STATISTICAL

QUALITY
CONTROL

Chapter Thirteen
McGraw-Hill/Irwin Copyright 2014 by The McGraw-Hill Companies, Inc. All rights reserved.
Learning Objectives
LO1301: Illustrate process variation and
explain how to measure it.
LO1302: Analyze process quality using
statistics.
LO1303: Analyze the quality of batches
of items using statistics.

13-2
Statistical Quality Control
(SQC)
The
quantitative Assignable variation
aspects of Variation that is caused by
factors that can be identified

quality and managed

manageme
nt
Processes Common variation
usually Variation that is inherent in
the process itself
exhibit
some
variation in 13-3
Measuring Variation

13-4
Variation and Specifications
Upper specification the maximum
acceptable value for a characteristic
Lower specification the minimum
acceptable value for a characteristic
Traditional View of Variability Taguchis View of Variability
Costs Costs

13-5
Process Capability
The ability of a process to consistently
produce a good or deliver a service with
a low probability of generating a defect
Specification limits range of variation
that is considered acceptable by the
designer or customer
Process limits range of variation that
a process is able to maintain with a high
degree of certainty

13-6
Process Capability

Process control limits exceed specification limits

process is not capable of meeting requirements

13-7
Process Capability

Specification control limits exceed process limits (for

improved process) process is capable of meeting
requirements
13-8
Process Capability Index
(Cpk)
Ratio of the range of values
produced divided by the range
of values allowed
Shows how well the parts
being produced fit into the
range specified by the design
specifications
Cpk larger than one indicates
process is capable
When the two numbers are not
close, indicates mean has
Excel: Process
shifted
Capability

13-9
Example 13.1
The quality assurance manager is assessing the
capability of a process that puts pressurized
grease in an aerosol can. The design
specifications call for an average of 60 pounds
per square inch (psi) of pressure in each can with
an upper specification limit of 65 psi and a lower
specification limit of 55 psi. A sample is taken
from production and it is found that the cans
average 61 psi with a standard deviation of 2 psi.
What is the capability of the process?

What is the probability of producing a defect?

13-10
 Example 13.1: Solution

13-11
 Process Control Procedures
Concerned with monitoring quality while
the product or service is being produced
Statistical process control - testing a

sample of output to determine if the

process is producing items within a
preselected range
Attributes - quality characteristics that

are classified as either conforming or

not conforming
Variable - characteristics that are

measured using an actual value

Excel: Statistic
al Process Contr
ol
13-12
 Process Control Measurements
p-Charts

Used when an item (or service) is either

good or bad (a yes-no decision)

13-13
Creating p-Charts
Calculate the sample proportions p for each
sample.

Calculate the average of the sample

proportions.

Calculate the standard deviation of the sample

proportion.

Calculate the control limits.

Plot the individual sample proportions, the

average of the proportions, and the control
limits.

13-14
Process Control Measurements
c-Charts

Used when an item (or service) may

have multiple defects

13-15
Variable Measurement Process Control
Charts X-bar and R-Charts

Size of samples
Preferable to keep small (usually 4 or 5 units)
Number of samples
Once chart set up, each sample compared to chart
Use about 25 samples to set up chart
Frequency of samples
Trade-off between cost of sampling and benefit of
adjusting the system
Control limits
Generally use z = 3

13-16
 X-bar and R-Charts

13-17
Process Control Charts Interpretation

13-18
Acceptance Sampling
Performed on goods that already exist to
determine what percentage of the
products conform to specifications
Executed through a sampling plan
Results include accept, reject, or retest

13-19
Acceptance Sampling
Purposes
Determine quality level
Ensure quality is within

predetermined level

13-20
 Acceptance Sampling
Disadvantages Advantages

Risks of accepting Economy

bad lots and Less handling damage
rejecting good Fewer inspectors
lots Upgrading of the
Added planning and
inspection job
documentation Applicability to
Sample provides
destructive testing
less information Entire lot rejection
than 100 percent (motivation for
inspection improvement)

13-21
Acceptance Sampling Designing a
Sampling Plan

Determine (1) how many units, n, to sample

from a lot, and (2) the maximum number of
defective items, c, that can be found in the
sample before the lot is rejected
Acceptable Lot tolerance
quality level percent
(AQL) defective (LTPD)
Maximum Percentage of
acceptable defectives that
percentage of defines consumers
defectives defined rejection point
by(producers
producer (consumers
risk) risk)
The probability of The probability of
rejecting a good lot accepting a bad lot
13-22
Operating Characteristic
Curve

13-23