ACCEPTANCE SAMPLING

Prof. Dr. Cengiz KAHRAMAN

stanbul Technical Universityy
Department of Industrial Engineering
Inspection of raw materials semi finished products or Inspection of raw materials, semi finished products, or
finished products is one aspect of quality assurance.
When inspection is for the purpose of acceptance or
f d b d dh d d h rejection of a product, based on adherence to a standard, the
type of inspection procedure employed is usually called
l acceptance sampling.
Acceptance sampling is most likely to be useful in the
following situations: g
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1 When testing is destructive 1. When testing is destructive,
2. When the cost of 100% inspection is extremely high,
h h l ll f bl 3. When 100%inspection is not technologically feasible or
would require so much time that production scheduling
ld b l d would be seriously impacted.
Its advantages are:
1. It is usually less expensive because there is less inspection.
2 Th i l h dli f th d t h d d 2. There is less handling of the product, hence reduced
damage.
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3 It is applicable to destructive testing 3. It is applicable to destructive testing.
4. Fewer personnel are involved in inspection activities.
f l d h f 5. It often greatly reduces the amount of inspection error.
6. The rejection of entire lots as opposed to the simple return
of defectives often provides a stronger motivation to the
vendor for quality improvements.
Its disadvantages are: Its disadvantages are:
1. There are risks of accepting bad lots and rejecting good
lots lots.
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2 Less information is usually generated about the product or 2. Less information is usually generated about the product or
about the process that manufactured the product.
3. Acceptance sampling requires planning and documentation
f h l d h of the acceptance sampling procedure whereas 100%
inspection does not.
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Types of Sampling Plans
There are a number of different ways to classify
acceptance-sampling plans. One major classification is by
attributes and variables.
Acceptance-sampling plans by attributes:
1. Single Sampling Plans g p g
2. Double Sampling Plans
3 Multiple-Sampling Plan 3. Multiple-Sampling Plan
4. Sequential Sampling
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1. Single Sampling Plans
A single-sampling plan is a lot-sentencing procedure in
which one sample of n units is selected at random from p
the lot, and the disposition of the lot is determined based
on the information contained in that sample. p
A single-sampling plan consists of a sample size n and
an acceptance number c an acceptance number c .
You select n items at random from the lot.
f h f d f h l If there are c or fewer defectives in the sample, accept
the lot, and if there are more than c defective items in
h l h l the sample, reject the lot.
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2. Double Sampling Plans
Double-sampling plans are somewhat more complicated.
Following an initial sample, a decision based on the information in
that sample is made either to
i. accept the lot,
ii. reject the lot,
iii. take a second sample.
If the second sample is taken, the information from both the first
and second sample is combined in order to reach a decision
h h j h l whether to accept or reject the lot.
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Multiple-Sampling Plans
A multiple-sampling plan is an extension of the double A multiple sampling plan is an extension of the double
sampling-plan concept.
Sequential Sampling Plans
Sequential sampling is the ultimate extension of
multiple-sampling multiple-sampling.
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Definition of a Single Sampling Plan
A single-sampling plan is defined by the sample size n
and the acceptance number c. p .
For example, N=10,000, n=89, c=2 means that from a
lot of size 10 000 a random sample of n=89 units is lot of size 10,000 a random sample of n 89 units is
inspected and the number of nonconforming or defective items
d observed d observed.
If the number of observed defectives d is less than or
l t =2 th l t ill b t d If th b f equal to c=2, the lot will be accepted. If the number of
observed defectives d is greater than 2, the lot will be
j t d rejected.
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Probability of acceptance with single sampling: Probability of acceptance with single sampling:
f h l f d f d If the lot fraction defective is p=0.01, n=89, and c=2
then
( )
( )
( ) ( ) 9397 . 0 99 . 0 01 . 0
! 89
2
89
2
=

= =
d
a
d
d P P ( )
( )
( ) ( )
! 89 ! 0

= d
a
d d
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Random Sampling
The units selected for inspection from the lot should be
chosen at random, and they should be representative of , y p
all the items in the lot.
The random-sampling concept is extremely important in The random-sampling concept is extremely important in
acceptance sampling.
U l d li d bi ill b i t d d Unless random sampling used, bias will be introduced.
For example, the vendor may ensure that the units
k d h f h l l d packaged on the top of the lot are extremely good
quality, knowing that the inspector will select the sample
f h l from the top layer.
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The technique often suggested for drawing a random q gg g
sample is to first assign a number to each item in the lot.
Then n random numbers are drawn, where the range of , g
these numbers is from 1 to the maximum number of
units in the lot.
This sequence of random numbers determines which
units in the lot will constitute the sample.
If products have serial or other code numbers, these
numbers can be used to avoid the process of actually
b h assigning numbers to each unit.
Another possibility would be to use a three-digit random
b h l h d h d d h number to represent the length, width and depth in a
container.
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The Operating-Characteristic (OC) Curve
An important measure of the performance of an
acceptance-sampling plan is the operating-characteristic p p g p p g
(OC) curve.
This curve plots the probability of accepting the lot This curve plots the probability of accepting the lot
versus the lot fraction defective.
Th OC h th b bilit th t l t b itt d The OC curve shows the probability that a lot submitted
with a certain fraction defective will be either accepted
j t d or rejected.
The OC curve of the sampling plan n=89, c=2 is shown
h f ll f in the following figure:
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The OC curve displays the probability that a lot
submitted with a certain fraction defective will be either
accepted or rejected for a given sampling plan.
The OC curve is developed by evaluating the following
equation for various values of p : q p
{ }
( )
( )

= =

c
d n
d
p p
n
c d P P 1
!
h f ll bl d l h l l d l f
{ }
( )
( )

= d
a
p p
d n d
c d P P
0
1
! !
The following table displays the calculated value of
several points on the curve:
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p = fraction
defective in lot
P
a
= P[Accepting
Lot]
N=10,000
n=89, c=2
defective in lot Lot]
0.005 0.9897
0.010 0.9397
n=89, c=2
0.015 0.8502
0.020 0.7366
0.025 0.6153
0.030 0.4985
0.035 0.3936
0.40 0.3042
0.50 0.1721
0.60 0.0919
0 70 0 0468 0.70 0.0468
0.80 0.0230
0 90 0 0109
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0.90 0.0109
In the sampling plan n=89, c=2, if the lots are 2%
defective, the probability of acceptance is approximately
0.74.
This means that if 100 lots from a process that
manufactures 2% defective product are submitted to this p
sampling plan, we will expect to accept 74 of the lots
and reject 26 of them. j
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Effect of n and c on OC Curves
The greater is the slope of the OC curve, the greater is
h d the discriminatory power.
Precision with which a sampling plan differentiates
between good and bad lots increases as the sample size n g p
increases.
In the following figure, note that the acceptance number
c is kept proportional to n: c is kept proportional to n :
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OCCurves
1.00
Pa
0.60
0.70
0.80
0.90
n=50, c=1
0 20
0.30
0.40
0.50
0.60
n=100, c=2
n=200 c=4
0.00
0.10
0.20
0 00 0 02 0 04 0 06 0 08 0 10
n=200, c=4
n=1000, c=20
0.00 0.02 0.04 0.06 0.08 0.10
Lotfraction defective, p
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The following figure shows how the OC curve changes The following figure shows how the OC curve changes
as the acceptance number changes.
As the acceptance number is decreased, the OC curve is
h f d h l f shifted to the left.
Changing the acceptance number, c, does not dramatically
change the slope of the OC curve. g p f
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OC Curves
1.0
Pa
OCCurves
0.7
0.8
0.9
n=89 c=2
0 4
0.5
0.6
0.7
n 89, c 2
n=89, c=1
0 1
0.2
0.3
0.4
89, c
n=89, c=0
0.0
0.1
0.00 0.02 0.04 0.06 0.08 0.10
Lotfraction defective, p
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A ft t bli h li l f A consumer often establishes a sampling plan for a
continuing supply of components or raw material with
f t t bl lit l l AQL reference to an acceptable quality level, AQL .
The AQL represents the poorest level of quality for the
d h h ld d b vendors process that the consumer would consider to be
acceptable as a process average.
It is simply a standard against which to judge the lots.
The consumer will also be interested in the other end of
the OC curve-that is, in the protection that is obtained
for individual lots of poor quality. p q y
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I h it ti th t bli h l t In such a situation, the consumer may establish a lot
tolerance percent defective (LTPD).
Th T h l l f l h h The LTPD is the poorest level of quality that the
consumer is willing to accept in an individual lot.
Note that the lot tolerance percent defective is not a
characteristic of the sampling plan, but is a level of lot
quality specified by the consumer.
It is possible to design acceptance-sampling plans that p g p p g p
give specified probabilities of acceptance at the LTPD
point. p
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Average Outgoing Quality Curve (AOQ Curve)
AOQ is the average value of lot quality that would be
b d l f l f obtained over a long sequence of lots from a process
with fraction defective p.
It is simple to develop a formula for AOQ.
Assume that the lot size is N and that all discovered
defectives are replaced with good units.
Then in lots of size N, we have:
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1. n items in the sample that, after inspection, contain no p , p ,
defectives, because all discovered defectives are
replaced.
2. N-n items that, if the lot is rejected, also contain no
defectives.
3. N-n items that, if the lot is accepted, contain p(N-n)
defectives.
Thus, lots in the outgoing stage of inspection have an g g g p
expected number of defective units equal to P
a
.p.(N-
n), which we may express as an average fraction
d f ll d h l defective, called the average outgoing quality or
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( ) N P ( )
N
n N p P
AOQ
a

=
To illustrate the use of the equation above, suppose that
N=10 000 =89 d =2 d th t th i i l t N=10,000, n=89, and c=2, and that the incoming lots
are of quality p=0.01:
0 01 0 3 7 p=0.01 P
a
=0,9397
( )
( )( )( )
N P ( )
( )( )( )
000 , 10
89 000 , 10 01 . 0 9397 . 0
=

=
N
n N p
a
P
AOQ
009313 . 0
,
=
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That is, the average outgoing quality is 0.93%
d f ti defective.
Note that as the lot size N becomes large relative to the
l h b sample size n, we may write the equation above as:
p P AOQ
a

Average outgoing quality will vary as the fraction

p Q
a
Average outgoing quality will vary as the fraction
defective of the incoming lots varies.
The curve that plots average outgoing quality against The curve that plots average outgoing quality against
incoming lot quality is called an AOQ curve.
Th AOQ f th li l =89 =2 i The AOQ curve for the sampling plan n=89, c=2 is
shown in the following figure:
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From examining the curve of AOQ we note that when From examining the curve of AOQ we note that when
the incoming quality is very good, the AOQ is also very
good good.
h h l l b d In contrast, when the incoming lot quality is very bad,
most of the lots are rejected and screened, which leads
d l l f l h l to a very good level of quality in the outgoing lots.
In between these extremes, the AOQ curve rises,
passes through a maximum, and descends. p g
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The maximum ordinate on the AOQ curve represents Q p
the worst possible average quality that would result
from the rectifying inspection program, and this point y g p p g , p
is called the average outgoing quality limit (AOQL).
From the figure above the AOQL is approximately From the figure above, the AOQL is approximately
0.0155.
Th t i tt h b d th f ti d f ti i i That is, no matter how bad the fraction defective is in
the incoming lots, the outgoing lots will never have a
lit l l th th 1 55% worse quality level on the average than 1.55%
defective.
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Average Total Inspection Curve
Another important measure relative to rectifying
h l f d b inspection is the total amount of inspection required by
the sampling program.
If the lots contain no defective items, no lots will be
rejected, and the amount of inspection per lot will be the
sample size n.
If the items are all defective, every lot will be submitted y
to 100% inspection, and the amount of inspection per
lot will be the lot size N.
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If the quality is 0<p<1, the average amount of inspection q y p , g p
per lot will vary between the sample size n and the lot
size N.
If the lot is of quality p and the probability of lot
acceptance is P then the average total inspection per lot acceptance is P
a
, then the average total inspection per lot
will be
( )( ) n N P n ATI + = 1 ( )( ) n N
a
P n ATI + = 1
Example: N=10,000, n=89, c=2, and p=0.01.
Since P
a
=0.9397, we have
a
ATI = 89 + (1-0.9397)(10,000-89) = 687
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Remember that this is an average number of units g
inspected over many lots with fraction defective p=0.01.
ATI curves for the sampling plan n=89, c=2, for lot sizes
f 1 000 5 000 d 10 000 h i th f ll i of 1,000, 5,000, and 10,000, are shown in the following
figure.
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ATI
N=10,000 10,000
ATI
N=5,000 5,000
N=1,000 1,000
0.02 0.04 0.06 0.08
Lot fraction defective, p
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Double-Sampling Plans
A double-sampling plan is defined by four parameters:
1. n
1
:sample size on the first sample p p
2. c
1
:acceptance number of the first sample
3. n
2
:sample size on the second sample 3. n
2
:sample size on the second sample
4. c
2
:acceptance number for both samples
The operation of double-sampling plan is illustrated
h ll h f ll f graphically in the following figure:
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Inspect a random sample of n
1

from the lot
d
1
: number of observed d
1
: number of observed
defectives
d
d
1 1
c d

2 1
c d >

d <
Reject
the lot
Accept
the lot
2 1 1
c d c <

Inspect a random sample of
n from the lot n
2
from the lot
d
2
: number of observed
defectives
a
m
p
l
i
n
g
A
c
c
e
p
t
a
n
c
e

S
a
Reject
the lot
Accept
the lot
2 2 1
c d d +

2 2 1
c d d +

A
37
the lot the lot
I n s p e c t r a n d o m s a m p l e
n 1 = 5 0
n
1
=50 c
1
=1
n 1 = 5 0
d 1 = # d e f e c t i v e s o b s e r v e d
n
2
=100 c
2
=3
A c c e p t
L o t
R e j e c t
L o t
1 1
1 d c =
1 2
3 d c > =
1 1 2
1 3
c d c
d
<

I n s p e c t r a n d o m s a m p l e
n 2 = 1 0 0
d 2 # d f t i b d
1
1 3 d <
S
a
m
p
l
i
n
g
d 2 = # d e f e c t i v e s o b s e r v e d
A
c
c
e
p
t
a
n
c
e

S
A c c e p t
L o t
R e j e c t
L o t
1 2 2
3 d d c + =
1 2 2
3 d d c + > =
38
Average Sample Number Curve
The average sample number curve of a double-sampling
plan is also usually of interest to the quality engineer plan is also usually of interest to the quality engineer.
l l h f h l d f In single sampling, the size of the sample inspected from
the lot is always constant, whereas in double-sampling,
h f h l l d d d h h the size of the sample selected depends on whether or
not the second sample is necessary.
The probability of drawing a second sample varies with p y g p
the fraction defective in the incoming lot.
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With complete inspection of the second sample, the p p p ,
average sample size in double sampling is equal to the
size of the first sample times the probability that there p p y
will only be one sample, plus the size of the combined
samples times the probability that a second sample will p p y p
be necessary.
Therefore a general formula for the average sample Therefore, a general formula for the average sample
number in double sampling is
( )( )
( )
I I
P
P n n P n ASN + + =
1
1
2 1 1
( )
I
P n n + = 1
2 1
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Where P
I
is the probability of making a lot dispositioning
I
p y g p g
decision on the first sample.
The following figure shows the average sample number The following figure shows the average sample number
curves for single and double sampling.
Average sample
Double sampling
Averagesample
number
Double sampling
Single
sampling
n
sampling
n
n
1
Lot fraction defective
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Average Total Inspection Curve in Double- g p
Sampling
ATI=ASN+(N-n
1
)P(d
1
>c
2
)+(N-n
1
-n
2
)P(d
1
+d
2
>c
2
)
h where
P(d
1
>c
2
)=1-P(d
1
c
2
) and
P(d
1
+d
2
>c
2
)=1-P
a
-P(d
1
>c
2
)
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STANDARD SAMPLING PLANS
MIL-STD 105E:
St d d li d f i ti b Standard sampling procedures for inspection by
attributes were developed duringWorldWar II.
h d l d MIL-STD 105E is the most widely used acceptance
sampling system for attributes in the world today.
The original version of the standard, MIL-STD 105A,
was issued in 1950.
Since then, there have been four revisions; the latest
version, MIL-STD 105E, was issued in 1989.
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Th d d d f h f l l The standard provides for three types of sampling: single
sampling, double sampling, and multiple sampling.

For each type of sampling plan, a provision is made for yp p g p p

either normal inspection, tightened inspection,
or reduced inspection. p
In the following switching rules for normal tightened In the following, switching rules for normal, tightened,
and reduced inspection in MIL-STD 105E are shown:
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Switching Rules
A step-by-step procedure for using MIL-STD 105E is as
f ll follows:
1. Choose the AQL.
2. Choose the inspection level.
3. Determine the lot size.
4. Find the appropriate sample size code letter.
5. Determine the appropriate type of sampling plan to pp p yp p g p
use (single, double, multiple).
6. Enter the appropriate table to find the type of plan to pp p yp p
be used.
7. Determine the corresponding normal and reduced p g
inspection plans to be used when required.
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The Dodge-Romig Sampling Plans
H.F. Dodge and H.G. Romig have developed a set of
sampling inspection tables for lot-by-lot inspection of
product by attributes.
Two types of sampling plans are presented in the tables
plans for lot tolerance percent defective (LTPD) p p
protection and plan that provide a specified average
outgoing quality limit (AOQL). g g q y
For each of these approaches to sampling plan design,
there are tables for single and double sampling. g p g
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Th d OQ l d d h h The Dodge-Romig AOQL plans are designed so that the
average total inspection for a given AOQL and a
f d ll b d specified process average p will be minimized.
Similarly, the LTPD plans are designed so that the
average total inspection is a minimum. g p
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