to create sampling plan for

non-critical parts that are acquired in lots or 10,000.
The Acceptable Quality Level (AQL) is 200 PPM and a
reject level at 1,000 PPM.
Sat>Quality Tools>Acceptance Sampling by Attributes
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The Operation Characteristic (OC)

Curves
1.0
0.6
100
0
0
500
1000
1500
2000
Average Total I nspection (ATI ) Curve
0.4
0.2
0.0
0
500
1000
1500
2000
Sample Size = 6679, Acceptance Number = 3
Define
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100000
80000
60000
40000
20000
0
Recognize
200
0.8
300
500
1000
1500
2000
Note the very large sample size required

when attribute data is used.
Control

Sampling Plan
Accept lot if defective items in 6679 sampled <= 3;
reject.
Defectives Probability Probability
Per Million
Accepting
Rejecting
AOQ
ATI
200
0.953
0.047 63.3 6834.2
1000
0.100
0.900 33.2 9667.9
Otherwise
Average outgoing quality limit (AOQL) = 96.6 at 440.9 defectives

per million.
Interpretation
If the lots really had 200 PPM defective then 95.3% of lots would
be accepted, the AOQ would be 63.3 PPM defective and the
average number of parts inspected per lot would be 6834.2.
If the lots had 1,000 PPM defective 10% or the lots would be
accepted.
The worst case average PPM for this sampling plan would be
96.6 PPM when the lots actually had 440.9 PPM.
These assume all rejected lots are 100% inspected and that all
defective units are reworked or scrapped.
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Your Turn
1.
2.
Create acceptance sampling plans for the gross weight of cereal boxes. The
specification limits are 12 ounces minimum 12.5 ounces maximum.
AQL = 500 RQL = 1000
First assume the process standard deviation is unknown.
Then assume the historic process standard deviation is .07 ounces.
Create an acceptance plan for attribute data with an AQL of .005 and a RQL
of .01
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Control

What We Have Learned
1. What is Acceptance Sampling?

2. Definitions of Key Terms.
3. How to create variable data acceptance sampling plans.
4. How to apply variable data acceptance sampling plans.
5. How to create attribute data acceptance sampling plans.
6. How to apply attribute data acceptance sampling plans.
Recognize
Define
Measure
Analyze
Improve
Control

Solutions to Student
Exercises
Recognize
Define
Measure
Analyze
Improve
Control

Creating the Plan Unknown
Recognize
Define
Measure
Analyze
Improve
Control

The Plan Unknown
Generated Plan(s)
Sample Size
1292
3.17795
0.0741023
Z.LSL = (mean - lower spec)/standard deviation

Z.USL = (upper spec - mean)/standard deviation
Accept lot if standard deviation <= MSD, Z.LSL >= k and Z.USL >= k; otherwise
reject.
Defectives
Probability
Probability
Per Million
Accepting
Rejecting
500
0.950
0.050
1000
0.101
0.899
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Control

Creating the Plan Known
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Measure
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Control

The Plan Known
Generated Plan(s)
Sample Size
147
3.19629
Z.LSL = (mean - lower spec)/historical standard deviation

Z.USL = (upper spec - mean)/historical standard deviation
Accept lot if Z.LSL >= k and Z.USL >= k; otherwise reject.
Defectives
Probability
Probability
Per Million
Accepting
Rejecting
500
0.950
0.050
1000
0.117
0.883
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Control

Creating the Attribute Sampling Plan
Recognize
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Measure
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Control

The Attribute Plan

Generated Plan(s)
Sample Size
45
Acceptance Number
Accept lot if defective items in 45 sampled <= 0;
Proportion
Probability
Probability
Defective
Accepting
Rejecting
0.001
0.956
0.044
0.050
0.099
0.901
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Otherwise reject.

The OC Curve

Sample Size = 45, Acceptance Number = 0
1.0
0.8
0.6
0.4
0.2
0.0
0.00
Recognize
Define
Measure
0.02
Analyze
0.04
0.06
Lot Proportion Defective
Improve
Control
0.08
0.10


08 Acceptance Sampling Plans - Ppm's

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Six Sigma

Green Belt Training

2007 American Society for Quality. All Rights Reserved.

What We Will Learn

1. What is Acceptance Sampling?

Page 2 Creating Sampling Plans 2.1

2007 American Society for Quality.

What is Acceptance Sampling?

Page 3 Creating Sampling Plans 2.1

2007 American Society for Quality.

Operating Characteristic (OC) Curve

Rejectable Quality Level (RQL)

The poorest level of quality that

Source: Minitab Help

Page 4 Creating Sampling Plans 2.1

2007 American Society for Quality.

Average Outgoing Quality (AOQ) Curve

Average total inspection (ATI) curve

Average Total Inspection (ATI) Curve

Average Total Inspection

Approximates the relationship between

Source: Minitab Help

Page 5 Creating Sampling Plans 2.1

2007 American Society for Quality.

Acceptance Sampling Plans for

Knowledge of the process standard deviation can

Page 6 Creating Sampling Plans 2.1

2007 American Society for Quality.

Pressure Release Valves are specified as 75 10 PSI.

Page 7 Creating Sampling Plans 2.1

2007 American Society for Quality.

Creating the Sampling Plan

Page 8 Creating Sampling Plans 2.1

2007 American Society for Quality.

Creating the Plan

Copy this number for

Critical Distance (k Value)

Maximum Standard Deviation (MSD)

Z.LSL = (mean - lower spec)/standard deviation

Page 9 Creating Sampling Plans 2.1

2007 American Society for Quality.

Acceptance Region Plot

Average Outgoing Quality (AOQ) Curve

Average Total Inspection (ATI) Curve

Lot Defectives Per Million

Average Total Inspection

AOQ (Defectives Per Million)

Incoming Lot Defectives Per Million

Lot Defectives Per Million

Sample Size = 546, Critical Distance = 3.69358

Page 10 Creating Sampling Plans 2.1

2007 American Society for Quality.

Making the Decision

Paste the k value here.

Page 11 Creating Sampling Plans 2.1

2007 American Society for Quality.

Making the Decision

Acceptance Sampling by Variables - Accept/Reject Lot

Make Accept or Reject Decision Using Valves

Lower Specification Limit (LSL)

Upper Specification Limit (USL)

Critical Distance (k Value)