MIE364H1S

Methods of Quality Control and Improvement

Course Instructor: Prof. V. Makis
Handout #1

A procedure of setting up control charts using historical data (should be recent

history).
Consider ( R, X ) charts. Data: X 1 ,..., X m and R1 ,..., Rm .
1. R chart with 3 sigma limits:
Calculate R , LCL = R D3 ( n), UCL = R D4 ( n), CL = R . If a point plots outside the
control limits:
a. A cause was found and was removed or disappeared delete the point
b. A cause was found and cannot be removed keep the point
c. No cause was found but not much information is available delete the
point
d. No cause was found and we are quite sure that there was none keep the
point
After deleting the points, recalculate Rnew , LCL new , and UCL new and plot the remaining
points again. If you still have points outside the control limits after several iterations (say,
2), there is a major problem with the process, causes should be found using other SPC
tools and removed. If all the points are between the limits, or you decide to keep the
R
points outside (b. or d.), find = FINAL and construct X chart using all historical data
d 2 ( n)
(unless n = 1). If you delete points on X chart, do not change . The rules a. to d. apply
also to X chart. 0 = X FINAL . Use the charts for future production and revise regularly.
Data in the table are the measurements of four consecutive units on an assembly line
taken every 30 minutes until 20 subgroups are obtained.

Subgroup
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

x1
72
56
55
44
97
83
47
88
57
13
26
46
49
71
71
67
55
49
72
61

x2
84
87
73
80
26
89
66
50
47
10
39
27
62
63
58
69
63
51
80
74

x3
79
33
22
54
48
91
53
84
41
30
52
63
78
82
69
70
72
55
61
62

x4
49
42
60
74
58
62
58
69
46
32
48
34
87
55
70
94
49
76
59
57

xbar
71
54.5
52.5
63
57.25
81.25
56
72.75
47.75
21.25
41.25
42.54
69
67.75
67
75
59.75
57.75
68
63.5

R
35
54
51
36
71
29
19
38
16
22
26
36
38
27
13
27
23
27
21
17

s
15.4704
23.64318
21.70253
16.8523
29.68024
13.27592
8.041559
17.23127
6.70199
11.35415
11.52895
15.7586
16.87207
11.52895
6.055301
12.72792
9.979145
12.41974
9.831921
7.325754

R Chart of x1, ..., x4

80
UCL=71.40

70

Sample Range

60
50
40
_
R=31.3

30
20
10
0

LCL=0
1

11
Sample

13

15

17

19

Xbar Chart of x1, ..., x4

90
UCL=82.24

80

Sample Mean

70
_
_
X=59.44

60
50
40

LCL=36.64

30
20

11
Sample

13

15

17

19

Xbar Chart of x1, ..., x4

90
UCL=84.25

Sample Mean

80

70
_
_
X=61.45

60

50

40

LCL=38.64
1

9
11
Sample

13

15

17

19

S Chart of x1, ..., x4

35
UCL=31.50

30

Sample StDev

25
20
_
S=13.90

15
10
5
0

LCL=0
1

11
Sample

13

15

17

19

Xbar Chart of x1, ..., x4

90
UCL=82.07

80

Sample Mean

70
_
_
X=59.44

60
50
40

LCL=36.81

30
20

11
Sample

13

15

17

19

Xbar Chart of x1, ..., x4

90
UCL=84.08

Sample Mean

80

70
_
_
X=61.45

60

50

40

LCL=38.82
1

9
11
Sample

13

15

17

19

(XBAR, S) Charts with Variable Sample (Group) Size

Data Display
Group
1
1
1
2
2
2
2
2
3
3
3
3
4
4
4
4

Data
72
84
79
49
56
87
33
42
55
73
22
60
44
80
54
74

Group
5
5
5
5
5
5
6
6
6
6
7
7
8
8
8
8

Data
97
26
48
58
83
89
91
62
47
66
53
58
88
50
84
69

Group
9
9
9
10
10
10
10
10
11
11
11
11
11
12
12
12

Data
57
47
41
46
13
10
30
32
26
39
52
48
46
27
63
34

Group
13
13
13
13
14
14
14
15
15
15
15
15
16
16
16

Data
49
62
78
87
71
63
82
55
71
58
69
70
67
69
70

Group
17
17
17
17
17
18
18
18
18
19
19
20
20
20
20
20
20

Data
94
55
63
72
49
49
51
55
76
72
80
61
59
61
74
62
57

S Chart of C2
40

Sample StDev

30

UCL=29.79

20

_
S=15.13

10

LCL=0.46

0
1

11
Sample

13

15

17

19

Tests performed with unequal sample sizes

Xbar Chart of C2
100
90

Sample Mean

80

UCL=78.91

70
_
_
X=59.44

60
50
40

LCL=39.97

30
1

20
1

11
Sample

13

15

17

19

Tests performed with unequal sample sizes

Use the estimate of from the S chart, delete X 10 , calculate new control limits
for the X chart and plot again. No change in S chart.