ENGR 3215

LECTURE 6
CHAPTER 6.2 & 8.3 (WITH OTHER REFERENCES)

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WHAT IS QUALITY CONTROL?

QUALITY CONTROL IS A SYSTEM DEVELOPED TO MAINTAIN

UNIFORM STANDARDS OF PRODUCTION QUALITY AT MINIMUM
COST LEVELS

• AID TO ACHIEVING CORPORATE EFFICIENCY

• TECHNICAL ACTIVITY AND MANAGEMENT WHICH IS
MEASURED BY CHARACTERISTICS OF PRODUCT QUALITY,
COMPARE IT WITH THE SPECIFICATION OR REQUIREMENTS
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Taken from: www.iosrjournals.org/iosr-jpte/papers/Vol4-Issue5/E04052331.pdf; 2/13/19

WHAT IS STATISTICAL QUALITY CONTROL?

• A SYSTEM BASED ON THE LAWS OF PROBABILITY

• A SYSTEM FOR CONTROLLING THE QUALITY OF
PRODUCTION WITHIN THE LIMITS SPECIFIED BY A
SAMPLING PROCEDURE AND AN ANALYSIS OF THE
RESULTS OF THE EXAMINATION

Taken from: www.iosrjournals.org/iosr-jpte/papers/Vol4-Issue5/E04052331.pdf; 2/13/19

WHY IS STATISTICAL QUALITY CONTROL USED?

• TO INVESTIGATE RAPIDLY THE OCCURRENCE OF

UNPREDICTABLE CAUSES OR SLIPS IN THE PROCESS

• TO ALLOW INVESTIGATION OF A PROCESS AND

CORRECTIVE ACTION TO BE PERFORMED BEFORE
MANY DEFECTIVE UNITS ARE PRODUCED/PROCURRED

• TEXT – REMOVE OR REDUCE PROCESS DIVERSITY

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Taken from: www.iosrjournals.org/iosr-jpte/papers/Vol4-Issue5/E04052331.pdf; 2/13/19

TYPES OF STATISTICAL QUALITY CONTROL

TWO TYPES OF STATISTICAL QUALITY CONTROL:

• PROCESS CONTROL – CONTROL CHARTS AND OTHER
QUALITY TOOLS ARE USED

• PRODUCT CONTROL – ACCEPTANCE SAMPLING IS

USED

Taken from: www.iosrjournals.org/iosr-jpte/papers/Vol4-Issue5/E04052331.pdf; 2/13/19

CONTROL CHART VARIATION SOURCES
• SPECIAL CAUSES – CAUSES ARE OUTSIDE THE QUALITY
MANAGEMENT SYSTEM – EQUIPMENT MISUSE, OPERATOR
ERROR, MISUSE OF RAW MATERIALS, ETC. – USUALLY ~15% OF
ERRORS - REQUIRES REVISION OF AVERAGE AND LIMITS

• COMMON CAUSE – FACTORS IN THE QUALITY MANAGEMENT

SYSTEM, VARIABILITY – DAMAGE TO PRODUCTION MACHINERY,
DELAY OF RAW MATERIALS, UNSTABLE WORKING CONDITIONS,
ETC. – USUALLY ~85% OF ERRORS – NO REVISION NEEDED
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Taken from: www.iosrjournals.org/iosr-jpte/papers/Vol4-Issue5/E04052331.pdf; 2/13/19

WHEN IS A PROCESS IN CONTROL?

• A PROCESS IS SAID TO OPERATE IN CONTROL WHEN

VARIATIONS EXIST ONLY FROM THE COMMON CAUSE
VARIATION

Taken from: www.iosrjournals.org/iosr-jpte/papers/Vol4-Issue5/E04052331.pdf; 2/13/19

WHAT IS PROCESS CAPABILITY?

• THE CAPABILITY OF A PROCESS, STATISTICALLY SPEAKING, IS

THE ABILITY OF THAT PROCESS – BASED ON HISTORICAL
PERFORMANCE – TO ACHIEVE MEASURABLE RESULTS THAT
SATISFY ESTABLISHED SPECIFICATIONS AND STATISTICAL
LIMITS. (ASSUMES PROCESS IS STABLE AND NORMAL DIST)

• PROCESS CAPABILITY INDICATES HOW WELL A PROCESS IS

ABLE TO PERFORM ITS SPECIFIED PURPOSE.

Taken from: www.isixsigma.com/resource-pages/competently-use-capability-analysis/; 2/12/19

OBJECTIVES IN A PROCESS CAPABILITY STUDY

TWO OBJECTIVES:
• MEASURE VARIABILITY OF PROCESS OUTPUT;
• COMPARE THE VARIABILITY TO PRODUCT TOLERANCE

Taken from: www.isixsigma.com/resource-pages/competently-use-capability-analysis/; 2/12/19

 WHY IS PROCESS CAPABILITY IMPORTANT?

WHEN THE CAPABILITY OF A PROCESS IS UNDERSTOOD AND

DOCUMENTED, IT CAN BE USED FOR MEASURING CONTINUAL
IMPROVEMENT:

• USING TRENDS OVER TIME;

• PRIORITIZING THE ORDER OF PROCESS IMPROVEMENT TO BE MADE; &

• DETERMINING WHETHER OR NOT A PROCESS IS CAPABLE OF MEETING
CUSTOMER REQUIREMENTS
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Taken from: www.isixsigma.com/resource-pages/competently-use-capability-analysis/; 2/12/19

PROCESS CAPABILITY RELATES TO CONTROL LIMITS

• ONLY WHEN A PROCESS IS IN STATISTICAL CONTROL IS IT POSSIBLE

TO ASSESS WHETHER THE PROCESS IS CAPABLE OF OR UNABLE TO
MEET PREDETERMINED SPECIFICATIONS
• THE RATIO OF PROCESS CAPABILITY OR CP INDEX RELATES THE
PROCESS DIFFERENCE (THE DIFFERENCE BETWEEN THE LIMITS OF
SCIENTIFIC TOLERANCE) TO THE DIFFERENCE BETWEEN THE BOUNDS
OF THE TWO-SIDED SPECIFICATION

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Taken from: www.isixsigma.com/resource-pages/competently-use-capability-analysis/; 2/12/19

PROCESS CAPABILITY RELATES TO CONTROL LIMITS

• ONLY WHEN A PROCESS IS IN STATISTICAL CONTROL IS IT POSSIBLE

TO ASSESS WHETHER THE PROCESS IS CAPABLE OF OR UNABLE TO
MEET PREDETERMINED SPECIFICATIONS
• THE RATIO OF PROCESS CAPABILITY OR CP INDEX RELATES THE
PROCESS DIFFERENCE (THE DIFFERENCE BETWEEN THE LIMITS OF
SCIENTIFIC TOLERANCE) TO THE DIFFERENCE BETWEEN THE BOUNDS
OF THE TWO-SIDED SPECIFICATION

Cpk takes off-centeredness into consideration 12

Taken from: www.isixsigma.com/tools-templates/capability-indices-process-capability/cp-cpk-pp-and-ppk-know/; 2/12/19

A PROCESS CAPABILITY EXAMPLE

• A MEASURE OF THE ABILITY

OF A PROCESS TO
PRODUCE CONSISTENT
RESULTS AND MEET
SPECIFICATIONS – THE
RATIO BETWEEN THE
PERMISSIBLE SPREAD AND
THE ACTUAL SPREAD OF A
PROCESS

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Taken from: www.isixsigma.com/resource-pages/competently-use-capability-analysis/; 2/12/19

ESTIMATING PROCESS CAPABILITY (CP)

• THE X VALUE GIVES THE MEAN OF OUR INDEPENDENT

VARIABLE

• THE STANDARD DEVIATION IS GIVEN BY

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EXAMPLE 6.1 FROM TEXT – USED FOR HOMEWORK

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ESTIMATING PROCESS CAPABILITY (CP)

Xbar+/-variability

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HOMEWORK PROBLEMS FOR 2/17

CHAPTER 6
• 6.6
• 6.8
• 6.10
• 6.18
• 6.42
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WHEN TO USE XBAR R VERSUS XBAR S CHARTS

HOMEWORK #1 PROBLEM ASKED THIS QUESTION – TO SEE HOW YOU

WOULD THINK ABOUT IT

• YOU WERE ASKED WHY YOUR CHARTS WERE NOT THE SAME – WHAT
CAUSED ONE CHART TO BE IN CONTROL AND THE OTHER TO BE OUT
OF CONTROL

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WHEN TO USE XBAR R VERSUS XBAR S CHARTS

• HOMEWORK - YOU ARE BEING JUDGED ON THE LEVEL OF

THOUGHT THAT YOU PUT INTO YOUR ANSWER – NOT RIGHT OR
WRONG

• THE DECISION OF WHICH CHART TO USE COMES DOWN TO

HOW WELL THE AVERAGE RANGE AND AVERAGE STANDARD
DEVIATION ESTIMATE THE POPULATION

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Taken from: https://andrewmilivojevich.com/xbar-r-chart-versus-xbar-s-chart/; 2/13/19

WHEN TO USE XBAR R VERSUS XBAR S CHARTS

• 50 SUBGROUPS WERE GENERATED WITH 15 SAMPLES IN EACH SUBGROUP

USING A MEAN OF 50 AND STANDARD DEVIATION OF 5. IN TOTAL,
THERE WERE 750 VALUES.

• SIMULATED VALUES USING MEAN = 50 AND STANDARD DEVIATION = 5

• FOR EACH SUBGROUP, OF N=5 TO
15 VALUES, THE RANGE WAS
COMPUTED AND THEN THE AVERAGE RANGE ACROSS ALL 50
SUBGROUPS WAS CALCULATED. THE AVERAGE RANGE WAS THEN
DIVIDED BY THE APPROPRIATE D2 CONSTANT FOR EACH SUBGROUP MADE
UP OF N = 5 TO N = 15 VALUES.
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Taken from: https://andrewmilivojevich.com/xbar-r-chart-versus-xbar-s-chart/; 2/13/19

STANDARD DEVIATION ESTIMATES
Standard Deviation Estimates Table of Average Standard
Based on the Range Deviation Estimates

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Taken from: https://andrewmilivojevich.com/xbar-r-chart-versus-xbar-s-chart/; 2/13/19

STANDARD DEVIATION ESTIMATES

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Taken from: https://andrewmilivojevich.com/xbar-r-chart-versus-xbar-s-chart/; 2/13/19

 WHEN TO USE XBAR R VERSUS XBAR S CHARTS

• THE POPULATION STANDARD DEVIATION IS SHOWN AS A HORIZONTAL LINE

THROUGH A STANDARD DEVIATION AT 5. NOTICE THAT THE STANDARD
DEVIATION, BASED ON THE AVERAGE RANGE, FOR N = 5 TO 11
ESTIMATES THE POPULATION STANDARD DEVIATION WELL. BUT, FOR THE
SAME RANGE OF SUBGROUPS (N = 5 TO 11), THE AVERAGE STANDARD
DEVIATION UNDER-ESTIMATES THE POPULATION STANDARD DEVIATION.

• BASED ON THIS OBSERVATION, WE’RE INCLINED TO BELIEVE THAT THE

AVERAGE RANGE ESTIMATES THE POPULATION STANDARD DEVIATION
WELL BETWEEN N = 5 THROUGH N = 11 VALUES PER SUBGROUP.
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Taken from: https://andrewmilivojevich.com/xbar-r-chart-versus-xbar-s-chart/; 2/13/19

 WHEN TO USE XBAR R VERSUS XBAR S CHARTS
• BUT WHAT HAPPENS WHEN YOU HAVE N = 12 OR MORE VALUES IN EACH
SUBGROUP? WE CAN SEE THAT THE STANDARD DEVIATION BASED ON THE AVERAGE
RANGE OVER ESTIMATES THE POPULATION STANDARD DEVIATION. IN THIS CASE, THE
CONTROL LIMITS FOR THE XBAR CHART WOULD BE WIDER.

• BUT NOTICE THAT THE AVERAGE STANDARD DEVIATION FOR N = 12 OR MORE

VALUES PER SUBGROUP ESTIMATES THE POPULATION WELL. IN THE CASE, THE
CONTROL LIMITS FOR THE XBAR CHART WOULD BE JUST RIGHT.

• BASED ON THIS SIMULATION, WE WOULD SUGGEST THAT WE USE THE XBAR R

CHART FOR N = 11 OR LESS VALUES PER SUBGROUP. OR, IF WE HAD N = 12 OR
MORE VALUES PER SUBGROUP WE WOULD SUGGEST THE USE THE XBAR S CHART.
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Taken from: https://andrewmilivojevich.com/xbar-r-chart-versus-xbar-s-chart/; 2/13/19