Quality Control Charts Analysis of Building Materials

QUALITY CONTROL CHARTS / SHERKO HASSAN ABDULRAHMAN
Iraqi Kurdistan Region

Presidency of the Ministerial Council
Ministry of Higher Education and Scientific Research
University of Sulaimani
College of Basic Education

A AP PP PL LY YI IN NG G S SO OM ME E Q QU UA AL LI IT TY Y C CO ON NT TR RO OL L
C CH HA AR RT TS S T TO O S ST TU UD DY Y T TH HE E S ST TR RE EN NG GT TH H O OF F B BU UI IL LD DI IN NG G
C CO ON NC CR RE ET TE E B BL LO OC CK KS S A AN ND D C CL LA AY Y B BU UI IL LD DI IN NG G B BR RI IC CK KS S

A A T TH HE ES SI IS S S SU UB BM MI IT TE ED D T TO O T TH HE E C CO OU UN NC CI IL L O OF F T TH HE E C CO OL LL LE EG GE E O OF F B BA AS SI IC C
E ED DU UC CA AT TI IO ON N O OF F U UN NI IV VE ER RS SI IT TY Y O OF F S SU UL LA AI IM MA AN NI I I IN N P PA AR RT TI IA AL L F FU UL LF FI IL LM ME EN NT T
O OF F T TH HE E R RE EQ QU UI IR RM ME EN NT TS S F FO OR R T TH HE E D DE EG GR RE EE E O OF F M MA AS ST TE ER R O OF F S SC CI IE EN NC CE E I IN N
S ST TA AT TI IS ST TI IC CS S

S SU UP PE ER RV VI IS SE ED D B BY Y
A AS SS SI IS ST TA AN NT T P PR RO OF FE ES SS SO OR R
D Dr r. . T TA AL LI IB B S SH HA AR RI IF F J JA AL LI IL L


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. . .,, .. .., .. ., , _,, .... ,. .

,,.. . ... ,. ,,.. . ... ,. ,,.. . ... ,. ,,.. . ... ,.
... ... ... ...


CERTIFICATION OF THE SUPERVISOR
I certify that (SHERKO HASSAN ABDULRAHMAN) was prepared this
thesis (Applying Some Quality Control Charts to Study the Strength of Building
Concrete Blocks and Clay Building Bricks) under my supervision at the
Department of Statistics (College of Basic Education / University of Sulaimani) in
partial fulfillment of the requirements for the degree of Master of Science in
Statistics.

Signature:
Supervisor: D Dr r. . T TA AL LI IB B S SH HA AR RI IF F J JA AL LI IL L
A As ss si is st ta an nt t P Pr ro of fe es ss so or r
Date: 9 / 12 / 2007


L LI IN NG GU UI IS ST TI IC C E EV VA AL LU UA AT TI IO ON N C CE ER RT TI IF FI IC CA AT TI IO ON N
I hereby certify that this thesis has been checked by me after indicating all
the grammatical and spelling mistakes; the thesis was given again to the candidate
to make the adequate corrections. After the second reading, I found that the
candidate corrected the indicated mistakes. Therefore, I certify that this thesis is
free from mistakes.

Signature
Name: Talla Abdullah Rashid
Date: / /


R RE EC CO OM MM ME EN ND DA AT TI IO ON N O OF F T TH HE E C CH HA AI IR RM MA AN N O OF F S SC CI IE EN NT TI IF FI IC C C CO OM MM MI IT TT TE EE E: :
In view of the available evidence and recommendations, I forward
this thesis for debate by the examining committee.

Signature:
Name : Dr. Jawad N. Hussain
Chairman of the College committee
on post-Graduate studies
Date 3 / 5 / 2008


M ME EM MB BE ER R E EX XA AM MI IN NI IN NG G C CO OM MM MI IT TT TE EE E
We certify that we have read this thesis as an Examining Committee,
examined the student (Sherko Hassan Abdualrahman) in its contents, and that in
our opinion it is adequate with (APPLYING SOME QUALITY CONTROL CHARTS TO
STUDY THE STRENGTH OF BUILDING CONCRETE BLOCKS AND CLAY BUILDING
BRICKS) as a thesis for the degree of Master of Science in Statistics.

Signature:
Name: Prof. Assist. Dr. Shawnm A. Muhayddin
Chairman
Date: 21 / 4 / 2008
Signature:
Name: Prof. Assist. Dr. Abdulrahim K. Rahi
Member
Date: / /

Signature:
Name: Prof. Assist. Dr. Samir M. Khdir
Member
Date: / /
Signature:
Name: Prof. Assist. Dr. Talib S. Jalil
Supervisor / Member
Date: / /


APPROVED BY THE COLLEGE COUNCIL
The council of the (college of Basic Education /University of Sulaimani) approves
the decision arrived at: / / by ( ) the examining committee.

Signature:
Name: Dr. Ezzadin N. Baban
Assist. Professor
Dean of the college of Basic Education
Date: 4 / 5 / 2008


D De ed di ic ca at te ed d T To o

- - M My y F Fa am mi il ly y
- - M My y c ch hi il ld dr re en n: :


A AC CK KN NO OW WL LE ED DG GE EM ME EN NT T

I would like to present my thanks to my Supervisor, (D Dr r. . T Ta al li ib b S Sh ha ar ri if f J Ja al li il l)
who gave me valuable advice and continuous guidance through preparing this
thesis.
I express my respect and appreciation to the council of higher education and
scientific research, the president of the University of Sulaimani, the dean of
College of Basic Education, the chairman of the department of (Mathematic and
Computer / College of Basic Education), and the entire staff and personnel of the
College of Basic Education.
I would like also to express my appreciation to the staff of the College of
Engineering / University of Sulaimani, especially Construction and Building
department, and all the staff of concrete and building material laboratory.
I express my respect and appreciation to all the staff of Constructional
Laboratory of Sulaimani / Ministry of Reconstruction and Housing, specially the
staff of concrete department for their assistance and valuable information about
BCB and CBB.
I would like to express my pure thanks and enormous gratitude to my
family, because really without them I could not prepare this thesis.

SHERKO


Lists of Abbreviations

SYMBOLS Details
ARL Average Run Length
BCB Building Concrete Blocks
CBB Clay Building Bricks
Cm Centimeter
CUSUM Cumulative Sum Chart
d Distance
E Expectation
eq Equation
EWBA Exponential Weighted Bayesian Average
GMA Geometric Moving Average
k Reference Value of CUSUM
LB Lower Bound
LCL Lower Control Limit
MA Moving Average
m Subgroup Number
M Mean
Max Maximum
Min Minimum
MR-chart Moving Range-chart
QC Quality Control
R Range
R
Average of range
SLB Standard Lower Bound
T Target
V Vertical
w Weighted
x Observed value
x
Sample average
X
Average of sample averages
0

Reference value
B

Bayesian estimate
r.s random sample
S Sample standard deviation
x
S
Standard deviation of subgroup average
S
Average of sample standard deviations


Abstract

A considerable amount of attention is paid to the concern of the quality
control by many researchers and engineers since the quality is considered the main
factor in many fields, such as industry, agriculture, health, education, and some
other scientific fields. Therefore, many companies and industry institutions have
tried to make their product's quality meet the standard specification, and to increase
the consumers for their products.
As it is obvious, any problem in the quality of the product may be resulted
from the quality of the raw materials in the process of production, the technical and
the problem in the machinery and all these affect the quality of the product. That is
why, the statistical quality control is necessary to detect changes in the behavior of
these processes.
As there is a great demand on BCB and CBB, that is why constructed many
of industries, such as BCB and CBB factories, the factories produce a large amount
of products; indeed, this may causes some problems and defects, in their products.
To controlling quality of their products and testing the strength of materials
or quality characteristics, established many of laboratories.
In this thesis, tested the strength of BCBs and CBBs, and use some
classical and new control charts, also the new suggested Exponential Weighted
Bayesian Average control chart (EWBA-chart), to know that these products meet
standard specification, such as International, Iraqi and Local standard
specifications.
We also have made a comparison between control charts, to know which of
them is the most sensitive and adequate in identifying changes or shifts in the
production process and reduce error in decision-making.


CONTENTS

No. Objects
page
Chapter 1: Quality Control and Basic Definitions
1.1 Introduction 1
1.2 Historical Background 3
1.3 The problem of the thesis 6
1.4 The aim of the thesis 6
1.5 Some Concepts Related to Quality Control 7

Chapter 2 : Control Charts
2.1 Quality Control Charts 10
2.1.1 Variable Quality Control Charts 11
2.1.2 Standard Control Charts 11
2.1.2.1 Shewhart Control Charts 11
2.1.2.2 Non-Shewhart Control Charts 15
2.1.3 Bayesian Process Control 19
2.1.4 EWBA-Chart 22

Chapter 3: Application of Some Control Charts on the Real Data
3.1 Introduction 24
3.2 Collection Data 25
3.3 Quality Control Charts interprets 25
Application 27
3.4 X-bar Charts 27
3.5 R- Charts 30
3.6 Geometric Moving Average Control Chart 35
3.7 Bayesian-Charts 40
3.8 Construction EWBA-Charts 47
3.9 Comparison between x-bar chart and Bayes-chart 52
3.10 Comparison between GMA-chart and EWBA-chart 52

Chapter 4: Conclusions and Recommendations
4.1 Conclusions 54
4.2 Recommendations 56
References 57
Appendix 60


C CH HA AP PT TE ER R 1 1
_ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

Q Qu ua al li it ty y C Co on nt tr ro ol l a an nd d B Ba as si ic c D De ef fi in ni it ti io on ns s

1.1. Introduction:
(1)(3)(4)(8)(24)

Quality control is the use of statistical techniques and activities to achieve,
sustain, and improve the quality of a product or service, and indirectly to improve
the technology to meet consumer requirements.
Quality control has become a major concern in todays competitive
industrial environment. Therefore, quality has become one of the most important
consumer decision factors in the selection among competing products and services.

The quality of product is determined by how a product meets the needs of
consumer and the ideal quality would be zero-defects or defectives. A defect or
nonconformity is the unit of a product that dose not satisfy consumers not conform
with the specification. The production process has variation in the quality of the
output. There are usually two types of variation in the quality of the output of the
process, which are stochastic variation and non-stochastic variation, which is due
to some assignable causes.
The variation can be traced to a particular problem or assignable cause (e.g.
human error, a problem with raw material, or machine failureetc).
Assignable causes occur at unpredictable times because of having a non-
stochastic nature, and the aim of the control chart is to detect them soon and
correction should be made after that.
The use of control chart became widespread after World War II. This was
due to the importance of maintaining quality production during that period.


Dr. Shewhart and many researchers were attending to control chart, improve,
and modify them to increase the sensitivity of these charts to detect out of control
signal. Quality control is receiving increasing attention as a management tool, by
which important characteristics of a product are observed, assessed, and compared
with some types of standards.

By using quality control charts, scientific valid methods and sticking to
standards specification, the following objectives can be achieved:
1. Improvement of the quality of products
2. Reducing the cost
3. Safety and health for customers and producers.
4. Conservation for consumer and producer from commercial skulduggery.
5. Increasing the chances of producing and marketing.
6. Reducing the defects or defectives.
This thesis begins with an introduction and the basic concepts about quality
control, and a historical background about the brief history of quality control, and
definitions of some concepts related to the quality control, in chapter one.
Chapter two contains theoretical side about some classical control charts,
Bayesian control chart and apply a new suggested control chart based on the
exponential weighted Bayesian average (EWBA).
Chapter three contains the application of some control charts on the real
data. Such as classical control charts, Bayesian control chart, and new control chart
(exponential weighted Bayesian average), and contained comparison between
some control chars to help us to obtain a good result in decision-making about the
production process.
Chapter four contains some conclusions, and recommendations for the future
study.


1.2. Historical Background:
Statistical quality control comparatively new, the science of statistics itself
belongs to two to three centuries ago. Moreover, it is the greatest development has
taken place during the 20
th
century.
The notion of using sampling and statistical analysis techniques in a
production started in 1920

and applied effectively to quality control as a result of
the development of sampling theory.

The first who applied the newly discovered statistical methods to the
problem of quality control was Walter A. Shewhart (18911963) in the Bell
Telephone Laboratories. He issued a memorandum on (May 16, 1924) that
featured a sketch of modern quality control chart to control and detect non-
stochastic variation in the process of a production. For the first time statistical
methods applied to the problem of quality control by Walter Shewhart and he kept
improving and working on this scheme, in 19261927 published three papers on
the (Quality Control and Control chart). Therefore, for the first time after
publishing these papers in the Journal of (American statistical society), he used
control chart in Bell Telephone Laboratories. This marked the beginning of
statistical quality control.
(3)(12)(19)

In 1931 W.A. Shewhart published a book on statistical quality control under
the title of (Economic Control of Quality of Manufactured Product), published by
(Van Nostrand in New York). He gave some lectures on statistical methods in
production and control charts at the University of London in 1932, and invited
Shewhart by Deming in 1938, to present seminars on control charts at the U.S.
Department of Agriculture Graduate School.
(7)(16)
From 1942 to 1946, the training courses on statistical quality control were
given to industry. And more than fifteen quality societies are formed in North


America, such as (American society for quality control) formed on 16 / 2 /1946.
This organization, through its publication, conference and training session, has
promoted the use of quality control for all types of production and service.
(3)(4)

In 1946, the International Standards Organization (ISO) was founded and the
Japanese Union of Scientists and Engineers (JUSE) was formed.
(12)(30)

In 1950 W. Edward Deming (19001993), who had worked with Shewhart
at Bell Telephone Laboratories, gave a series of lectures on statistical method to
Japanese Engineers and on quality responsibility to top management.
(3)
In addition, Joseph M. Juran was invited by the Japanese to give lecture on
quality management and improvement in 1954.
(3)(12)

The British statistician, (E.S.Page) in 1954, when he was in the statistical
laboratory at the Cambirg University, introduced a new control chart in the name
of CUSUM (Cumulative Sum) control chart. This is a draw of Cumulative Sum of
error of observations. In 1959 statistician, Barnard introduced a V-Mask, for
making the decision with CUSUM-chart.
(12)(23)
The statistician S.Roberts introduced 3-new control charts. The first was
based on Moving Average (1958), the second was the Moving Range (1958), and
the third was based on Geometric Moving Average (1959). The decision about the
production process for these three charts are depending on the past data as well as
the current data, therefore the decision is not based on a single plotted data
.
(11)(18)(20)

Van Dobberede Bruyn (1968), tabulated simulation results of Average Run
Length (ARLs) for (CUSUM) procedures with different decision intervals and
reference values.
(14)(25)
Brook and Evans (1972), used Markov chain to approximate the moment
and percentages points of Run Length distribution for integervalued (CUSUM)
procedures.
(12)(14)


Lucas (1982) introduced a new control chart, which was a composite from
shewhart control chart and CUSUM control chart. This chart was sensitive to
detect small and large changes at the same time.
(33)

Bourke (1991), proposed the Run-Length control chart, based on the plotting
of the number (RL) of conforming items between successive nonconforming items.
(14)
AL-RASSAM (1996) introduced (Bayesian Two Dimensional Control Chart
for Monitoring Production Process).
(33)

Al-Zbedy (1997), constructed two new charts (Bayes chart for fraction
defectives and defects).
(29)

Lucas (1998), and Olwell had been studied the steps of CUSUM control
charts to control quality characteristics of output of a process.
(12)
Hamad (2003), proposed the use of Beta-content tolerance intervals as the
basis for control limits and more precisely probability control limits.
(12)
Yeh (2004), and others suggested the new control charts for (CUSUM
Control Chart) in the name of (CUSUM M-Chart) to detect small changes.
(22)

Al- Rawy (2004), used characteristic function and applied quality control on
the birth of premature children.
(35)
Rashid (2006), used multivariate control chart for two characteristics of
cement in Taslujah cement factory in Sulaimani.
(33)
Nainawa N. Dawd (2006), studied Process Capability Indices by Simulation,
using process capability in order to asses the real capability of the production
process whose distribution is different from the normal distribution and used
Quality Control Charts to determine specification limits.
(27)
Dler Al-Debagay used (Bayesian Decision Technique for Ala Pepsi Soft
Drinks Company in Sulaimani).
(28)


1.3. The problem of thesis:
In undertaking any research, there must be a problem or some problems.
A quality control problem may be an error or mistake, the correction of
which requires effort and expense.
In general, there are two problems in product quality:
- Deviations from target line specifications.
- Excessive variability around target line specifications.
This thesis tries to study the tolerance strength of Building Concrete Blocks
(BCB) and Clay Building Bricks (CBB). Therefore, these two are used more than
any other materials in building houses, schools, hospitals, and in general
construction and reconstruction process.
This is the reason behind increasing the factories of building concrete blocks
and Clay Building Bricks. To control the quality of these products is very hard and
shows the defects in the quality of the product. In all production process, we need
to monitor the extent to which our products meet specifications. This is why, the
study of the variation in the data of a process helps us to analyze the process,
evaluate its effectiveness in producing highquality, low cost, output and adjust,
and improve the process to achieve better results.

1.4. The aim of thesis:

The prime objective of this thesis is to:
Study state of the quality strength of the Building Concrete Blocks (BCBs)
and Clay Building Bricks (CBBs) for some factories by using different control
charts, including a new suggested Exponential Weighted Bayesian Average-chart
(EWBA-chart) to see if these products meet the international, Iraqi and Local
specification standard.


_ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
C Co on nt tr ro ol l C Ch ha ar rt ts s

2.1. Quality Control Charts:
(3)(12)(13)

Control charts are widely used in industry as a tool to monitor output
process. Different types of control charts may be used depending upon the type of
the data that is measured or computed from samples. A control chart always has a
centerline for the average value of the quality characteristic, and two other
horizontal lines, an upper line called the upper control limit (UCL), and a lower
line for the lower control limit (LCL), are shown on the Fig. 2-1.
The control limits are chosen because if the process in control means that all
of the plotted points will fall between them, and no action is necessary. If a point
falls outside one of the control limits, this would be an indication that the process
is out of control. Then, an action should be taken, and this is to search for
assignable causes (or non-stochastic cause or causes).

Figure 2-1 General control chart
The control limits usually are set at (3) from the centerline.
(UCL, LCL) = T 3
Sample Number
Q
u
a
l
i
t
y

Centerline

Upper Control Limit
Lower Control Limit


where:
T = target value (centerline)
= standard deviation
The quality control charts are divided into two main types, which are
variable quality control chart, and attribute quality control chart. The terms
variable and attribute are associated with the type of data being collected from the
production line of the process.
(13)

2.1.1. Variable Quality Control Charts:
(12)
A quality characteristic that is measured on a numerical scale is called a
variable; and includes dimensions such as length or width, temperature, time, and
volume (can be measured in fraction or decimals).
When dealing with a quality characteristic that is of variable type, it is
usually preferable to monitor both the mean level of the quality characteristic and
its variability.
The variable quality control charts are divided into two types:
(i). Shewhart variable quality control charts
(ii). Non-Shewhart variable quality control charts
This thesis has divided control charts into two main parts:
(a) Standard Control Charts
(b) Bayesian process Control Charts

2.1.2. Standard Control Charts:

2.1.2.1. Shewhart Control Charts:
The familiar shewhart control charts are:
. X-chart (Average-chart or Meanchart)
. R-chart (Rangechart)
. -chart (Standard deviation chart)


1. X-Chart:
(9)(12)
X-chart for variables data, (data that is both quantitative and continuous in
measurement, such as a measured dimension or time).
The aim of using the x-chart is to control the mean level of the output of a
process.
The point plots on this chart are the average ( x) of subgroups data, calculate
from:

n
x
x
n
1 i
i
j
=
=

The centerline of the -chart is ( X) calculate from:

m
x
X
m
1 j
j
=
= ... (2-1)
The control limits of the -chart are established at three-standard deviation
(3) from the target value, and calculate by the formulas:

x x
3 X UCL + = ... (2-2)

x x
3 X LCL = ... (2-3)
In practice the calculations are simplified by using (for n < 10)
R A X UCL
2
+ = .. (2-4)
R A X LCL
2
= == = ... (2-5)
where:

2
d
R
=
R = average of the subgroup range


But for (n 10) the control limits are:

1
A X UCL + ++ + = == = ... (2-6)
=
1
A X LCL ... (2-7)
where:
= average of the subgroups (or samples) standard deviations
The constants (A
1
)

and (A
2
)

are quality control factors given in the table (9)
in the appendix.

2. R-Chart (Range Chart):
(12)(3)
The R-chart is developed from the range of each subgroup data. The aim of
using Range chart is to control the variation in the output of a process. The point
plots on this chart are the range (R) of subgroup data, calculate from:
R
j
= Max{x
1
, x
2
, ,x
n
} - Min{x
1
, x
2
, ,x
n
} .... (2-8)
When subgroup sizes are less than (10), both ( R-chart and s-chart) will
graphically portray the same variation, however, as subgroup sizes increase to (10)
or more, extreme values have an undue influence on the R-chart. Therefore, at
larger subgroup sizes the s-chart ( -chart) is used.
(3)

If the sample size is relatively small, (n < 10) it is preferable to use R-chart
The centerline for the R-chart is ( R ), calculate from:

m
R
R
m
1 j
j
=
=
.... (2-9)
The control limits for the control chart, calculate by the formulas:

R
3 R UCL + = .... (2-10)

R
3 R LCL = .... (2-11)
In practice, the calculations are simplified by using the formulas:
R D UCL
4
= == = .. (2-12)


R D LCL
3
= == = .. (2-13)
Remark:
In general the (R-chart) is not symmetric around target line, because for (n =
2, 3, ..., 6), the D
3
= 0.
The constant D
3
and D
4
are the quality control factors given in the table (9)
of the appendix.

3. -Chart:
(3)(12)

The aim of using (sigmachart) is to control the variation of the output in the
quality of a process.
The point plots on this chart is ( ) or standard deviation of sample.
The centerline of sigma-chart is ( ) and calculated as:

m
j
m
1 j

=
=

If is unknown, then it would be estimated from the data.

2
d
R
=
The action lines are:

4
B 3 UCL = == = + ++ + = == = ... (2-14)
= =
3
B 3 LCL ... (2-15)
The constants d
2
, B
3
and B
4
are quality control factors given in the table (9) of
the appendix.
2.1.2.2. Non-Shewhart control charts:
Many other variable control charts (classical) introduced by the statisticians
denoted as non-shewhart charts. The reasons behind introducing these charts
mainly are;
i. The decision in using Shewhart charts is based on a single plotted point.


ii. Shewhart charts are not very sensitive to small changes in the process
parameters.
Popular non-Shewhart control charts are:
1- Cumulative Sum Control Scheme (CUSUM-scheme).
2- Moving Average Control Chart (MA-chart).
3- Moving Range Control Chart (MR-chart).
4- Geometric Moving Average Control Chart (GMA-chart).
1. Cumulative Sum Control Scheme (CUSUM):
(25)

The Cumulative Sum Control Scheme was first introduced by Page (1954).
In fact this is not like Shewhart or other control charts in the sense that it has
central line and control limits, this is why, in literature it is called scheme, but it is
just a graph of (n, S
n
) as given in fig. (2-2)

Figure 2-2 Cumulative Sum Control-Scheme
The aim of using this chart is to control the mean level of output of a
process. Cumulative Sum Control Scheme is more effective than Shewhart control
charts for detecting small process shifts. Consider a CUSUM chart with reference
value (k), and observations: x
1
, x
2
,, x
m .

Calculate CUSUM values by the formula:
S
n
Observation
(n,S
n
)
(1, S
1
)


nk x ) k x ( S
j
n
1 j
j n
= =
=
... (2-16)
where:
k is constant
S
n
= accumulative of differences from the reference value.
For taking the decision in CUSUM-Scheme used:
1- V-Mask.
2- Decision Interval.
If the graph of CUSUM crosses one of the arms of the V. mask, then an
action should be taken, and this would be to search for assignable causes.

Figure 2-3 V-Mask

2. Moving Average Control Chart (MA-chart):
(12)

The aim of using this chart is to control the mean level of the output of a
process. It is generally used for detecting small shifts in the process mean. The
formula for calculating moving averages of order (k); for x
1
,x
2
,x
3
,...,x
N
is:

k
x ... x x
x
j ) 2 k ( j ) 1 k ( j k
) 1 k ( j
+ + +
=

, j= k, k+1, ,N

Upper arm
Lower arm
Vertex
Origin

d (
(

Observation
Sn


where:
k _ 1
The centerline of the moving average chart is:

1 k n
x ... x x
X
) k (
1 k N
) k (
2
) k (
1
k
1
+
+ + +
=
+
... (2-17)
The variance of the moving average control chart is:

k k k
) x ( V
) x ( V
k
i
i
) k (
2
2
2
2
1

=

= =

=

The control limits for moving average chart are:

k
2
k
X
k
X
k
2
k
X
k
X
R A X 3 X LCL
R A X 3 X UCL
k k
k k
= =
+ = + =
... (2-18)
where:
k
k
X
=

The point plots on this chart are the moving average (
k
x ).
Observe that the decision is not based on a single plotted point as in
Shewhart charts. Different moving averages have some common observations.

3. Moving Range Control Chart (MR-chart):
(3)

The aim of using this chart is to control the variation of the output of a
process (or to control standard deviation of a process). The formula for calculating
moving range of order (k), for x
1
, x
2
, x
3
,...,x
N
is a group of observations:

} x ,..., x , x { Min } x ,..., x , x { Max R
i ) 2 k ( i ) 1 k ( i i ) 2 k ( i ) 1 k ( i
k
) 1 k ( i
=
, i=k, k+1,, N
The centerline of this chart is:


1 k N
R
R
k
j
1 k N
1 j
+ ++ +
= == =
+ ++ +
= == =

The action lines of this chart are:

k
3 R
R
k
4 R
R
R D 3 R LCL
R D 3 R UCL
k
k
= =
= + =
... (2-19)
The point plots on this chart is the moving range ( R
k
).
One can observe that here also the decision is not based on a single plotted
point because different moving ranges have some common observations.

4. Geometric Moving Average Control Chart (GMA-chart):
(12)(8)(6)

By Roberts (1959) introduced Geometric Moving Average Control Chart.
The aim of using this chart is to control the mean level of the quality of the
output of a process.
The GMA-chart is sensitive to detect a small change of the quality of a
process.
The point plots of this chart are GMA (Z
j
), which is calculated as:
Z
j
= ( 1 - u )Z
j-1
+ j x ... (2-20)
where u the weight parameter (u) ( 0 < u <1). Smoothing Constant.
The successive values of GMA are:
Z
1
= (1- u)Z
0
+ 1 x

Z
2
= (1- u)Z
1
+ u 2 x

=

(1- u)
2
Z
0

+ u(1- u) 1 x +

u 2 x

Therefore at the stage (m) the GMA is:
Z
m
=

(1- u)
m
Z
0

+ u(1- u)
m-1
1 x +

u(1- u)
m-2
2 x +

..... +

u m x
.. ..
.. ..
Z
N
=

(1- u)
N
Z
0

+ u(1- u)
N-1
1 x +

u(1- u)
N-2
2 x +

..... +

u N x


The centerline of GMA-chart is:
T = Z
0
= target value (if predetermined).
And
X T = == = = Z
0
(if it is not predetermined)
and then:
n ) 2 (
Z

=
... (2-21)

z 0
z 0
3 Z LCL
3 Z UCL
=
+ =
... (2-22)

2.1.3. Bayesian Process Control

Introduction
(5)(15)(17)(30)(31)(34)

Bayesian inference method is distinguished from classical statistical
inference methods by the fact that the Bayesian inference method can be applied to
every type of problems and often shapes the optimal method to use. Statisticians,
philosophers, and computer scientists have proposed numerous guides to reliable
inference. In addition, Bayesian inference method judges upper most as the most
versatile and often the most effective set of methods to use for a broad range of
inductive inference problems.
Bayesian inference is statistical inference in which evidence or observations
are used to update or to newly infer the probability that a hypothesis may be true.
The name "Bayesian" comes from the frequent use of Bayes'theorem in the
inference process. Bayes' theorem was derived from the work of the Reverend
Thomas Bayes (1702-1761).


Bayesian Parameter Estimation :
(21)

A Bayes estimator combines information from a prior probability ) ( P ,
defines that the distribution of ( ) before sampling, and a likelihood function;
L( ) = ) | x ,..., x , x ( P
n

2 1
defines that joint distribution of (n) random
observation (x
1
,x
2
,,x
n
) from population. To arrive at posterior probability
distribution and;
) x ,..., x , x | ( P
n 2 1
defines that the distribution of ( ) after sampling, and
summarizes all the information about ( ).
where:
) | x ,... x , x ( p ) ( L Function Likelihood
n 2 1
= =
) | x ( p
i
n
1 i
=
=
, i = 1,2,,n , (if xs are independent)
and:
The prior distribution of is p( ) [I( )]
1/2
= Jefferys standard non-
informative prior
In the Bayesian parameter estimation formula below, x
1
,x
2
,,x
n
stands as a
random sample got from a population with pdf f(x; ).
Posterior probability prior probability likelihood function
where:
is read as proportion to.
) | x ,..., x , x ( P ) ( P ) x ,..., x , x | ( P
n 2 1 n 2 1

Then Bayesian Estimate is:

) x ,..., x , x | (
n 2 1 B

(Under quadratic loss function)
(2-23)

Bayesian Estimation for mean of Normal Distribution:
The normal distribution is central to inference and other fields of statistics.


To obtain Bayes estimate for the mean of N ( ,
2
) where
2
is known.
Bayesian estimate (
B
):
) , ( N ~ ) ( p
2
0 0

=
n
1 i
2
i
2
} ) x (
2
1
{ EXP ) ( L
) ( L ) ( p ) x | ( p

=
n
1 i
2
i
2
2
0
2
0
} ) x (
2
1
{ EXP } ) (
2
1
{ EXP

=
n
1 i
2
2
2
0
2
0
} ) x (
n
) (
1
{
2
1
EXP
Let:
A =
2
0
1
prior precision
B =
2
n
likelihood precision
D = A + B posterior precision
a =
0
mean of prior distribution
b = x average of sample
And:

B A
) Bb Aa (
c
+
+
=

2 2
0
2
n 1 1
posterior precision

n 0
i
n 0 0
w w
) x w ( ) w (
+
+
=
... (2-24)
where:


2
0
0
1
w
= = prior precision

0
is the mean of the prior distribution.

2
0
is the variance of the prior distribution.

2
n
n
n
w
=
is sample (or Likelihood) precision
x is the average of sample (or subgroup)
} ) (
1
{ EXP ) x | ( p
2
2

The centerline and control limits of B-chart are:
Centerline =
0

The action limits are:
R A 3 UCL
2 0 0 B
B
+ = + =

R A 3 LCL
2 0 0 B
B
= =

2.1.4. EWBA - Chart:
The Exponential Weighted Bayesian Average Chart is very effective for
detecting small process shifts since EWBA Chart can be viewed as a Exponential
Weighted Bayes Average of all past and current data. That is why; EWBA chart is
an effective alternative to the shewhart control charts and Geometric Moving
Average Chart, when we are interested in detecting small shifts.
The aim of using this chart is to control the mean level of the quality of
output of a process (or the mean of a process).
The plotted points on the EWBA Chart are (Z
j
) which may be calculated
from:
Z
j
= (1- ) Z
j-1
+
j
B
... (2-25)


Where u is the weight parameter (0 < u < 1).
The successive values of EWBA are:
Z
1
= (1- u)Z
0
+
1 B

Z
2
= (1- u)Z
1
+
2 B

=

(1- u)
2
Z
0

+ u(1- u)
1 B
+
2 B

Therefore at the stage (m) the EWBA is:
Z
m
=

(1- u)
m
Z
0

+ u(1- u)
m-1
1 B
+

u(1- u)
m-2

2 B
+

..... +

u
Bm

to:

Z
n
=

(1- u)
N
Z
0

+ u(1- u)
N-1
1 B
+

u(1- u)
N-2

2 B
+

..... +

u
Bm

The centerline of EWBA-chart is:
T = Z
EWBA
= target value (if predetermined).
And
0 B
T = = Z
EWBA0
= x (if it is not predetermined)

EWBA 0
EWBA 0
3 Z LCL
3 Z UCL
=
+ =

where:
Z
0
= Z
EWBA0

) x ... x | ( E
n 1 EWBA
= Standard deviation of the posterior
distribution


_ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

A Ap pp pl li ic ca at ti io on n o of f S So om me e C Co on nt tr ro ol l C Ch ha ar rt ts s o on n t th he e R Re ea al l D Da at ta a

3.1 Introduction:
(2) (10)(32)

The use of different materials in building and construction, such as Building
Concrete Blocks (BCB) and Clay Building Bricks (CBB) are gaining popularity
because of high strength of these materials and low prices.
BCB is a hardened building material usually consists of (sand, gravel,
cement, and water). The BCB may be solid or hollow. The hollow type is widely
used in building. The actual dimension of BCB is (20 20 40) cm
3
.
CBB is a hardened building material which is constructed from clay (clay
and silt). It has uniform dimension and of different dimension such as
(2411.57.5) cm
3
.
The different types and various colors of CBB are produced when the CBB
burned by kiln in different grades (750-1000) Centigrade.
The strength of the BCB and CBB are certainly the most important
characteristic that must be tested to see if it conforms with the required
specifications. To achieve the desired strength, manufacturer must carefully control
the production process, which they normally do by using statistical process control
technique. The American Standard, Iraqi Standard, of Testing Materials, and other
organizations have developed a variety of methods for testing the strength. Quality
control charts are widely used by the Engineers of BCBs and CBBs production
processes, and by the Engineers at the site to continually monitor the strength of
these products. Standard test methods have been developed for this purpose as
well.
Engineering Department usually specify the required compressive strength
time of building blocks which is normally 28 days and compressive strength unit


Kilo-grams per square centimeter (Kg/Cm
2
) or MEGA PASCALs (MPa) and
pounds per square inch (p/s inch). 28 days is however a long time to wait to
determine the desired hardness that is to be obtained. Therefore, 7 days and 14
days can be useful to predict the ultimate 28 days compressive strength of the
BCB. 25% strength may be gained between (7 and 28) days, and often it is
observed with 100%.
BCB is typically sampled while being placed, with testing acceptance
requiring, that the samples testing be processed under laboratory conditions
(standard processor).
In addition, the test compressive strength for CBB can be done at any age.

3.2. Collection Data:
The Data, which is collected for quality control purposes, is obtained
directly from the production line. The data shown in the tables (1, 2, 3, 4, 5, 6, 7
and 8) in the appendix were obtained from inspection compressive strength of
BCB at different age (7, 14 and 28) days and CBB of different {types A (Iraqi Clay
Building Bricks) and type B (Foreign Clay Building Bricks)} by Hydraulic
Machines directly in:
1. Concrete and Building Material Laboratory / College of Engineering /
University of Sulaimani.
2. Constructional Laboratory of Sulaimani / Ministry of Reconstruction and
Housing.
The purpose of this work is to test the quality strength of BCB and CBB, use
quality control charts and analyze the results. Therefore; we were inspected
compressive strength of those materials and recorded the required data during the
collection of the data.


3.3. Quality Control Charts Interprets:
To construct control charts for the processes of BCB and CBB products, we
are using the collected data given in the tables (1, 2, 3, 4, 5, 6, 7 and 8) in the
appendix, concerning the strength of BCB at ( age 7, 14, and 28 days ) and CBB
{type (A) and type (B)}. The following control charts are constructed from the
collected data mentioned above, then the data would be plotted on them and
analyze these charts in the quality strength sense.

(a) Standard Control Charts:
The following classical control charts are used for testing compressive
strength of BCB and CBB.
1- X- Bar Chart
2- R-Chart
3- GMA-Chart

(b) Bayesian process Control:
Here, we take B-chart and the new suggested EWBA-chart into
consideration to test the compressive strength of BCB and CBB.
1- B-chart (Bayesian-Chart)
2- EWBA-Chart
Notice:
1. In this thesis, the Minitab statistical software will be used to construct the
control charts.
2. Collected data by inspection compressive strength of BCB during two
different periods. The first one started from 29/8/2006 to 11/1/2007 and the second
one started from 19/4/2007 to 19/8/2007.
3- Construction control charts with only centerline and standard lower bound
(SLB) because of nature of real data were obtained by testing compressive strength
of BCB and CBB directly from laboratories.


4- Local Standard Lower Bound used to control quality of output of the
process.
5- Constructed control charts, for (age 28 Days), on the strength of Building
Concrete Blocks, and deferent type of Clay Building Bricks.
6- Constructed some control charts, for (ages 7 and 14 days) on the Building
Concrete Blocks, they exist in the appendix.

A Ap pp pl li ic ca at ti io o

. .
. .. .

. .


_ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _

4-1. Conclusions:
On the basis of the results that are obtained from analytic real data on the
compressive strength of the BCB and CBB in this thesis, we draw some
conclusions a concerning using quality control charts to monitor these products, as
the following:

4-2. Recommendations:

The following recommendations for future studies are suggested:


References:

1- Alt, F. B. (1985). Multivariate Quality Control, in Encyclopedia of Statistical
Sciences, Vol. 6, N. L. Johnson and S. Kotz, (eds.) Wiley, New York.
2- Bayan Anwer Ali (2005). Punching Shear Strength of High Reinforced
Concrete Slabs, a thesis submitted to the council of the college of engineering of
university of Sulaimani.
3-Besterfield, Dale H. Besterfield, ph.D., p.E. (1986). Quality Control, II edition.
4- Bisgaard, W. G. Hunter, and L. Pallesen, (1984). Economic Selection of
Quality of Manufactured Product, Technometric, Vol. 26(1), pp. 9-18.
5- Bolstad, William M. (2004). Introduction to Bayesian Statistics, John Wiley
ISBN 0-471-27020-2.
6- Borror, C. M., C. W. champ, and S. E. Rigdon, (1998). Poisson EWMA
Control Charts, Journal of Quality Technology, Vol. 30(4), pp. 352-361.
7- Del Castillo, E., (1998). Statistical Process Adjustment for Quality Control,
Prentice Hall. Inc. New Jersey 07458.
8- Enrique del Castillo (2002). Statistical Adjustment for Quality Control, John
Wiley & Sones. Inc New York, printed in U.S.A.
9- Hamad. M. (2003). Tolerance Interval Control Limits for the x, R, and S
chart, Quality Engineering, Vol. 15(3), pp. 471-487.
10- Harmer E. Davis, Georg Earl Troxell, Clement T. Wiskocil (1964). The
Testing and Inspection Engineering Materials, third edition.
11- MacGregor, J. F., and T. J. Harris (1993). The Exponential Weighted Moving
Average, Journal of Quality Technology, Vol. 25(2), pp. 106-118.
12-Montgomery, Doglas C.Montgomery(2005).Statistical Quality Control,5
th

edition
13- Murray R. Spiegel, Larry J. Stephens (1999). Schaums Outlines-Theory and
Problems of Statistics, Chapter 19, Statistical Process Control and Process


Capability- pp. 470-494 / third edition.
14 - M Xie, TN Goh, V Kuralmani, (2002). Statistical Models and Control Charts
for High-Quality Process, Kluwer Academic Published Boston / Dordrecht /
London.
15 - Peter Congdon, Bayesian Statistical Modeling, Queen Mary, University of
London. UK.
16- Runger, G.C., and M.C Testik (2003). Control Charts for Monitoring Fault
Signatures: Cuscore Versus GLR, Quality and Reliability Engineering
International, Vol. 19(4), pp. 387-396.
17- Samuel A. Schmitt (1969). An Elementary Introduction to Bayesian Statistics
Measuring Uncertainty.
18- Steir, S. H. (1999). EWMA Control Charts with Tim-Varying Control Limits
and Fast Initial Response, Journal Quality Technology Vol. 32(3), pp. 199-208.
19- Walter A. Shewhart, from internet / Deming W. Edwards (1967), Walter A.
Shewhart 1891-1967, American Statistician, Vol. 21(April., 1967), pp 39-40.
20- Testik, M.C.,and C.M.Borror(2004).Design Strategies for the Multivariate
EWMA Control Chart, to appear in Quality and Reliability Engineering
International.
21- Winkler, Robert L, Introduction to Bayesian Inference and Decision, 2
nd

Edition (2003), probabilistic ISBN 0-9647938-4-9.
22- Yeh, Arthur B, Dennis K.J.Lin and Chandramouliswaran Venkataramani:
(2003),Unified CUSUM chart for Monitoring Process Mean and Variability ,
(Quality Technology and Quantitative Management Vol. 1 No. 1 pp 65-86)


--' ~ -' ,-' -, - :
23 - -`' ',-= -, ) 1987 ( -'---'' ,-,-=- -'- ,=,-'' -=,-'' , ,--'' -'-'=--
, -''' _,--'' ,--='- ''- .-,-'' -'='' .-,-'' .
24 - -`,-'' ' ' - - ,-'-- ,, ,-- , ) 1988 ( " ,-'' = '' - - =, , '', - -', -'-
,-',-'' ' =` ,- " '' -', - '' ,' '' '' , - = '' - --'' '- .-,-'' -'= -' , ='-=''
-- _',`' -='' . .-,-'' ''' .
25 - ='' _`' . - ,- - -'-'' , -'= ,=''--= . -,' ,-= -= ) 1992 ( " ,'=' ,- -'--
-=,-'' ,,-=-'' -=,-'' =,' , ,',-'' " ,-'-=`' ,'= ,-=' -''' --,-'' --- -=- .
26 - = - -, =' ,-= ) 1980 ( ' - , - ,-=,'' ='--'' ,=,-'' -=,-'' =-'' '= -,
, ,-'--`' ,'-`' ' `'' --' -'= .,`' --'' --' -'-- .
27 - ,- -,'- -,-- ,,- ) 2006 " :( '' ,-- ,'-'' ---- -'-,- -'--=' -'='- _'--`' ,'-
-''=-'' " ,--='- ''- -'--`' , -'-`' ,-'' _`- -'= .,-' / ''' .
28 - ,-'' - - _, ' , -= -' , ) 2007 " :( - -,'-' ,-=- -'-,--'' `' --,- ,- ,
,''' -,'-'' == ,--- ---= " `'---='- ''- -'--`', -'- - ,-'-,'-'' -'= / ''' .
29 - -'' , = - = - , ) 1997 " :( = -=,-'' ,- =,' ,,- ,=,-'' -'-- _' " - ''- ,--='
- .-,-'' -'= -'--`' , -'-`' ,' -'-=`' .
30 - '' ' - '--''--=,-- = - .-, '--- ,--'' - -,==- ) 1990 ( " ,,--''
-=,-'', '' - =, , -'' ='--'' - '-- , " . '' -', - ' -=-'' , '''' , .-,-'' -'= -'''
--'' '- -- , ='-='' / .-,-'' ''' .
31 - '' - ' - - ', =' --' ) 2001 ( " ,=='' ,='' _-'--'' -' ,- -,+-- " ''-
,--='- ---- -'-=`' - _'' - -'--`' , -'-`' ,' -,-'' -'= . / ''' .
32 - - ' , -' , , ,--' : ) 1983 ( ) --' '' -' - - -' ( -'-- -'= - ,'
---+'' .
33 - -,- =- -,' .'-= -- : ) 2006 ( " -,--'' -'--'' =--' ,=,-'' -=,-'' -'=,' '-=--'
,=,-' -`' - - - - - ' . - - - = - =,'-' " -'-=`' - _'' ---- ,--='- ''- ,'
-'-`' -'--`', - '= - -'' ' -, ,-' / '''


34 - -'' ' , - ' '= --=- '' : ) 1996 ( " - ' ,, =, -` ,- -' '' , - -'- ' -
--,= _'--`' - -'' _ = ' -' " - '' =`' - _'' ---- ,--='- - -' - ' , -'-`'
, -'--`' - -'= .-,-'' / ''' .
35 - -- _''- , -= ,,''' ) : 2007 ( " ,-=- _- ,=,-'' -=,-'' ,,--'' ''-'' '-=--'
_'= _-='' .'-=`' -'-`,'' " '- ,' -'-=`' - ,--='- ' '' , -'--'='' ,'= -'= -',-',
.-,-'' .-,-'' ''' .
36 - .-'' ,-'' - =,-=- - -'-- -,-= '-= ,-- -'-'- '' -'' ,-'--`' -'--=-'' -,-
- ,-'' , -,=-'' , ,--'' ) 2001 ( " -',- =`' , -',-'' -'- - .' ,-'--`' " - -'-- - ''' .


APPENDIX:

1- Tables
2- Some Control Charts on the Strength of BCB
3- Material(BCB & CBB) Specifications
4- Abstract in Arabic Language
5- Abstract in Kurdish Language


TABLE (3) Compressive Strength of BCB age 28 days (First period).
*
Measurements (Kg )
Subgroup
No.
Date Time
x
1
x
2
x
3
x
4
Average

R
a
n
g
e

GMA
Bayes

EWB
01
13/ 11
2006
12:30 pm 53 48 46 58 51.3 12 53.1 51.7 53.3
02 14 / 11 01:00 pm 56 59 52 57 56.0 07 53.6 55.9
53.8
03 15 / 11 02:00 pm 54 57 45 47 50.8 12 53.1 51.3
53.3
04 16 / 11 02:00 pm 49 45 59 43 49.0 16 52.3 50.3
52.7
05 18 / 11 09:00 am 50 58 44 48 50.0 14 51.8 50.8
52.3
06 19 / 11 10:30 am 64 57 52 53 56.5 12 52.7 56.0
53.1
07 21 / 11 12:30 pm 51 56 48 54 52.3 08 52.6 52.4
52.9
08 25 / 11 09:00 am 59 66 54 63 60.5 12 54.2 59.3
54.2
09 26 / 11 10:00 am 61 53 56 61 57.8 08 54.9 57.3
54.8
10 28 / 11 01:00 pm 50 60 56 48 53.5 12 54.6 53.5
54.6
11 04 / 12 10:00 am 62 48 49 47 51.5 15 54.0 52.1
54.1
12 06 / 12 11:30 am 60 60 55 57 58.0 05 54.8 57.8
54.8
13 09 / 12 09:00 am 59 55 56 52 55.5 07 54.9 55.4
54.9
14 11 / 12 09:00 am 60 46 51 48 51.3 14 54.2 51.8
54.3
15 13 / 12 02:00 pm 58 57 60 53 57.0 07 54.8 56.8
54.8
16 14 / 12 10:00 am 59 60 53 60 58.0 07 55.4 57.6
55.4
17 16 / 12 11:00 am 58 56 52 53 54.8 06 55.3 54.7
55.2
18 18 / 12 11:00 am 45 39 41 55 45.0 16 53.2 47.5
53.7
19 20 / 12 01:00 pm 44 53 54 51 50.5 10 52.7 50.9
53.1
20 21 / 12 09:00 am 50 59 61 57 56.8 11 53.5 56.3
53.8
21 22 / 12 11:00 am 54 56 53 50 53.3 06 53.5 53.3
53.7
22 23 / 12 09:00 am 54 47 43 53 49.3 11 52.6 50.0
52.9
23 24/ 12/ 06 11:00 am 48 57 53 59 54.3 11 52.9 54.1
53.2
24 10/ 01/ 07 02:00 pm 50 50 55 51 51.5 05 52.7 51.6
52.9
25 11/ 01/ 07 02:00 pm 54 55 52 59 55.0 07 53.1 54.9
53.3
Sum 1339.5 251 1340.5 1343.3 1345.1


* inspected from (concrete and building materials laboratory/College of Engineering/Univ. of
Sulaimani)

Quality Control Charts Analysis of Building Materials

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Iraqi Kurdistan Region

is the mean of the prior distribution.

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