STATISTICAL

QUALITY
CONTROL

Chapter Thirteen
McGraw-Hill/Irwin Copyright © 2014 by The McGraw-Hill Companies, Inc. All rights reserved.
 Learning Objectives
 LO13–01: Illustrate process variation and explain
how to measure it.
 LO13–02: Analyze process quality using statistics.
 LO13–03: Analyze the quality of batches of items
using statistics.

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Statistical Quality Control (SQC)
 The
quantitative Assignable variation
aspects of • Variation that is caused by factors that
can be identified and managed
quality
management
 Processes
usually exhibit Common variation
some variation • Variation that is inherent in the process
itself
in their output

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 Measuring Variation


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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 Costs Taguchi’s View of Variability Costs

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 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

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 Process Capability

Process control limits exceed specification limits – process is not

capable of meeting requirements

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 Process Capability

Specification control limits exceed process limits (for improved process) –

process is capable of meeting requirements

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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 shifted

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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?

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Example 13.1: Solution

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 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

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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.

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 Process Control Measurements –
p-Charts
 Used when an item (or service) is either good or
bad (a yes-no decision)

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Example: Calculations
Total number of defects from all samples 91
p   0.03033
Number of samples x Sample size 3,000

sp 

p 1 p
0.030331  0.03033
 0.00990
n 300

UCL  p  3s p  0.03033  30.00990  0.06003

LCL  p  3s p  0.03033  30.00990  0.00063
 Process Control Measurements –
c-Charts
 Used when an item (or service) may have multiple
defects

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c-Chart for Cab Company
c = 54 complaints/9 days = 6 complaints/day

UCLc = c + 3 c 14 – UCLc = 13.35

=6+3 6

Number defective
12 –
= 13.35 10 –
8 –
6 – c= 6
LCLc = c - 3 c 4 –
=6-3 6 2 – LCLc = 0
=0 0 – | | | | | | | | |
1 2 3 4 5 6 7 8 9
Day
 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

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X-bar and R-Charts

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Example

20
Example: Calculations and Chart
Process Control Charts – Interpretation

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 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

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Acceptance Sampling – Purposes

 Determine quality level

 Ensure quality is within predetermined
level

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 Acceptance Sampling
Disadvantages Advantages

 Risks of accepting  Economy

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

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 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 quality Lot tolerance percent
level (AQL) defective (LTPD)
• Maximum acceptable • Percentage of defectives
percentage of defectives that defines consumer’s
defined by producer rejection point

 (producer’s risk)  (consumer’s risk)

• The probability of • The probability of
rejecting a good lot accepting a bad lot

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 Single Sampling Plan
 Defined by n and c
 n is sample size
 c is the acceptance number
 Values for n and c are determined by the
interaction of four factors
1. AQL or acceptable quality level
2. α
3. LTPD or lot tolerance percent defective
4. β
 Risk
1. Acceptable quality level (AQL)
 Maximum acceptable percentage of defectives defined by
producer
2. The  (producer’s risk)
 The probability of rejecting a good lot
3. Lot tolerance percent defective (LTPD)
 Percentage of defectives that defines consumer’s rejection point
4. The  (consumer’s risk)
 The probability of accepting a bad lot
 Example
 Hi-Tech Industries manufactures Z-band radar
scanners used to detect speed traps. The printed
circuit boards in the scanners are purchased from an
outside vendor. The vendor produces the boards to an
AQL of 2% defectives and is willing to run a 5% risk
(α) of having lots of this level or fewer defectives
rejected. Hi-Tech considers lots of 8% or more
defectives (LTPD) unacceptable and wants to ensure
that it will accept such poor quality lots no more than
10% of the time (β). A large shipment has just been
delivered. What values of n and c should be selected
to determine the quality of this lot? 29
Example
 AQL = 0.02
  = 0.05
 LTPD = 0.08
 β = 0.10

 c = LTPD/AQL = 0.08/0.02 = 4
 n = 1.970 / 0.02 = 98.5  99
Operating Characteristic Curve

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