6/22/2015

Chapter 5 (Week 7)
Random Sample & CLT, Normal
Approximation & X bar R Charts
Dr. S.Rajalingam

L2 & L3 - X-bar and R Charts

Learning Outcomes
At the end of the lesson student should be able to

Understand the concept of SPC especially for

X-bar and R charts
Calculate and plot X-bar and R charts
Calculate the process mean and standard
deviation
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Introduction to Statistical Process Control

(SPC)
What is Quality Control?:

Quality control is designed to prevent the production of

products that do not meet certain acceptance criteria
(spec).
Action could be taken by rejecting those products.

Scrap or re-work.

In

most of the case re-worked will be more costly and

time consuming.
Thus results in decreased productivity, customer
dissatisfaction, loss of competitive position, and
higher cost.
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What is Quality Control?:

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What is Quality Control?:

Introduction - SPC

Statistical process control (SPC), is a powerful

tools that implement the concept of prevention as a
shift from the traditional quality by
inspection/correction.

SPC is a technique that employs statistical tools for

controlling and improving processes.

SPC is an important ingredient in continuous

process improvement (CPI) strategies. It uses
simple statistical means to control, monitor, and
improve processes.
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Introduction - SPC

Among the most commonly used tools of

SPC (7QC tools):
Histograms
Cause-and-effect

diagrams

Pareto

diagrams
Control charts
Scatter diagrams
Flow charts
Check sheet
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Control Chart

The most important SPC tool is called control

charts:
graphical

representations of process performance over

time
concerned

with how (or whether) processes vary at

different intervals and identifying nonrandom or
assignable causes of variation.

provide

a powerful analytical tool for monitoring process

variability and other changes in process mean

Sample 1 - Control Chart

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Sample 2 Control Chart

11

X-bar,

and R Charts

X and Range, R Charts are a set of control charts for

variables data (data that is both quantitative and
continuous in measurement, such as a measured
dimension or time).

The X chart monitors the process location over time,

based on the average of a series of observations,
called a subgroup.

The Range chart monitors the variation between

observations in the subgroup over time.

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Sample : X-bar and R Charts

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When to Use an X-bar and R Chart

X - R charts are used when you can rationally collect

measurements in groups (subgroups) of between two

and ten observations.

The charts' x bar -axes are time based, so that the

charts show a history of the process.

The data is time-ordered; that is, entered in the

sequence from which it was generated.

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How to draw - X Bar and R Charts

x Chart Control Limits
UCL = x + A 2 R
LCL = x - A 2 R

R Chart Control Limits

UCL = D 4 R
LCL = D 3 R

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Construct X-bar and R chart - Example

The following collection of data represents
samples of the amount of force applied in a
gluing process:
Determine if the process is in control by
calculating the appropriate upper and lower
control limits of the X-bar and R charts.

Samples - Data
Sample
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Obs 1
10.68
10.79
10.78
10.59
10.69
10.75
10.79
10.74
10.77
10.72
10.79
10.62
10.66
10.81
10.66

Obs 2
10.689
10.86
10.667
10.727
10.708
10.714
10.713
10.779
10.773
10.671
10.821
10.802
10.822
10.749
10.681

Obs 3
10.776
10.601
10.838
10.812
10.79
10.738
10.689
10.11
10.641
10.708
10.764
10.818
10.893
10.859
10.644

Obs 4
10.798
10.746
10.785
10.775
10.758
10.719
10.877
10.737
10.644
10.85
10.658
10.872
10.544
10.801
10.747

Obs 5
10.714
10.779
10.723
10.73
10.671
10.606
10.603
10.75
10.725
10.712
10.708
10.727
10.75
10.701
10.728

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Step 1. Calculate sample means, sample ranges,

mean of means, and mean of ranges.
Sample
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Obs 1
10.68
10.79
10.78
10.59
10.69
10.75
10.79
10.74
10.77
10.72
10.79
10.62
10.66
10.81
10.66

Obs 2
10.689
10.86
10.667
10.727
10.708
10.714
10.713
10.779
10.773
10.671
10.821
10.802
10.822
10.749
10.681

Obs 3
10.776
10.601
10.838
10.812
10.79
10.738
10.689
10.11
10.641
10.708
10.764
10.818
10.893
10.859
10.644

Obs 4
10.798
10.746
10.785
10.775
10.758
10.719
10.877
10.737
10.644
10.85
10.658
10.872
10.544
10.801
10.747

Obs 5
10.714
10.779
10.723
10.73
10.671
10.606
10.603
10.75
10.725
10.712
10.708
10.727
10.75
10.701
10.728
Averages

Avg
10.732
10.755
10.759
10.727
10.724
10.705
10.735
10.624
10.710
10.732
10.748
10.768
10.733
10.783
10.692

Range
0.116
0.259
0.171
0.221
0.119
0.143
0.274
0.669
0.132
0.179
0.163
0.250
0.349
0.158
0.103

10.728 0.220400

Definition
The average X - calculated from a set of n data
values as:

Sub-grouped data:
the average of the subgroups' averages,
sometimes called the estimate process mean,

where n is the subgroup size and m is the total number of

subgroups included in the analysis.

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Step 2. Determine Control Limit Formulas

and Necessary Tabled Values
x Chart Con trol Limit s
n
2
3
4
5
6
7
8
9
10
11

UCL = x + A 2 R
LCL = x - A 2 R
R Chart Co ntrol Limi ts
UCL = D 4 R
LCL = D 3 R

A2
1.88
1.02
0.73
0.58
0.48
0.42
0.37
0.34
0.31
0.29

D3
0
0
0
0
0
0.08
0.14
0.18
0.22
0.26

D4
3.27
2.57
2.28
2.11
2.00
1.92
1.86
1.82
1.78
1.74

where the constant A2, D3 and D4 are tabulated for various

sample sizes in Appendix A Table VII.

Steps 3&4. Calculate x-bar Chart and Plot

Values
UCL = x + A2 R 10.728 0.58( 0.2204 )=10.856
LCL = x - A2 R 10.728-0.58( 0.2204 )=10.601
10.900
10.850

Means

10.800
10.750
10.700

Sample
mean
UCL

10.650

LCL

10.600

grand
mean of x

10.550
1

10

11

12

13

14

15

Sample

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Definition
Average Range - The average of the
subgroup ranges (R-bar) centre line

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Steps 5&6: Calculate R-chart and Plot

Values
UCL = D4 R ( 2.11)(0.2204) 0.46504
LCL = D3 R (0)(0.2204) 0
0.800
0.700
0.600
0.500

Range
UCL
LCL
R-bar

R 0.400
0.300
0.200
0.100
0.000
1

10 11 12 13 14 15

Sample

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Process Mean and Process

Standard Deviation

Estimated

Process mean:
by

i 1

Process standard deviation:

Estimated

by

r
d2

where d 2

3
A2 n
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Example 2- (8-1) page 427

A component part for a jet aircraft engine is manufactured
by an investment casting process. The vane opening on
this casting is an important functional parameter of the part.
We will illustrate the use of
and R control charts to
assess the statistical stability of this process. The table
presents 20 samples of five parts each. The values given in
the table have been coded by using the last three digits of
the dimension; that is, 31.6 should be 0.50316 inch.
(a) Construct
and R control charts.
(b) After the process is in control, estimate the process
mean and standard deviation.
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Sample Number

x1

x2

x3

x4

x5

33

29

31

32

33

31.6

r
4

33

31

35

37

31

33.4

35

37

33

34

36

35.0

30

31

33

34

33

32.2

33

34

35

33

34

33.8

38

37

39

40

38

38.4

30

31

32

34

31

31.6

29

39

38

39

39

36.8

10

28

33

35

36

43

35.0

15

10

38

33

32

35

32

34.0

11

28

30

28

32

31

29.8

12

31

35

35

35

34

34.0

13

27

32

34

35

37

33.0

10

14

33

33

35

37

36

34.8

15

35

37

32

35

39

35.6

16

33

33

27

31

30

30.8

17

35

34

34

30

32

33.0

18

32

33

30

30

33

31.6

19

25

27

34

27

28

28.2

20

35

35

36

33

30

33.8

6
27

Solution
The quantities
are shown at the foot of Table
8-1. The value of A2 for samples of size 5 is
. Then the
trial control limits for the
chart are

or

For the R chart, the trial control limits are

n
2
3
4
5
6
7
8
9
10
11

A2
1.88
1.02
0.73
0.58
0.48
0.42
0.37
0.34
0.31
0.29

D3
0
0
0
0
0
0.08
0.14
0.18
0.22
0.26

D4
3.27
2.57
2.28
2.11
2.00
1.92
1.86
1.82
1.78
1.74

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The

and R control charts for vane opening

29

Note that samples 6, 8, 11, and 19 are out of control on

the chart and that sample 9 is out of control on the R
chart.

Suppose that all of these assignable causes can be traced

to a defective tool in the wax-molding area. We should
discard these five samples and recomputed the limits for
the and R charts.

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The revised limits are, for the

chart is,

and for the R chart is,

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and R control charts for vane opening, revised limits

32

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(b)

The estimate process mean is (revised data)

m

x
i 1

33.21

The estimate process SD is (revised data)

d2

3
A2 n

3
2.325
(0.577)( 5 )

r
5

2.15
d 2 2.325
33

END

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