CONTROL CHARTS FOR NON-NORMAL PROCESSES

P-CHARTS np-CHARTS C-CHARTS U-CHARTS

WHAT GENERATES ND OUTPUT?

IF AN EVENT IS THE RESULT OF A RELATIVELY LARGE NUMBER OF SMALL, CHANCE, INDEPENDENT INFLUENCES, THEN ITS OUTPUT WILL BE ND. MANY PROCESSES ARE ND BECAUSE: WE HAVE WORKED HARD TO ELIMINATE THE VERY LARGE INFLUENCES, THUS ONLY A RELATIVELY LARGE NUMBER OF SMALL, INDEPENDENT INFLUENCES REMAIN. WHAT IF A PROCESS IS NOT NORMALLY DISTRIBUTED? THAT IS OUR FOCUS HERE!
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

 

Statistical Sampling--Data


Attribute (Discrete, Go no-go information)

 

Defectives--refers to the acceptability of product across a range of characteristics. Defects--refers to the number of defects per unit-may be higher than the number of defectives.

Variable (Continuous)


Usually measured by the mean and the standard deviation.

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

THE BINOMIAL DISTRIBUTION

  

Attribute (Go no-go information) We monitor the number of defectives over time. The relevant population parameter being controlled is the population proportion Pie (P) We want to assure that the population proportion remains in control. We want to make sure the population proportion does not become defective. The critical assumption is that Pie remains constant over Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved time.
.

DISTRIBUTION OF SAMPLE PROPORTIONS POP IS NOT ND = .98 SAMPLE LOOKS LIKE POP, P = .99 DIST. OF SAMPLE PS IS ND
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

P-CHARTS
Require large samples nu30. When population proportion is known: P = T s Z T(1 - T)/n When population proportion is unknown: _ _ _ P = P s Z P(1 - P)/n Where P-Bar is an estimate of T
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Constructing a p-Chart No. of defective Monitors

Sample n Defectives 1 100 4 2 100 2 3 100 5 4 100 3 5 100 6 6 100 4 7 100 3 8 100 8 9 100 1 10 100 2 11 100 3 12 100 2 13 100 2 14 100 8 100 3 Stephen15 A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

P-CHART FORMULAS
Total Number of Defectives p= Total Number of Observations

Sp =

p (1- p) n

UCL = p + Z sp LCL = p - Z sp
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

1. Calculate the sample proportion, p, for each sample.

Defectives 4 2 5 3 6 4 3 7 1 2 3 2 2 8 3
Irwin/McGraw-Hill

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved. Stephen A. DeLurgio and The McGraw-Hill Companies, Inc., 1998

p 0.04 0.02 0.05 0.03 0.06 0.04 0.03 0.07 0.01 0.02 0.03 0.02 0.02 0.08 0.03

2. Calculate the average of the sample proportions.

3. Calculate the standard deviation of the sample proportion

55 p= = 0.037 1500

.037(1 - .037) p (1 - p) sp = = = .0188 n 100

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Irwin/McGraw-Hill

The McGraw-Hill Companies, Inc., 1998

4. Calculate the control limits.

UCL = p + Z s p LCL = p - Z s p

.037 s 3(.0188)
UCL = 0.093 LCL = -0.0197 (or 0)
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Irwin/McGraw-Hill

The McGraw-Hill Companies, Inc., 1998

p-Chart (Continued)
5. Plot the individual sample proportions, the average of the proportions, and the control limits

You will be asked to duplicate these results using SPSS. What do you infer from the following control chart?

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Control Chart: PCHART

.10

.08

Proportion Nonconforming

.06

.04

PCHART UCL = .0942

.02 Center = .0373 0.00 1.00 3.00 5.00 7.00 9.00 11.00 13.00 15.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 LCL = .0000

Sigma level: 3
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Np-CHART


   

Sometimes we express binomial occurrences in units. The formula is simply: Mean = nP-bar (e.g., 100*.037 = 3.7 Were n = number in sample P = best estimate of the population proportion Sigma(np) = Sqrt(nP-bar(1-P-bar)

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

DISTRIBUTION OF SAMPLE DEFECTS - nP POP IS NOT ND n = 100*.98 = 98 SAMPLE LOOKS LIKE POP, P = 100*.99 = 99 DIST. OF SAMPLE nPS IS ND
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

nP Theory
nP-CHARTS Require large samples nu30: When population proportion is known: nP = nT s Z nT(1 - T) When population proportion is unknown: _ _ _ nP = nP s Z nP(1 - P) Where P-Bar is an estimate of T
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Constructing an np-Chart Step 1,

Sample n Defectives = np 1 100 4 2 100 2 3 100 5 4 100 3 5 100 6 6 100 4 7 100 3 8 100 8 9 100 1 10 100 2 11 100 3 12 100 2 13 100 2 14 100 8 15 100 3 Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Calculate nP-bar
Total Number of Defectives p= Sample Observations

Snp = np (1  p )
UCL = np + Z s np LCL = np - Z s np
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

2. Calculate the average of the sample proportions.

55 n p = 100 * = 3.7 1500

3. Calculate the standard deviation of the sample proportion

s np =

np (1 - p)

3.7(1 - .037)

= 1.89

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Irwin/McGraw-Hill

The McGraw-Hill Companies, Inc., 1998

4. Calculate the control limits.

UCL = n p + Z s np

3.73 s 3(1.896)
UCL = 9.42 LCL = 0
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

LCL = n p - Z s np

Irwin/McGraw-Hill

The McGraw-Hill Companies, Inc., 1998

p-Chart (Continued)
5. Plot the individual sample proportions, the average of the proportions, and the control limits

You will be asked to duplicate these results using SPSS.

What do you infer from the following np-chart?

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Control Chart: PCHART

10

N ber Nonconform um ing

PCHART UCL = 9.4207

2 Center = 3.7333 0 1.00 3.00 5.00 7.00 9.00 11.00 13.00 15.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 LCL = .0000

Sigma level: 3

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

___

DEFECTS PER UNIT OF TIME OR SPACE C Charts

Frequently, there are processes that yield distributions that follow a Poisson Distribution. The Poisson Distribution is a discrete distribution which takes on the values X = 0, 1, 2, 3,... It models the events per unit of time or space.


___
Determined by its mean,

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

C-CHARTS POISSON DIST.

     

In Quality Control the Poisson Distribution measures: Number of blemishes or defects per unit of time or space such as: Blemishes per sqft. on painted panel. Defective ICs per Wafer. Number of defects per sqft. on furniture surface. Number of typos per page in your paper.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

 Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Consider Defective ICs on a Wafer How about 1 Giga Bit Chips

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

http://www.austin.cc.tx.us/HongXiao/overview/history-semi/sld015.htm

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

http://www.austin.cc.tx.us/HongXiao/ overview/history-semi/sld016.htm

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

POISSON GENERATING PROCESS

      

Probability of an occurrence is very very low. No. of possible points is very very high. Prob. remains constant. ___ Defined completely by its mean. C Variance = Mean ___ Standard Deviation = Sqrt(Mean) =sqrt( C ) A Skewed distribution to the right. High probability of low number, very low, but a finite probability of high number.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

POISSON AND EXPONENTIAL



If the time or space between events follows an exponential distribution, then the rate of occurrence of the event will likely follow a Poisson. That is, the Poisson and Exponential Distribution are inverses of each other.

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

Source:http://info.bio.cmu.edu/Course s/03438/PBC97Poisson/PoissonPage. html#distribution

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

C-Chart
  

Mean = UCL = LCL =

___

C
___

C
___

+ 3 sqrt( ___) C - 3 sqrt( ___) C

Consider an example, a company measures the number of defects per square foot of expensive floor tile. Service example, mistakes made per hour per call center worker.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

SAMPLE DEFECTS/SQFT 1 5 2 4 3 7 4 6 5 8 6 5 7 6 8 5 9 16 10 10 11 9 12 7 13 8 14 11 15 9 16 5 17 7 18 6 19 10 20 8 21 9 22 9 23 7 24 5 Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved. 25 7

nwohs si eulav tsellams ehT .tsixe sedom elpitluM .a 00.981 00095.6 01765.2 00.5 a 0000.7 0065.7 0 52 muS ecnairaV noitaiveD .dtS edoM naideM naeM gnissiM dilaV N NOSSIOP

SPSS DESCRIPTIVE STATISTICS

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

scitsitatS

0.001 0.69 0.29 0.48 0.86 0.65 0.63 0.42 0.4 tnecreP evitalumuC

SPSS DESCRIPTIVE STATISTICS

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

0.001 0.4 0.4 0.8 0.61 0.21 0.02 0.21 0.02 0.4 tnecreP dilaV

0.001 0.4 0.4 0.8 0.61 0.21 0.02 0.21 0.02 0.4 tnecreP

52 1 1 2 4 3 5 3 5 1 ycneuqerF

latoT 00.61 00.11 00.01 00.9 00.8 00.7 00.6 00.5 00.4

dilaV

NOSSIOP

SPSS DESCRIPTIVE STATISTICS

10 8

2 Std. Dev = 2.57 Mean = 7.6 0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 N = 25.00
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

POISSON

C-Chart What Do You Infer?

Control Chart: POISSON
20

10

N n on rm s o c fo itie

POISSON UCL = 15.8086 Center = 7.5600 0 1.00 3.00 5.00 9.00 13.00 17.00 21.00 25.00 7.00 11.00 15.00 19.00 23.00 Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved. LCL = .0000

Sigma level: 3

U-CHART Nonconformities Per Unit



 

Used in same situation as c-Chart but when sample sizes vary. This means area of time or space varies. Consider situation with different size panels or furniture. Service: Mistakes made for employees in a call center, but actual phone time varies. We want to control defects per square foot.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

SAMPLE SQMETERS NONCONF 1 200 5 2 300 14 3 250 8 4 150 8 5 250 12 6 100 6 7 200 20 8 150 10 9 150 6 10 250 10 11 300 9 12 250 16 13 200 12 14 250 10 15 100 6 16 200 8 17 200 5 18 100 5 19 300 14 20 200 8 Stephen MEANS A. DeLurgio and MGraw-Hill, 2004 all rights reserved. 205 9.6

Whats the problem here?

7 6

1 0 5.0 7.5 10.0 12.5 15.0 17.5 20.0

Std. Dev = 4.06 Mean = 9.6 N = 20.00

NONCONFO
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

NONCONFORMITY/100 SQM Looks more like a Poisson

6

Std. Dev = 3.56 Mean = 9.9 N = 20.00 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0

NONP100

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

u-Chart for Carpet Data Mitra page 354

Control Chart: NONCONFO
.12

.10

Fraction o N f onconform ities

.08

.06 NONCONFO .04 UCL .02 0.00 Center = .0468 LCL

0 .0 20 0 .0 19 0 .0 18 0 .0 17 0 .0 16 0 .0 15 0 .0 14 0 .0 13 0 .0 12 0 .0 11 0 .0 10 00 9. 00 8. 00 7. 00 6. 00 5. 00 4. 00 3. 00 2. 00 1.
Sigma level: 3 Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

So:http://www.mathsrevision.net/alev el/statistics/normal_distribution2.php
 

Poisson Approximation The normal distribution can also be used to approximate the Poisson distribution for large values of C (the mean of the Poisson distribution). If X ~ Po(C) then for large values of C, X ~ N(C, C) approximately. This last statement denotes that X is ND with mean of C and variance of C.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

ND APPROXIMATIONS FOR BINOMIAL



For Binomial, the higher the value of N and the closer p is to .5, the better the ND approximates the Binomial. (See link on next slide.) When n*p nd n*(1-p) are much greater than 5 then the ND approximates the Binomial Dist. For large n (say n > 20) and p not too near 0 or 1 (say 0.05 < p < 0.95) the distribution approximately follows the Normal distribution.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

SIMULATING APPROXIMATIONS
  

Fun with statistics: Normal Approximation of Binomial http://www.ruf.rice.edu/~lane/stat_sim/binom _demo.html

Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.

So:http://www.mathsrevision.net/alev el/statistics/normal_distribution2.php
 

 

Binomial Approximation The normal distribution can be used as an approximation to the binomial distribution, under certain circumstances, namely: If X ~ B(n, p) and if n is large and/or p is close to , then X is approximately N(np, npq) (where q = 1 - p). In some cases, working out a problem using the Normal distribution may be easier than using a Binomial.
Stephen A. DeLurgio and MGraw-Hill, 2004 all rights reserved.