What is a control chart?

The control chart is a graph used to study how a

process changes over time. Data is plotted in time
order. It does not show cause for a variation.

WHY THESE EVOLVED?

No 2 things are alike
Variation exists - even if variation is small, precision
instruments show differences.
To keep track of these variations we use control
charts.

Source of variation
Random and Non Random variations.
Equipment

Environment

- tool wear, electrical fluctuations for

welding
- tensile strength, moisture content
(e.g. raw material)
- temperature, light, humidity

Operator

- method, motivation level, training

Inspection

- inspector, inspection equipment,

environment

Material

Statistical stability
A process is statistically stable over time
(with respect to characteristic X) if the
distribution of X does not change over time

Process Capability
Process Capability is a measure of the
ability of the process to meet specifications.

TYPES OF CONTROL CHARTS:

1. Control chart for variables
1.
2.

X R chart
X S chart

2. Control chart for attributes

1.
n- chart
2.
np chart
3.
c- chart
4.
u- chart

Variable
A single quality characteristic that can be measured
on a numerical scale.
E.g. height, weight , age etc

AttributeA quality characteristic that can not be measured but

is a discrete one . Attribute data arise when you are
determining only the presence or absence of
something: success or failure

CHOICE OF SAMPLE SIZE:

Large sample size is easy to take but the

control chart will be smooth which means
that average will normalize the small
defects.
So small sample sizes should be taken such
that smaller problems can be found out.

Average Run Length

The average run length (ARL) is a very
important
way
of
determining
the
appropriate sample size and sampling
frequency.
Let p = probability that any point exceeds
the control limits. Then,

1
ARL
p

The average run length gives us the length of

time (or number of samples) that should plot in
control before a point plots outside the control
limits.

( X R CHART )
A control chart mainly consists of control limits
which set up a quality characteristic.
In X R chart, two charts are drawn. These
are X chart and R chart.
X bar chart monitors the between sample
variability
R chart monitors the within sample variability.

Steps to draw chart :

1.
2.
3.
4.
5.
6.

Select quality characteristic.

Select sample number and sample size.
Find out the corresponding mean and range.
Find x and R
Find the control limits.
Draw the chart by plotting sample number
on abscissa/ordinate and sample size on
ordinate/abscissa.

 Control limits for R chart:

UCL D4 R
Center Line R
D/D
D LCL
= 1+(3D
3 R ) and D
4

is max (0, 1-(3D3/D2)

Control limits for X Chart :

UCL x A 2 R
Where
A2 is 3 Line
(D2n)
Center

LCL x A 2 R

X BAR AND R CHART EXAMPLE

x Chart Control Limits

UCL = x + A 2 R
LCL = x - A 2 R
R Chart Control Limits
UCL = D 4 R
LCL = D3 R

UCL = D 4 R ( 2.11)( 0.2204) 0.46504

LCL = D3 R (0)( 0.2204) 0

UCL = x + A2 R 10.728 .58( 0.2204 )=10.856

LCL = x - A2 R 10.728-.58( 0.2204 )=10.601
10.900
10.850

Means

10.800
10.750
10.700

Sample
mean
UCL

10.650

LCL

10.600

grand
mean of x

10.550
1

Sample

10

11

12

13

14

15

Trial Control Limits

The control limits obtained from equations of range
should be treated as trial control limits.
If this process is in control for the m samples collected,
then the system was in control in the past.
If all points plot inside the control limits and no
systematic behavior is identified, then the process was
in control in the past, and the trial control limits are
suitable for controlling current or future production.

Trial control limits and the out-ofcontrol process

If points plot out of control, then the control limits
must be revised.

Before revising, identify out of control points and

look for assignable causes. If assignable causes
can be found, then discard the point(s) and
recalculate the control limits.

Trial control limits and the out-ofcontrol process

If no assignable causes can be found then
1) either discard the point(s) as if an
assignable cause had been found or 2)
retain the point(s) considering the trial
control limits as appropriate for current
control

( x - s control chart )
It consists of two charts :
X bar Chart
S Chart
In this chart, we are using standard deviation
as a measure of variation.
Both R and s measure dispersion of data
When n<10 R chart s chart
When n10 S chart better , R not accurate
any more.

 R chart - simple, only use XH (highest) and

XL(lowest)
S chart - more calculation
- use ALL xis more accurate,
need calculate sub-group sample
standard deviation
STANDARD DEVIATION (S) :
n

(X
i 1

X)

n -1

The upper and lower control limits for the

chart are given as

UCL x A 3 S
CL x
LCL x A 3 S
where A3 is found in the Appendix

X BAR S CHART EXAMPLE

Process Out Of Control

1. A point falls outside control limits
assignable cause present
process producing unstable process
must be investigated, corrected

2. Unnatural runs of variation even

within 3 limits :
7 or more points above or below center line
(in a row)
10 out of 11 points on one side
12 out of 14 points on one side
6 points increasing/decreasing
2 out of 3 in Zone A (WL)
4 out of 5 in Zone B.

3. For two zones 1.5 each 2 or more

points beyond 1.5

ANALYSIS FOR OUT-OF-CONTROL

Patterns

1. Change/Jump in level
shift in mean
Causes - process parameters change, diff / new
operator, change in raw material

2. Trend or steady change in level

drifting mean common, upward or downward
direction
tool wear, gradual change in temp. viscosity of
chemical used

3. Recurring cycles

Wavy, periodic high & low points

Recurring effects of temp., humidity

(morning vs. evening)
4. Two populations (mixture)
many points near or outside limits due to

large difference in material quality

2 or more machines

different test method

Thank You
Make Presentation much more fun