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National Guard
Black Belt Training
Module 26
Control Charts
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TOOLS
Process Mapping
ACTIVITIES
Map Current Process / Go & See Process Cycle Efficiency/TOC
Identify Key Input, Process, Output Metrics Littles Law
Develop Operational Definitions Operational Definitions
Develop Data Collection Plan Data Collection Plan
Validate Measurement System Statistical Sampling
Collect Baseline Data Measurement System Analysis
Identify Performance Gaps TPM
Estimate Financial/Operational Benefits Generic Pull
Determine Process Stability/Capability Setup Reduction
Complete Measure Tollgate Control Charts
Histograms
Constraint Identification
Process Capability
Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO
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Learning Objectives
Control chart fundamentals
Use of control charts to identify Common Cause and
Special Cause variation
Factors to consider in constructing control charts
Variables control charts
Attribute control charts
Understand the interpretation and application of these
charts
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15
_
10 X=10.58
5
LC L=2.67
3 6 9 12 15 18 21 24 27 30
10.0 U C L=9.71
7.5
Moving Range
5.0
__
M R=2.97
2.5
0.0 LC L=0
3 6 9 12 15 18 21 24 27 30
O bse r v ation
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_
10 X=10.58
5
LC L=2.67
3 6 9 12 15 18 21 24 27 30
O bse r v a tion
10.0 U C L=9.71
7.5
Moving Range
5.0
__
M R=2.97
2.5
0.0 LC L=0
3 6 9 12 15 18 21 24 27 30
O bse r v a tion
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Process Control
When a process is in control
This implies a stable, predictable amount of variation (common
cause variation)
This does not mean a "good" or desirable amount of variation
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Introduction to Xbar-R
Xbar-R Charts are a way of displaying variable data
Examples of variable data: width, diameter, temperature, weight,
time, etc.
R Chart: a look at Precision
Displays changes in the within subgroup dispersion of the
process. Often called Short-Term Variation.
Asks "Is the variation in the measurements within subgroups
consistent?
Must be in control before we can build or use the Xbar chart
Xbar Chart: a look at Accuracy
Shows changes in the average value of the process and is a
visualization of the Longer-Term Variation
Asks "Is the variation between the averages of the subgroups
more than that predicted by the variation within the subgroups?
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Double click on
C-1 Ave Hold Time
This places it in the 5
Variables box
Type in 5 for your
Subgroup size
Xbar Chart 12 _
_
X=10.88
10
8
LC L=6.79
1 2 3 4 5
Sample
16
U C L=15.01
12
Sample Range
R Chart 8 _
R=7.10
0 LC L=0
1 2 3 4 5
Sample
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I-MR Chart
The Individuals and Moving Range chart is also for
continuous data
It can be used for many transactional applications:
Revenue or cost tracking
Customer satisfaction
Call times
System response times
Wait times
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15
_
10 X=10.58
5
LC L=2.67
3 6 9 12 15 18 21 24 27 30
O bse r v ation
10.0 U C L=9.71
7.5
Moving Range
5.0
__
M R=2.97
2.5
0.0 LC L=0
3 6 9 12 15 18 21 24 27 30
O bse r v ation
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_ X
X=10.58
10
5
LCL
LCL=2.67
3 6 9 12 15 18 21 24 27 30
Observat ion
The UCL (Upper Control Limit) and the LCL (Lower Control Limit) are
calculated by Minitab using the sample/process data
The control limits approximate +/- 3 standard deviations (99+% of the data)
Here, 99+% of the pizzas are prepared between 2.6 and 18.7 minutes
Be careful not to confuse control limits and specification limits! If a data
point appears outside of the control limits, there is less than a 1% chance
that this was part of the normal process. Since it is very unlikely that this
value occurred by chance, it is called Special Cause variation.
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17.5 1
15.0 UCL=15.29
Individual Value
12.5
_
10.0 X=9.87
7.5 3 3
3 3 3
3 3 3
5.0
3 LCL=4.45
3 6 9 12 15 18 21 24 27
Observation
Individuals Chart
Plot each individual time measurement
Calculate the Centerline
The centerline on an Individuals chart is the overall average
Verify that the average is 9.6
The control limits will be calculated by a formula in Minitab. They
approximate +/- 3 standard deviations of the pizza prep times
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Pizza Exercise
Moving Range Chart
Calculate the ranges
The first range is between points 1 and 2
Range = Max - Min
12 - 7 = 5
The next range is between points 2 and 3
Range = Max - Min
11 - 7 = 4
Continue for the next 2 ranges
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3. Double click on
C1 Pizza Preparation
Time. This places it in
the Variables box.
4. Click OK
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15
_
10 X=10.58
5
LC L=2.67
3 6 9 12 15 18 21 24 27 30
O bser vation
10.0 U C L=9.71
7.5
M oving Range
5.0
__
M R=2.97
2.5
0.0 LC L=0
3 6 9 12 15 18 21 24 27 30
O bser vation
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Run:
Upper Control Limit A run is a series of points occurring
Center Line continually on one side of the center line. A
run of seven points is considered abnormal.
Lower Control Limit Also considered abnormal: 10 out of 11,12 of 14,
or 16 of 20 points on one
side of the center line.
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UCL
Approaching control limits:
CL 2 of 3 points lying outside the
2s line is considered abnormal.
LCL
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Next Steps
Identify assignable causes
Establish that the data are normally distributed
without the special cause data points
Circle the special causes
Eliminate special causes from the control limit
calculation
Recalculate control limits
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caused these
5
Out of Control LC L=2.52
7.5
5.0
__
MR=3.07
2.5
0.0 LC L=0
3 6 9 12 15 18 21 24 27 30
Observation
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Attribute Control
Charts
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Discrete/Attribute Data
To select an attribute chart, first choose between plotting defects or defective
units. Then decide between fixed or variable opportunity. The variable
opportunity charts are used more frequently.
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P-Chart
P-Charts should be used whenever we are monitoring
proportion defective (percentage defective is just another
proportion)
Some uses of the P-Chart in transactional applications would
be:
Billing errors (proportion of total bills that had errors)
Defective loan applications
Proportion of invoices with errors
Proportion of missing reservations
Defective room service orders
Missing items
Proportion of customers who were dissatisfied with service
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9
Proportion Defective 0.021
420
Note: Percentage Defective, in this case,
would be 2.1% defective
Calculate the proportion defective for days 2-5
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3. Double click on
C-4 Defective Pizzas.
This places it in the
Variables box.
4. Place cursor in the
Subgroups sizes box
and then double click on
C-5 Number of Pizzas
to move it there
5. Click OK
Note: Minitab calculates the proportion defective for us. We enter the
defective units in the Variable box. Then we enter the total units over
that time period in the Subgroup sizes box.
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P-Chart
P Chart of Defective Pizzas
0.05 1
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Individual V alue
15
_
10 X=10.69
1
10.0 U C L=10.04
M oving Range
7.5
5.0
0.0 LC L=0
Process is predictable
3 6 9 12 15 18 21 24 27 30
O bser vation
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7.5
Time = 15 Minutes
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Takeaways
Control limits are calculated from a time series of the characteristic we are
measuring
Different formulas are available, depending on the type of data
Control limits should not be recalculated each time data are collected
The control limits are a function of the sampling and subgrouping plan
Variation due to "assignable cause" is often the easiest variation to
reduce/eliminate
Control limits are not related to standards! Nor are they specifications!
Control limits are a measure of what the process is doing/has done. It is the
present/past tense, not the future (what we want the process to do or what it
has the potential to do)
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References
Wheeler, Donald J. & Chambers, David S.,
Understanding Statistical Process Control, Second
Edition, SPC Press, Knoxville Tennessee, 1992
Pruit, James M. & Snyder, Helmut, Essentials of SPC
in the Process Industries, Instrument Society of
America, 1996
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APPENDIX
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