Individual Moving Range (I-MR) Charts

The Swiss Army Knife of Process Charts

SPC Selection Process

Choose Appropriate Control Chart

ATTRIBUTE

type of data

CONTINUOUS

DEFECTS

type of attribute data

DEFECTIVES

type of defect

type of subgroups CONSTANT VARIABLE Sample size 1

subgroup size

CONSTANT

VARIABLE

2-9

10+

C Chart Number of Incidences

U Chart Incidences per Unit

NP Chart Number of Defectives

P Chart Proportion Defectives

I MR Chart Individual s& Moving Range

XR Chart Mean & Range

XS Chart Mean & Std. Dev.

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

Individual Moving Range (I-MR Chart) Control charts for variables data Monitors the process over time Individual Chart
Plots each measurement as a separate data point Each data point stands on its own (subgroup size = 1)

Moving Range Chart

Uses a default value of 2, which means each data point plots the difference (range) between two consecutive data points as they come from the process in sequential order There will be one less data point in the Moving Range chart than the Individual chart

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

Sample Individual Moving Range Chart

I-MR Chart of Systolic Blood Pressure

180
1 1 1 1

Individual V alue

160 140 120 100 1 8 15 22 29 36 O bser vation 43 50 57 64

U C L=165.38

_ X=134.24

LC L=103.10

40

U C L=38.25

M oving Range

30 20 10 0 1 8 15 22 29 36 O bser vation 43 50 57 64 __ M R=11.71

LC L=0

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

Xbar-R Charts
Control charts for variables data Monitors the process over time The distribution does not have to be approximately normal Based on the average of a series of observations, called a subgroup Monitors the variation between observations in the subgroup over time The larger the subgroup, the more sensitive the chart will be to shifts, providing a Rational Subgroup can be formed
What is a rational subgroup?

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

What is it and where does it come from? Rational Subgroup

Items which were produced under the same conditions When possible, formed by using consecutive units Each subgroups statistics are compared to the control limits, and patterns of variation between subgroups are analyzed

Picture a Stable Distribution A group of objects containing a characteristic of interest

Distribution

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

Where do Subgroups Come From? Subgroup: A subset of the distribution of interest

Subgroup 1 Subgroup 2 Subgroup 3

Subgroup N

I-MR XBarR Charts

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Sample Xbar-R Chart

Xbar-R Chart of Glucose Readings

110 105 100 95 90 1 3 5 7 9 11 Sample 13 15 17 19 LC L=90.05 _ _ X=99.69 U C L=109.33

Sample M ean

48

U C L=51.99

Sample Range

36 24 12

_ R=28.63

LC L=5.27 0 1 3 5 7 9 11 Sample 13 15 17 19

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

When to Use I-MR/Xbar-R

I-MR
When you have a limited number of individual measurements

Xbar-R
When you can collect measurements in groups (subgroups) of between two and ten observations

For subgroup sizes greater than ten

Use Xbar / Sigma charts

Must have data that is time-ordered

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

Interpreting R Charts
Always look at the Range chart first
Control limits on the I-MR are derived from the change in range (moving range) The control limits on the Xbar-R chart are derived from the average range If the Range chart is out of control, then the control limits on the Individual and X-bar chart are meaningless.

Look for out of control points

Special causes must be eliminated There should be more than five distinct values plotted No single value should appear more than 25% of the time

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

10

I-MR Chart
Looking at the moving range chart, what does the out of control point tell you?
I-MR Chart of Individual
8 U C L=7.810

Individual V alue

6 4 2 0 LC L=-0.810 1 4 7 10 13 16 O bser vation 19 22 25 28 _ X=3.5

6.0

U C L=5.295

M oving Range

4.5 3.0 1.5 0.0 1 4 7 10 13 16 O bser vation 19 22 25 28 __ M R=1.621 LC L=0

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

11

Interpreting R Charts
Average charts become more sensitive to process changes as the subgroup size is increased
What does that mean?

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

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Sensitive to Process Changes

As the subgroup size increases the control limits of the range chart increase
Xbar-R Chart of Glucose Readings (Subgroup Size 3)
120 110 100 90 80 1 7 13 19 25 31 Sample 37 43 49 55 LC L=82.65 _ _ X=99.69
1

Xbar-R Chart of Glucose Readings (Subgroup Size 9)

110

U C L=116.72
Sample M ean
105 100 95 90 1 3 5 7 9 11 Sample 13 15 17 19

U C L=109.33

Sample M ean

_ _ X=99.69

LC L=90.05

40

U C L=42.86
Sample Range

48 36 24 12

U C L=51.99

Sample Range

30 20 10 0 1 7 13 19 25 31 Sample 37 43 49 55 LC L=0 _ R=16.65

_ R=28.63

LC L=5.27 0 1 3 5 7 9 11 Sample 13 15 17 19

Range Chart
UCL 42.86 LCL 0
I-MR XBarR Charts

Range Chart
UCL 52.99 LCL 5.27
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Interpreting Individual/Xbar Charts

Individual/Xbar Charts
Interpret the points on the X-bar chart relative to the control limits and Run Tests Look for out of control points Look for obvious non-random behavior

Averages in the Xbar Chart cannot be compared to requirements

What does that mean?

I-MR XBarR Charts

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Xbar-R Cannot Be Compared to Requirements

Both charts use same data set Look at the control limits on the Individual and Xbar Charts
Individual Readings
I-MR Chart of Glucose Readings
140 U C L=131.17

Same Readings in Subgroups of 9

Xbar-R Chart of Glucose Readings
110 105 100 95 90 1 3 5 7 9 11 Sample 13 15 17 19 LC L=90.05 _ _ X=99.69 U C L=109.33

Individual V alue

100 80

_ X=99.69

LC L=68.20 60 1 19 37 55 73 91 109 O bser vation 127 145 163

40 30 20 10 0 1 19 37 55 73 91 109 O bser vation 127 145 163

U C L=38.68

Sample M ean

120

48

U C L=51.99

M oving Range

Sample Range

36 24 12

_ R=28.63

__ M R=11.84

LC L=0

LC L=5.27 0 1 3 5 7 9 11 Sample 13 15 17 19

UCL 131.17 LCL 68.2

I-MR XBarR Charts Coventry Healthcare Larry Dyer MBB

UCL 109.33 LCL 90.05

15

The Control Chart Cookbook

General Steps for Constructing I-MR Charts

1. 2. 3. 4. 5. Select characteristic (critical X or CTQ) to be charted Determine the purpose of the chart Select data-collection points Determine the measurement method/criteria Drop the data into Minitab or other charting software

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

16

Questions?

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB

Run Tests Western Electric Rules

One or more observations occurring more than 3 Standard Deviations from the average, i.e. any points occurring above or below the Control Limits. Two out of three consecutive observations, all on the same side of the average and occurring more than two Standard Deviations away form the average. Four out of five consecutive observations, all on one side of the Center Line occurring more than one Standard Deviation from the average. Eight consecutive observations on one side of the average.
UCL +2 +1 Average -1 -2 LCL

Fifteen consecutive observations occurring within one Standard Deviation from the average.

UCL +2 +1 Average -1 -2 LCL

UCL +2 +1 Average -1 -2 LCL

Eight consecutive observations that are more than one Standard Deviation from the average.

UCL +2 +1 Average -1 -2 LCL

UCL +2 +1 Average -1 -2 LCL

Fourteen consecutive observations that alternate up and down.

UCL +2 +1 Average -1 -2 LCL

UCL +2 +1 Average -1 -2 LCL

Six consecutive observations that trend downward or upward.

UCL +2 +1 Average -1 -2 LCL

I-MR XBarR Charts

Coventry Healthcare Larry Dyer MBB