SUBJECT

PRODUCTION
OF
MANAGEMENT
A
Presentation
on
STATISTICAL
QUALITY
CONTROL

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 Statistical quality control refers to the use of
statistical methods in the monitoring and
maintaining of the quality of products and
services.
Statistical quality control (SQC) is the term
used to describe the set of statistical tools used
by quality professionals.

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 Descriptive statistics include the mean,
standard deviation, and range.
Second method, referred to as acceptance
sampling, can be used when a decision
must be made to accept or reject a group
of parts or items based on the quality
found in a sample.
Third method, referred to as statistical
process control, uses graphical displays
known as control charts to determine
whether a process should be continued or
should be adjusted to achieve the desired
quality.

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 Variation exists in all processes.
Variation can be categorized as either:
Common or Random causes of variation, or
Random causes that we cannot identify

Unavoidable, e.g. slight differences in process

variables like diameter, weight, service time,

temperature.
Assignable causes of variation
Causes can be identified and eliminated: poor
employee training, worn tool, machine
needing repair.

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 Statistical process control uses sampling and
statistical methods to monitor the quality of an
ongoing process such as a production
operation.
A graphical display referred to as a control
chart provides a basis for deciding whether
the variation in the output of a process is due
to common causes (randomly occurring
variations) or to out-of-the-ordinary assignable
causes.
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 Whenever assignable causes are
identified, a decision can be made to
adjust the process in order to bring
the output back to acceptable quality
levels.

Control charts can be classified by

the type of data they contain. For
instance, an x-chart is employed in
situations where a sample mean is
used to measure the quality of the
output.
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 Quantitative data such as length,
weight, and temperature can be
monitored with an x-chart. Process
variability can be monitored using a
range or R-chart.

In cases in which the quality of

output is measured in terms of the
number of defectives or the
proportion of defectives in the
sample, an np-chart or a p-chart can
be used.
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 StatisticalProcess
Control (SPC)
monitoring production
process to detect and
prevent poor quality
UCL
Sample
subset of items
produced to use for
inspection
LCL
Control Charts
process is within
statistical control limits

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Random Non-Random

inherent in a process special causes

depends on equipment and machinery, identifiable and correctable

engineering, operator, and system of
measurement

natural occurrences include equipment out of adjustment,

defective materials, changes in parts or
materials, broken machinery or equipment,
operator fatigue or poor work methods, or
errors due to lack of training

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 Control Charts (aka process or QC
charts) show sample data plotted on a
graph with CL, UCL, and LCL
Control chart for variables are used to
monitor characteristics that can be
measured, e.g. length, weight, diameter,
time
Control charts for attributes that are used
a product characteristic that can be
evaluated with a discrete response
good bad; yes - no

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 Out of control
Upper
control
limit

Process
average

Lower
control
limit

1 2 3 4 5 6 7 8 9 10
Sample number
x-bar charts
It is used to monitor the changes in the
mean of a process (central tendencies).

R-bar charts
It is used to monitor the dispersion or
variability of the process

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 A factory produces 50 cylinders per hour. Samples of 10
cylinders are taken at random from the production at every
hour and the diameters of cylinders are measured. Draw X-bar
and R charts and decide whether the process is under control
or not.

(For n=4 A2= 0.73 D3= 0, D4=2.28)

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Sample no. x1 x2 x3 x4

1 230 238 242 250

2 220 230 218 242
3 222 232 236 240
4 250 240 230 225
5 228 242 235 225
6 248 222 220 230
7 232 232 242 242
8 236 234 235 237
9 231 248 251 271
10 220 222 224 231
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Sample x1 x2 x3 x4 Sigma Mean Range
no. Xi X-bar R
1 230 238 242 250 960 240.00 20
2 220 230 218 242 910 227.50 24
3 222 232 236 240 930 232.50 18
4 250 240 230 225 945 236.25 25
5 228 242 235 225 930 232.50 17
6 248 222 220 230 920 230.00 28
7 232 232 242 242 948 237.00 10
8 236 234 235 237 942 235.50 3
9 231 248 251 271 1001 250.25 40
10 220 222 224 231 897 224.25 11
Total 2345.75 196

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 Now,

x
x 2345.75
234.75
m 10

R
R 196
19.6
m 10

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 Central line C.L =
x 234.75
U.C.L = x A2 * R
=234.75 + (0.73) (19.6)
=249.06

L.C.L= x A2 * R
=234.75- (0.73) (19.6)
=220.72

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 Central Line = R 19.6

U.C.L = D 4 R (2.28) * (19.96)

=45.50

L.C.L = D3R (0) * (19.96)

=0

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 Attributes are discrete events; yes/no,
pass/fail
Use P-Charts for quality
characteristics that are discrete and
involve yes/no or good/bad decisions
Number of leaking caulking tubes in a
box of 48
Number of broken eggs in a carton

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 UCL = p + zp
LCL = p - zp

z = number of standard deviations from

process average
p = sample proportion defective; an estimate
of process average
p = standard deviation of sample proportion

p (1 - p)
p = n
 A Production manager of a BKT tire company has inspected
the number of defective tires in five random samples with 20
tires in each sample. The table below shows the number of
defective tires in each sample of 20 tires. Calculate the
control limits.

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 Evaluating the ability of a production process
to meet or exceed preset specifications. This
is called process capability.

Product specifications, often called

tolerances, are preset ranges of acceptable
quality characteristics, such as product
dimensions.

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 1)Measure the variability of the output of a
process, and

2)
Compare that variability with a proposed
specification or product tolerance.

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 Toproduce an acceptable product, the
process must be capable and in control
before production begins.

USL LSL
Cp
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Cpk helps to address a possible
lack of centering of the process.

USL LSL
Cpk min ,
3 3

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 Three possible ranges for Cp

Cp = 1, as in Fig. (a), process

variability just meets specifications

Cp 1, as in Fig. (b), process not capable

of producing within specifications

Cp 1, as in Fig. (c), process

exceeds minimal specifications

Oneshortcoming, Cp assumes that the

process is centered on the specification
range

Cp=Cpk when process is centered

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 The table below shows the information gathered from production
runs on each machine. Are they all acceptable?
solution:
MACHINE USL-LSL 6 Machine A
USL LSL .4
1.33
A 0.05 .4 .3 Cp
6 6(.05)

B .1 .4 .6
C .2 .4 1. Machine B

cp=

Machine c

cp=

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 Design specifications call for a
target value of 16.0 0.2 OZ.
(USL = 16.2 & LSL = 15.8)
Observed process output has now
shifted and has a of 15.9 and a
of 0.1 oz.

16.2 15.9 15.9 15.8

Cpk min
,

3(.1) 3(.1)
.1
Cpk .33
.3

Cpk is less than 1, revealing that

the process is not capable

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 Honda Statistical Process Control.mp4

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