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To accompany
Quantitative Analysis for Management, Tenth Edition,
by Render, Stair, and Hanna 2008 Prentice-Hall, Inc.
Power Point slides created by Jeff Heyl 2009 Prentice-Hall, Inc.
Learning Objectives
After completing this chapter, students will be able to:
Define the quality of a product or service
Develop four types of control charts: x, R, p, and c
Understand the basic theoretical underpinnings of
statistical quality control, including the central
limit theorem
Know whether a process is in control
17.1 Introduction
17.2 Defining Quality and TQM
17.3 Statistical Process Control
17.4 Control Charts for Variables
17.5 Control Charts for Attributes
Table 17.1
Upper
control
limit
Lower
control
limit Normal behavior
Target
Lower
control
limit Two plots near upper control Two plots near lower control.
Upper Investigate for cause. Investigate for cause.
control
limit
Target
Lower
control
limit Run of 5 above central line. Run of 5 below central
Investigate for cause. line. Investigate for cause.
2009 Prentice-Hall, Inc. 17 9
Statistical Process Control
Patterns to look for in control charts Figure 17.1
Upper
control
limit
Target
Lower
control
limit Trends in either direction 5 Erratic behavior.
plots. Investigate for cause Investigate.
of progressive change.
99.7% of all x
fall within 3 x
| | | | | | |
3 x 2 x 1 x x = +1 x +2 x +3 x
(mean)
Figure 17.2 Standard error x
x
n
2009 Prentice-Hall, Inc. 17 18
Setting the x-Chart Limits
If we know the standard deviation of the process,
we can set the control limits using
Upper control limit (UCL) x z x
Lower control limit (UCL) x z x
where
x = mean of the sample means
z = number of normal standard
x deviations x
= standard deviation of the sampling n
distribution of the sample means =
2009 Prentice-Hall, Inc. 17 19
Box Filling Example
A large production lot of boxes of cornflakes is
sampled every hour
To set control limits that include 99.7% of the
sample, 36 boxes are randomly selected and
weighed
The standard deviation is estimated to be 2
ounces and the average mean of all the samples
taken is 16 ounces
So x 16, x 2, n 36, z 3 and the control limits
are
2
UCLx x z x 16 3 16 1 17 ounces
36
2
LCLx x z x 16 3 16 1 15 ounces
36
2009 Prentice-Hall, Inc. 17 20
Box Filling Example
If the process standard deviation is not available
or difficult to compute (a common situation) the
previous equations are impractical
In practice the calculation of the control limits is
based on the average range rather than the
standard deviation
UCLx x A2 R
LCLx x A2 R
where
R = average of the samples
A2 = value found in Table 17.2
x = mean of the sample means
2009 Prentice-Hall, Inc. 17 21
Factors for Computing
Control Chart Limits
SAMPLE SIZE, n MEAN FACTOR, A2 UPPER RANGE, D4 LOWER RANGE, D3
2 1.880 3.268 0
3 1.023 2.574 0
4 0.729 2.282 0
5 0.577 2.115 0
6 0.483 2.004 0
7 0.419 1.924 0.076
8 0.373 1.864 0.136
9 0.337 1.816 0.184
10 0.308 1.777 0.223
12 0.266 1.716 0.284
14 0.235 1.671 0.329
16 0.212 1.636 0.364
18 0.194 1.608 0.392
20 0.180 1.586 0.414
25 0.153 1.541 0.459
Table 17.2
2009 Prentice-Hall, Inc. 17 22
Super Cola Example
Super Cola bottles are labeled net weight 16
ounces
The overall process mean is 16.01 ounces and
the average range is 0.25 ounces
What are the upper and lower control limits for
this process?
UCLx x A2 R LCLx x A2 R
16.01 + (0.577)(0.25) 16.01 (0.577)(0.25)
16.01 + 0.144 16.01 0.144
16.154 15.866
UCLR D4 R
LCLR D3 R
where
UCLR D4 R
(2.114)(53 pounds)
112.042 pounds
LCLR D3 R
(0)(53 pounds)
0
2009 Prentice-Hall, Inc. 17 26
Five Steps to Follow in Using
x and R-Charts
1. Collect 20 to 25 samples of n = 4 or n = 5 from a
stable process and compute the mean and range
of each
2. Compute the overall means ( x and R ), set
appropriate control limits, usually at 99.7% level
and calculate the preliminary upper and lower
control limits. If process not currently stable, use
the desired mean, m, instead of x to calculate
limits.
3. Graph the sample means and ranges on their
respective control charts and determine whether
they fall outside the acceptable limits
x chart R-chart
2009 Prentice-Hall, Inc. 17 28
Control Charts for Attributes
We need a different type of chart to
measure attributes
These attributes are often classified as
defective or nondefective
There are two kinds of attribute control
charts
1. Charts that measure the percent defective in
a sample are called p-charts
2. Charts that count the number of defects in a
sample are called c-charts
0.12
Out of Control
0.11
0.10 UCLp = 0.10
Fraction Defective
0.09
0.08
0.07
0.06
0.05
0.04 p 0.04
0.03
0.02
0.01 LCLp = 0.00
| | | | | | | | | | | | | | | | | | | |
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sample Number
Figure 17.3
Program 17.1A
2009 Prentice-Hall, Inc. 17 34
ARCO p-Chart Example
Output from Excel QMs p-chart analysis of the
ARCO data
Program 17.1B
2009 Prentice-Hall, Inc. 17 35
c-Charts
In the previous example we counted the number of
defective records entered in the database
But records may contain more than one defect
We use c-charts to control the number of defects
per unit of output
c-charts are based on the Poisson distribution
which has its variance equal to its mean
The mean is c and the standard deviation is equal
to c
To compute the control limits we use
c3 c
54
c 6 complaints per day
9
Thus