5.2.7 Statistical Quality Tools: CONTROL CHARTS.

The Control Chart is the fundamental tool of statistical process control, as it indicates the range of variability that is built into a system (known as common cause variation). Thus, it helps determine whether or not a process is operating consistently or if a special cause has occurred to change the process mean or variance. Shewhart created the Control Chart in order to detect the presence of uncontrolled variation. Thus he provided both a simple but effective vehicle for the presentation of data and an operational definition of when a process is in trouble. The Control Chart seeks to determine if a sequence of data may be used for predictions of what will occur in the future. The bounds of the control chart are marked by Upper Control Limit and the Lower Control Limit and they are calculated by applying statistical formulas to data from the process. Data points that fall outside these bounds represent variations due to special causes, which can typically be found and eliminated. On the other hand, improvements in common cause variation require fundamental changes in the process A process that only has variation due to common or natural causes it is stable or in statistical control, no matter if its variability is much o a little, but is predictable in the in the immediate future. A process that has special or assignable causes of variation is it is out of control or instable. In an out of control process the future is unpredictable because in any moment these situations can occur and affect the process. A process will be considered out of control when more than 20% of the points are out off the Control Limits. There are two different types of Control Charts depending on the type of variable measured. If its a discrete variable (countable, integers without decimal numbers) you can use C Control Charts. If its a continuous variable (measurable with decimal numbers or fractions) you have to use a x-R Control Chart. Procedure: 1. Determine the appropriate time period for collecting and plotting data. 2. Choose the appropriate Control Chart: C or x-R depending on the type or variable (discrete or continuous).

For discrete variables (countable or integers): 3. Calculate the mean (average) for all the values dividing the number of the total addition divided by the quantity of data you have (n). 4. Calculate the Upper Control Limit = C + 3 C 5. Calculate the Lower Control Limit = C - 3 C 6. Draw the axes for the graph. The x-axis is for the Time and the y-axis is for the quantity. 7. Draw the Upper Control Limit with a non continuous line. 8. Draw the Lower Control Limit with a non continuous line it its a negative number draw it over de cero axe. 9. Plotter each data point. 10. Join the points with a line. 11. Circle the points out of the Control Limits. 12. Say if the process is out or control or not. 13. Give your conclusions and suggestions. For continuous variables (measurable, decimal or fractions): 3. Identify the number or quantity of each sample. 4. Calculate the mean (average) for each sample or subgroup dividing the total sum by the quantity of data. 5. Calculate the Overall Average (average of the averages): x x= n 6. Calculate de Range of each sample or subgroup by subtracting the biggest value form the lowest. 7. Calculate the Average of all the subgroups Ranges: R + R R= n + R +...+ R + x + x +...+x

8. Calculate the Control Limits for the x: UCL = x + A R LCL = x - A R 9. Calculate the Control Limits for the R: UCL = D R LCL = D R 10. Draw the Control Chart axes for the graph. The x-axis is for the Time and the y-axis is for the quantity. YOU ALWAYS HAVE TO PUT THE x GRAPH IN THE UPPER PART AND THE R BELOW IT. 11. Draw the Upper Control Limit with a non continuous line for the x and another for the R. 12. Draw the Lower Control Limit with a non continuous line for the x and another for the R it its a negative number draw it over de cero axe. 13. Plotter the average and the range for each period of time. 14. Join the average points with a line and the Range points with a line. 15. Circle the points out of the Control Limits. 16. Say if the process is out or control or not. 17. Give your conclusions and suggestions for the mean. 18. Give your conclusions and suggestions for the Range (dispersion).
(Look for the constants A , D , D in the Table for Control Chart constants, you must be careful when selecting the raw, thats the quantity of items sampled in each subgroup per time).

Note: If you need to calculate the standard deviation instead of doing it for each data using the formula, you can easily use the constant d from the table and you get the same value. R

= d

5.2.7.1. Control Charts: C Control Chart. 1. A factory that produces paint and solvents has a problem. Some workers were intoxicated. a) Draw a graph and analyze the variability of the intoxicated workers per month. b) Give conclusions. c) Suggest three probable causes of this problem. Propose an action plan for investigating or reducing the problem. Months 2010 January 2008 February 2008 March 2008 April 2008 Mayo 2008 June 2008 July 2008 August 2008 September 2008 October 2008 November 2008 December 2008 January 2009 February 2009 March 2009 April 2009 Mayo 2009 June 2009 Intoxicated workers

6 5 4 4 1 3 3 7 5 7 5 12 5 4 7 2 4 2

2. Analyze the detected defects found in at the final inspection of a 50 airplanes.

House number Quantity of defects. House number Quantity of defects.

1 7

2 6

3 6

4 7

5 4

6 7

7 8

8 12

9 9

10 9

11 8

12 5

13 5

14 9

15 8

16 15

17 6

18 4

19 13

20 7

21 8

22 15

23 6

24 6

25 10

26 7

27 13

28 4

29 5

30 9

House number Quantity of defects. House number Quantity of defects.

31 3

32 4

33 6

34 7

35 14

36 18

37 11

38 11

39 11

40 8

41 10

42 8

43 7

44 16

45 13

46 12

47 9

48 11

49 11

50 8

a) Draw a Control Graph for the first 25 airplanes. b) Draw a Control Graph for the airplane from 26th to 50th. (with the same scale that the first graph. c) Draw a Control Graph for the airplane from 26th to 50th. (with the same scale that the other graphs). d) Compare the three graphs and give you conclusions. Which will be the best option to control the process? e) Is the process out of control? Explain.

4.2.7.2 Control Charts: x-R Control Chart 2. Theres a factory where the rising water level is checked by a water level sensor with a pressure sensor. The pressure of the air in the plastic tube rises as it compressed by the rising water. The engineers want to make a Control Chart for controlling the pressure, They decided to take five lectures of the water level seven times a day and they made the next table.

09:15 a.m. 10:45 a.m. 12:15 p.m. 81.9 81.7 81.9 81.8 81.2 81.7 81.7 81.4 81.8 81.8 81.6 81.3 81.2 81.3 81.5

13:45 am 81.9 81.8 81.9 82.0 81.7

15:15 pm 81.8 81.2 81.8 82.3 81.5

16:45 pm 18:15 pm 81.2 81.6 81.5 81.5 81.9 81.5 81.6 81.8 82.0 81.2

a) Draw a Control Chart. b) Is the process out of control? Give your conclusions and suggestions.

2.- In a enterprise for doing cement, an important characteristic of the sacks is its weight, which has to be 50 Kg.. They want to check if the process is under control. A weigh sensor took samples of 4 sacks each hour for the next 24 hours, and they were registered as it is shown in the next table. Draw the graphic and analyze if the process is under control, give your conclusions.
Sample or Subgrup 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Sacks weight (Kg)

50.2 50.3 49.8 50.0 50.2 49.2 49.6 50.2 50.1 50.8 50.7 50.3 49.3 50.2 48.8 50.9 49.7 49.4 49.9 49.7 50.6 49.9 49.6 49.6 49.9 50.2 50.0 49.4 49.8 50.7 49.9 49.5 49.3 49.6 48.8 49.6 49.3 50.5 50.2 49.5 48.8 49.3 49.7 49.2 49.6 49.9 50.2 48.9 49.0 50.0 50.0 50.1 49.1 49.1 49.5 49.5 49.0 49.8 49.7 49.4 49.2 50.2 49.5 49.3 49.6 49.4 49.9 49.4 49.6 50.0 49.9 50.2 50.1 49.3 49.7 50.5 49.9 49.8 49.9 50.6 49.3 50.4 50.1 49.3 50.5 50.9 49.6 49.9 49.5 50.2 49.1 49.7 49.6 49.7 48.7 49.0

Mean

Range