Topic 9.

0 : Statistical Process
Control For Variables Data
1. Statistical Fundamentals
2. Process Control Charts / SPC
3. Some Control Chart Concepts for
Variables
4. Process Capability for Variables
5. Other Statistical Techniques in Quality
Management
Topic 10.0 : Statistical
Process Control For
Attributes Data
1. What is an Attribute
2. Generic Process for developing structure
Charts
3. Understanding Attributes Control Charts
4. Choosing the Right Attributes Chart
Statistical
Fundamentals
1. What Is Statistical
Thinking
Is a decision-making skill demonstrated by the
ability to draw conclusions based on data.
Statistical thinking is based on three concepts:

All work occurs in a system of

interconnected processes.
All processes have variation (the amount of
variation tends to be underestimated).
Understanding variation and reducing
variation are important keys to success.
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2. Why Do Statistics Sometimes
Fail in the Workplace?
Lack of knowledge about the tools.
General disdain for all things mathematical
creates a natural barrier to the use of statistics.

4
3. What Do We Mean by the Term
Statistical Quality Control?

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4. Understanding Process
Variation
Processes involve variation. Some
variation can be managed and some
cannot.
If too much variation, the process not fit
correctly, product not function properly,
and firms will get bad reputation/image.
TWO types of variation commonly occur:
1.Random variation
2.Non-random
variation

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Random
Is uncontrollable
Variation
In centered around a mean and
occurs with a somewhat
consistent amount of dispersion.
The amount of random variation
in a process may be either large
or small

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Non-Random
Variation
The event may be
shift in a process
mean or some
unexpected
occurrence.

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Process Stability
Means that the variation we
observe in the process is random
variation (common cause) and
not nonrandom variation.
To determine process stability,
we use process chart.
Process charts are graphs
designed to signal process
workers when nonrandom
variation is occurring in a 9
Process Control Charts / Statistical
Process Control (SPC)
A methodology for monitoring a
process to identify special causes of
variation and signal the need to take
corrective action when appropriate
SPC relies on control charts

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Histograms vs. Control
Charts
Histograms do not take into account changes over
time.
Control charts can tell us when a process changes
Control Chart Applications
Establish state of statistical control
Monitor a process and signal when it
goes out of control
Determine process capability

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Process capability calculations make
little sense if the process is not in
statistical control because the data
are confounded by special causes
that do not represent the inherent
capability of the process.
Capability Versus Control

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Commonly Used Control
Charts
Variables data
x-bar and R-charts
x-bar and s-charts
Charts for individuals (x-charts)
Attribute data
For defectives (p-chart, np-
chart)
For defects (c-chart, u-chart)

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 Variables data
Is a continuous measurement
such as weight, height, or
volume.

Attribute data
Is an either-or situation OK or
Not OK, Good or Bad

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Developing Control Charts
1. Prepare
Choose measurement
Determine how to collect data, sample
size, and frequency of sampling
Set up an initial control chart
2. Collect Data
Record data
Calculate appropriate statistics
Plot statistics on chart
3. Determine trial control limits
Center line (process average)
Compute UCL, LCL
4. Analyze and interpret results
Determine if in control
Eliminate out-of-control points
Recompute control limits as
necessary
5. Use as a problem-solving tool
Continue to collect and plot data
Take corrective action when
necessary
6. Compute process capability
Important Remark
When a process is in statistical
control, the points on a control chart
fluctuate randomly between the
control limits with no recognizable
pattern.
General Procedure for
Developing Process Charts
Identify critical operations
(Variable

@ Attribute)
Identify critical product
characteristics
Determine whether variable @
attribute
Select the appropriate chart
Establish control limits
Update limit.
Typical Out-of-Control Patterns
(Interpreting Control Charts)
Point outside control limits
Sudden shift in process average
Cycles
Trends
Hugging the center line
Hugging the control limits
Instability

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Shift in Process Average
Identifying Potential Shifts
Cycles
Trend
Important Remark
Control charts indicate when to take
action, and more importantly, when
to leave a process alone.
Process Capability
Calculations
Special Variables Control Charts
x-bar and R charts
X and Moving Range (MR)
charts
Charts for Attributes
Fraction nonconforming (p-chart)
Fixed sample size
Variable sample size

np-chart for number nonconforming

Charts for defects

c-chart
u-chart
Control Chart Formulas
Control Chart Design Issues
Basis for sampling
Sample size
Frequency of sampling
Location of control limits

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In determining the method of
sampling, samples should be chosen
to be as homogeneous as possible so
that each sample reflects the system
of common causes or assignable
causes that may be present at that
point in time.
In practice, samples of about five
have been found to work well in
detecting process shifts of two
standard deviations or larger. To
detect smaller shifts in the process
mean, larger sample sizes of 15 to 25
must be used.
See Figure Below
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Latihan Berdasarkan Data Sediakan
Carta Kawalan
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
Attribute Chart
See Figure on the page INITIAL STAGE
See Figure on the page INITIAL
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
See Figure on page 66
See Figure on page 66
See Figure on page 66
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
Cont
 FIGURE 33 SHEET

Che Azlan Taib, Uni. Utara Malaysia

c.azlan@uum.edu.my
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my
(See above figure)
(See above figure)
Che Azlan Taib, Uni. Utara Malaysia
c.azlan@uum.edu.my