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X-Bar and R Control Charts

X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Control Chart
In Statistical Control
Out of Control
Assignable Cause
Types the control charts
Process Flowchart
PFMEA
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Guidelines for the Design of the Control Chart
Specify sample size, control limit width, and frequency of sampling
If the main purpose of the x-bar chart is to detect moderate to large process
shifts, then small sample sizes are sufficient (n = 4, 5, or 6)
If the main purpose of the x-bar chart is to detect small process shifts, larger
sample sizes are needed (as much as 15 to 25)
If increasing the sample size is not an option, then sensitizing procedures can
be used to detect small shiftsbut this can result in increased false alarms.
R chart is insensitive to shifts in process standard deviation. Try S or S
2
chart.
The OC curve can be helpful in determining an appropriate sample size.
In general, small frequent samples are more desirable.
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Interpreting patterns in X-Bar and R Control Charts
General rules to determine whether a process is in control:
No points outside the control limits.
The number of points above and below the center line are about the same.
Points seem to fall randomly above and below the center line.
Most points are near center line, and only a few are close to control limits.
One point outside control limits:
measurement or calculation error, power surge, a broken tool, incomplete
operation.
Sudden shift in process average:
new operator or inspector, new machine setting.
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Cycles:
Operator rotation or fatigue at the end of shift, different gauges, seasonal
effects such as temperature and humidity.
Trends:
x-bar-chart learning effect, dirt or chip buildup, tool wear, aging of equipment;
R-chart (increasing trend) gradual decline in material quality; R-chart
(decreasing trend) improved skills, better materials.
Hugging the center line:
sample taken over various machines canceling out the variation within the
sample.
Instability:
difficult to identify causes. Typically, over-adjustment of machine.
Always, R-chart analysis before the x-bar-chart analysis.
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Estimating the Process Standard Deviation
The process standard deviation can be estimated using a function of the sample
average range.
This is an unbiased estimator of
2

d
R

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X-Bar and s Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
s-Control Chart
For the x-bar control chart in this case

5
4
6
B LCL
C CL
B UCL

m
i
i
s
m
s
1
1
s B LCL
s CL
s B UCL
3
4

1
) (
1
2

n
x x
s
n
j
ij
i
s A X LCL
X CL
s A X UCL
3
3

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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
What if you could not get a sample size greater than 1 (n =1), such in
Automated inspection and measurement technology is used, and every unit
manufactured is analyzed.
The production rate is very slow, and it is inconvenient to allow samples sizes
of N > 1 to accumulate before analysis
The X and MR charts are useful for samples of sizes n = 1.
Moving Range Chart
The moving range (MR) is defined as the absolute difference between two
successive observations:
MR
i
= |x
i
- x
i-1
|
which will indicate possible shifts or changes in the process from one
observation to the next.
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
X and Moving Range Charts
The X chart is the plot of the individual observations. The control limits are
Where
The control limits on the moving range chart are:
2
2
3
3
d
MR
x LCL
x CL
d
MR
x UCL

1
1

m
MR
MR
m
i
i
0
4

LCL
MR CL
MR D UCL
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Interpretation of the X and MR Charts
X Charts can be interpreted similar to x-bar charts. MR charts cannot be
interpreted the same as x-bar or R charts.
Since the MR chart plots data that are correlated with one another, then
looking for patterns on the chart does not make sense.
MR chart cannot really supply useful information about process variability.
More emphasis should be placed on interpretation of the X chart. The X chart is
the plot of the individual observations. The control limits are
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X-Bar and R Control Charts
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Control vs. Specification
Limits
Control limits are derived from
natural process variability, or the
natural tolerance limits of a process
Specification limits are determined
externally, for example by
customers or designers
There is no mathematical or
statistical relationship between the
control limits and the specification
limits
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Examples
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
Packages of corn oil bottle are filled by a machine and weighed. The
weights (in ounces) for 15 successive bottles have been collected and are
displayed in following table . The engineer wishes to determine whether the
filling process is in control.
MR
i
= |x
i
- x
i-1
|
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Examples
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples
The x-bar control chart limit in this case are
Based on n=1 where is approximated in the constant table from the first row
as n=2 (d
2
= 1.128 , D
4
= 3.267)
The moving range control limits are
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Examples
X-Bar and R
Control
Charts
Industrial Engineering
MR and s
Control
Charts
Examples