Академический Документы
Профессиональный Документы
Культура Документы
Page 1 of 25
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s charts
From ControlsWiki
Note: Video lecture available for this section!
Authors: Chris Bauman, Jennifer De Heck, Evan Leonard, Merrick Miranda Stewards: Eric Black, Stacy Young, Dan Carter, Megan Boekeloo Date created: 11/30/06; Revised 11/19/07 First round reviews for this page (http://controls.engin.umich.edu/wiki/index.php/Image:SPCChartReviews.doc) Rebuttal for this page (http://controls.engin.umich.edu/wiki/index.php/Image:SPCChartRebuttal.doc)
Contents
1 Introduction 2 Control Chart Background 3 Control Chart Functions 4 Sample Size and Subgrouping 5 X-Bar, R-Charts, and S-Charts 6 Example 1 7 Example 2 8 Example 3 9 Multiple Choice Question 1 10 Multiple Choice Question 2 11 Multiple Choice Question 3 12 Multiple Choice Answers 13 Sage's Corner 14 References
Introduction
Control charts are one of the most commonly used methods of Statisical Process Control (http://controls.engin.umich.edu/wiki/index.php/What_is_6_sigma% 3F#Statistical_Process_Control|) (SPC), which monitors the stability of a process. The main features of a control chart include the data points, a centerline (mean value), and upper and lower limits (bounds to indicate where a process output is considered "out of control").They visually display the fluctuations of a particular process variable, such as temperature, in a way that lets the engineer
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 2 of 25
easily determine whether these variations fall within the specified process limits. Control charts are also known as Shewhart charts after Walter Shewhart, who developed them in the early 1900s.
Figure I. Control chart showing PDF for a data set The centerline is the mean value of the data set and the green, blue and red lines represent one, two, and three standard deviations from the mean value. In generalized terms, if data points fall within three standard deviations of the mean (within the red lines), the process is considered to be in control. These rules are discussed in greater detail later in this section.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 3 of 25
Control Charts are commonly used in six sigma control today, as a means of overall process improvement. For more on six-sigma control, see six sigma (http://en.wikipedia.org/wiki/Six_sigma) .
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 4 of 25
- Finally, the population size, N is assumed to be infinite. Alternatively, if the population is finite but the sample size is less than 5% of the population size, we can still approximate the population to be near infinite. That is, n/N <= 0.05 where n is the sample size and N is the population size. [5]
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 5 of 25
Note: The upper and lower control limits are calculated using the grand average and either the average range and average sigma. Example calculations are shown in the Creating Control Charts Section. The quality of the individual points of a subset is determined unstable if any of the following occurs: Rule 1: Any point falls beyond 3 from the centerline(this is represented by the upper and lower control limts). Rule 2: Two out of three consecutive points fall beyond 2 on the same side of the centerline. Rule 3: Four out of five consecutive points fall beyond 1 on the same side of the centerline. Rule 4: Nine or more consecutive points fall on the same side of the centerline.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 6 of 25
Figure III. Quality control rules. The quality of a subset is determined unstable according to the following rules:
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 7 of 25
1. Any subset value is more than three standard deviations from the centerline. 2. Two consecutive subset values are more than two standard deviations from the centerline and are on the same side of the centerline. 3. Three consecutive subset values are more than one standard deviation from the centerline and are on the same side of the centerline. Creating Control Charts To establish upper and lower control limits on control charts, there are a number of methods. We will discuss the method for the number of components in a subset, n, less than 15. For methods involving n > 15 and other techniques, see Process Control and Optimization, Liptak, 2.34. Here, the table of constants for computing limits, and the limit equations are presented below. Please note that Table A below does NOT contain data for a sample problem. Any time you make a control chart, you refer to this table. The values in the table are used in the equations for the upper control limit (UCL), lower control limit (LCL), etc. This will be explained in the examples below. If you are interested in how these constants were derived, there is a more detailed explanation in Control Chart Constants.
Table A: Table of Constants To determine the value for n, the number of subgroups
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 8 of 25
In order to determine the upper (UCL) and lower (LCL) limits for the x-bar charts, you need to know how many subgroups (n) there are in your data. Once you know the value of n, you can obtain the correct constants (A2, A3, etc.) to complete your control chart. This can be confusing when you first attend to create a x-bar control chart. The value of n is the number of subgroups within each data point. For example, if you are taking temperature measurements every min and there are three temperature readings per minute, then the value of n would be 3. And if this same experiment was taking four temperature readings per minute, then the value of n would be 4. Here are some examples with different tables of data to help you further in determining n:
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s chart... Page 9 of 25
Example 3: n= 3 since there are three readings of temperature. After creating multiple control charts, determining the value of n will become quite easy. Calculating UCL and LCL For the X-Bar chart the following equations can be used to establish limits, where grand average, is the average range, and is the average standard deviation. Calculating Grand Average, Average Range and Average Standard Deviation To calculate the grand average, first find the average of the n readings at each time point. The grand average is the average of the averages at each time point. To calculate the grand range, first determine the range of the n readings at each time point. The grand range is the average of the ranges at each time point. To calculate the average standard deviation, first determine the standard deviation of the n readings at each time point. The average standard deviation is the average of the standard deviations at each time point. Note: You will need to calculate either the grand range or the average standard deviation, not both. For X-bar charts, the UCL and LCL may be determined as follows: is the
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 10 of 25
Alternatively,
The centerline is
The following flow chart demonstrates the general method for constructing an X-bar chart, R-chart, or S-chart:
Calculating Region Boundaries To determine if your system is out of control, you will need to section your data into regions A, B, and C, below and above the grand average. These regions are shown in Figure III. To calculate the boundaries between these regions, you must first calculate the UCL and LCL. The boundaries are evenly spaced between the UCL and LCL. One way to calculate the boundaries is shown below.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 11 of 25
Boundary between A and B above XGA = XGA + (UCL XGA) * 2 / 3 Boundary Between B and C above XGA = XGA + (UCL XGA) * 1 / 3 Boundary Between A and B below XGA = LCL + (XGA LCL) * 2 / 3 Boundary Between B and C below XGA = LCL + (XGA LCL) * 2 / 3
Example 1
Assume that in the manufacture of 1 kg Mischmetal ingots, the product weight varies with the batch. Below are a number of subsets taken at normal operating conditions (subsets 1-7), with the weight values given in kg. Construct the X-Bar, R-charts, and S-charts for the experimental data (subsets 811). Measurements are taken sequentially in increasing subset number.
Solution: First, the average, range, and standard deviation are calculated for each subset.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 12 of 25
Next, the grand average XGA, average range RA, and average standard deviation SA are computed for the subsets taken under normal operating conditions, and thus the centerlines are known. Here n=4.
).
).
Note: Since n=4 (a relatively small subset size), both calculate the UCL and LCL. R-chart limits are computed.
and
The individual points in subsets 8-11 are plotted below to demonstrate how they vary with in comparison with the control limits.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 13 of 25
Figure E-1: Chart of individual points in subsets 8-11. The subgroup averages are shown in the following X-Bar chart:
Figure E-2: X-Bar chart for subsets 8-11. The R-chart is shown below:
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 14 of 25
Figure E-3: R-chart for subsets 8-11. The S-chart is shown below:
Figure E-4: S-chart for subsets 8-11. The experimental data is shown to be in control, as it obeys all of the rules given above.
Example 2
Its your first day on the job as a chemical engineer in a plant, and one of your responsibilities is to monitor the pH of a particular process. You are asked by your boss to monitor the stability of the system. She gives you some baseline data for the process, and you collect data for the process during your first day. Construct X-bar and R-Charts to report your results.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 15 of 25
To be consistent with the baseline data, each hour you take four pH readings. The data you collect is displayed below. Table 2: Experimental data
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 16 of 25
Solution For this situation, there are k=24 subsets because there are 24 data sets. For each subset, n=4 because there are four pH measurements taken each hour. The first thing you do is calculate the mean and range of each subset. The means are calculated using the AVERAGE() Excel function and the ranges are calculated using MAX() MIN(). Once these values are calculated, the Grand Average XGA and average range RA are calculated. These values are simply the means of each subsets mean and range. This data is displayed below. Table 3: Data used to calculate and grand average and Range.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 17 of 25
Now that you know XGA = 7.01 and RA = 0.12, you can calculate the upper control limit, UCL, and lower control limit, LCL, for the X-bar control chart. From Table A, A2 = 0.729 when n=4. Using equations UCL and LCL for X-bar charts listed above:
Then the UCL = 7.0982, LCL = 6.9251 and XGA = 7.01 are plotted in Excel along with the average values of each subset from the experimental data to produce the X-bar control chart.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 18 of 25
Table 4: Average subset values and ranges plotted on the X-bar and R-chart
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 19 of 25
Then, to construct the Range charts, the upper and lower control limits were found. For n=4, D3 = 0 and D4 = 2.282 so then:
Then, UCL = 0.2710, LCL = 0, RA = 0.12, and the ranges for each subset were plotted vs. time in Excel (Figure E-6).
Figure E-6: Range control chart From both of these charts, the process is in control because all rules for stabilty are met. Rule 1: No point falls beyond the UCl and LCL. Rule 2: Two out of three consecutive points do not fall beyond 2 on the same side of the centerline. Rule 3: Four out of five consecutive points do not fall beyond 1 on the same side of the centerline. Rule 4: Nine or more consecutive points do not fall on the same side of the centerline. It's important that both of these charts be used for a given set of data because it is possible that a point could be beyond the control band in the Range chart while nothing is out of control on the Xbar chart. Another issue worth noting is that if the control charts for this pH data did show some points beyond the LCL or UCL, this does not necessarily mean that the process itself is out of control. It probably just means that the pH sensor needs to be recalibrated.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 20 of 25
Example 3
A simple out-of-control example with a sample constructed control chart. You have been analyzing the odd operation of a temperature sensor in one of the plant's CSTR reactors. This particular CSTR's temperature sensor consists of three small thermocouples spaced around the reactor: T1, T2, and T3. The CSTR is jacketed and cooled with industrial water. The reaction taking place in the reactor is moderately exothermic. You know the thermocouples are working fine; you just tested them, but a technician suggests the CSTR has been operating out of control for the last 10 days. There have been daily samples taken and there is a control chart created from the CSTR's grand average and standard deviation from the year's operation. You are assigned to see if the CSTR is operating out of control. The grand average is 307.47 units of temperature and the grand standard deviation is 4.67 units of temperature. The data is provided for construction of the control chart in Table 1 and the data from the last 10 troublesome days is shown in Table 2. You decide to plot the troublesome data onto the control chart to see if it violates any stability rules.
Table 3-1. Data for Construction of Control Chart The way I found A_3 or in this case, R_3, I used the control charts constants table which is found on this wiki page. I decided to use the x-bar using the standard deviations) but you can also use use the range). I found that the value for n(number of subgroups) is three since the CSTR's temperature sensor consists of three small thermocouples (T1,T2,T3). Therefore by looking at the constant chart, I get A_3( or R_3 in this case) to be 1.954. Here's the table below:
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 21 of 25
Also, you will notice if you used the range instead of the standard deviation to determine the UCL,LCL, etc. that the values will be roughly the same. Here's the table in comparing the values of UCL and LCL using either A_2 (range) or A_3(stdev):
Note: These values were using the same grand average (307.47), the grand standard deviation (4.67) and the grand range (8.80)
Table 3-2. Sample Data from Past 10 Troublesome Days Solution When the sample data was graphed onto the control chart, the image below was seen.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 22 of 25
Figure 3-1. 10-Day Data Graphed Onto Control Chart We can see from the control chart that the CSTR system is clearly out of control. Each thermocouple was tested to see which stability rules it violates. The first thermocouple (T1) violates every stability rule. Rule 1 - Several points from the T1 data fall above the upper control line. Rule 2 - There are many instances where at least two out of three consecutive points fall above the zone AB threshold. Rule 3 - There are eight consecutive points falling above the BC threshold. Rule 4 - Nine consecutive points fall above the mean value. Judging on this thermocouple's performance, we can say that the system is out of control, but we will analyze the other thermocouples' performance for good measure. The second thermocouple (T2) violates stability rule 1, 2, and 3. Rule 1 - One point falls below the lower control line. Rule 2 - Two consecutive points (samples 9 and 10) fall beyond the AB threshold. Rule 3 - Of the last five samples from T2, four are beyond the BC threshold. The third thermocouple (T3) does not violate any stability rules and the results it displays are within control. This system is out of control because the data from the thermocouples falls beyond the threshold rules for the unit's control chart. This could be explained with many potential situations. One is explained below.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 23 of 25
If the CSTR's agitator is knocked loose, the agitation could become erratic. The erratic agitation could create eddy currents and hot spots in the CSTR. The entire system is out of control because you know that the thermocouples are operating fine and more than one thermocouple violates the stability rules.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 24 of 25
Question 3: A
Sage's Corner
SPC Control Presentation
References
Wheeler, Donald J., and David S. Chambers. Understanding Statistical Process Control. 2nd ed. Knoxville: SPC P. 37-88. [1] Box, George E., William G. Hunter, and J S. Hunter. Statistics for Experimenters: An Introduction to Design, Data Analysis, and Model Building. New York: John Wiley & Sons. 43-45. [2] Liptak, Bela G. "Process Control and Optimization." Instrument Engineers' Handbook 4: 405-413. [3] Woolf, Peter, Amy Keating, Christopher Burge, and Michael Yaffe. Statistics and Probability Primer for Computational Biologists. Massachusetts Institute of Technology. 2004. [4] Anderson, David R., Sweeney, Dennis J. and Williams, Thomas A. Statistics for Business and Economics, 10e. Thompson South-Western. 2008. [5] Retrieved from "http://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_and_construction,_sam -bar,_r_charts,_s_charts" This page was last modified on 20 May 2013, at 14:32.
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013
SPC: Basic control charts: theory and construction, sample size, x-bar, r charts, s ch... Page 25 of 25
https://controls.engin.umich.edu/wiki/index.php/SPC:_Basic_control_charts:_theory_a... 5/28/2013