Quantitative Control Diagram

Characteristics measurement or product quality can be done by many ways, such as direct measurement, indirect measurement, using caliber, or with comparison. Direct and indirect measurement (using equipment which ability to indicate the number) is the best way since it is easy to estimate and determine the cause of process instability. However, the direct measurement (quantitatively) results numbers in some cases can not be executed, such as in determining the product quality where only to distinguish two condition that are good or bad (qualitatively). Such that it needs two kinds of control diagrams due to the way to measure the product, that are qualitative control diagram and quantitative control diagram.

The principle of constructing quantitative control diagram had been discussed before, therefore the way how to use that is discussed below. As for qualitative control diagram it needs a little different basic of statistics, such that it will be discussed after. If the quality of product can be measured, then it needs qualitative control diagram. There are two kinds of qualitative control diagram that can be used simultaneously i.e. range control diagram (R-chart) to control process variabil-ity, and Average control diagram (sample average chart) to control average process level. The two kinds of control diagram can be used whether for the starting process or the running process. It needs to notice that in the step of introduction to diagram control usage, the production process can not be disturbed.

The starting effort can be forced to avoid the influence to product quality (psychologically disturbs the operator). Its application needs time, little by little process characteristics will be recognized through this control diagram. 1. Measurement Object Selection For single process level it is possible to finish directly some specifications. In the starting step it is needed to determine one measurement object which according to estimation and experience is the critical one (become the cause factor of product rejection or because of easy to be outside of the tolerance, and this is the process characteristics. )

For example in manufacturing a machine component, diameter or length measurement will be easy to be executed rather than measure the roundness, eccentricity, inclination or inner thread. After trying the control diagram for measurement object, then observe, is it needed to measure other objects. If other object also be a critical matter, then it needs special equipment which make it possible to measure some other object easily. (remember, operator skill is main factor). By doing that, some diagram control is used simultaneously.

2. Sample size determination and sample taken period Sample size and its period are related each other. If the size is big, then the period is long, while small sample has short period. The second way is suggested since with the small sample range calculation is enough (not the standard deviation). To get similar, we form the habit to get sample with the size 4 pieces from the newest, if the production speed high, it is taken from the newest twelve. Sample taking period is determined by the production speed. If the speed less than 100 pieces per hour, then sample can be taken every 4 hours until 1 hours. For the speed more than 100 pieces per hour, sample can be taken every 1 hour until hour.

Period and sample size as above is the general direction used in the first step of control diagram usage. Depends on the process condition, if the process then indicates the process variability and/or average process level change fast, then the period of taking sample is increased, while the sample size remains 4 to make easy procedure. Opposite situation occurs that is the period is lengthen if the process condition does not change fast (means that the measurement object does not become critical, if so, does it need to select other measurement object ?). The way of sample taken discussed above has the aim to know the process condition fast, such that the action of correction can be done if needed to avoid the possibility of product outside the tolerance.

if it is wanted to have tight quality control in the meaning that it may not be a product rejected from the entire production, then it can be done to combine sampling method and total inspection. In the last case, all the product can be grouped according to the time taken (batching). If the last taken sample indicates critical condition, ten the sample is taken from the last taken group. The result is plotted on the control diagram as usual ( made separate) and determined to do total measurement to all product or not.

3. Measurement and measurement data writing To make the procedure easy, measurement as much as can results easy data, in the meaning that the number is little ( only one or two number vary), and with the same sign (all positive or all negative, to avoid miscalculation). For example the data in the table discussed before (again written below), for measuring the height of object which vary from 5.346 to 5.362 mm, the measuring equipment had better only point the difference to 5.300 mm. Such that, on the control diagram only written one or two numbers. Zero point of the measuring equipment should be set (set wit the standard measuring equipment) such that the area of measurement only include a little value below the tolerance and a little upper the tolerance if using for the product with positive measurement value.

No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

(mm) 5.352 5.356 5.356 5.352 5.348 5.354 5.357 5.346 5.354 5.352

No. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

(mm) 5.358 5.352 5.354 5.355 5.354 5.357 5.357 5.359 5.356 5.358

No. 21. 22. 23. 24. 25 26. 27. 28. 29. 30.

(mm) No. 5.359 5.358 5.355 5.358 5.357 5.354 5.359 5.357 5.355 5.358 31. 32. 33. 34. 35 36. 37. 38. 39. 40.

(mm) 5.357 5.358 5.359 5.358 5.356 5.359 5.362 5.360 5.356 5.358

No. 41. 42. 43. 44. 45 46. 47. 48. 49. 50.

(mm) 5.357 5.355 5.356 5.360 5.362 5.357 5.360 5.362 5.360 5.359

Measurement data is written on the special measurement sheet for this purpose. On the sheet it is written in several rows according to the sample series number. (See the table below). On the top, it is written all explanation needed such as number of duty, number of drawing, machine number, operator, product name, measurer, zero setting, nominal dimension, tolerance, measurement unit, and sampling period. If necessary, below that allocated space for noting all the important evens (change of material, tool, operator etc.). Such that it is easy to check the cause if characteristics change.

Duty no. : 21

Drawing no. 146

Machine no. 02

Operator : Ade

Product name : Shaft Dimension : 25.08 No. of Product 1 2 Total : Average : Range : 1 40 15 2

Measurer : Marjanto Tolerance : +/- 0,02

Sampling period : 2 hours Zero point : 25.06 Unit : m

Sample Number 3 4 35 5 20 6 7 8 25 9 15 10 20 11 12

25 20

20 15

Example of measurement sheet

4. Determination of Relative Precession Index (RPI) After the process running and results 10 sample, then the calculation needed for control diagram can be started, while the production process can be let running. Average calculation can be done, that is the total average (x) of 10 sample averages and range averages (R). The first action is to determine the process precession. For this, it needs Relative Precession Index (RPI) that is :
RPI = Tolerance T = Range average R

If in the specification only limit is written (tolerance not written), then RPI is calculated based on subtraction of process average value (x) and the limit value divided by half of range value.
Limit value (Spec.) - x RPI = 1/2 R
(5.3.1)

Then by using the following table 5.3.1, determination of process precision class can be done.

Table 5.3.1 Process variability classification relative to tolerance Size of Sample Low precision RPI value (equation 5.3.1) Medium precision High precision

2 3 4 5 and 6

less than 6 less than 4 less than 3 less than 2.5

6-7 45 3- 4 2.5 -3.5

more than 7 more than 5 more than 4 more than 3.5

Process Condition

unsatisfied, product outside specification can not be avoided

satisfied as long as process average value inside the warning limit

satisfied, as long as process average value inside the modified warning limit

4. Determination Warning limit, Control limit, and Action Based on the determination results of process precision class, the limits on the control diagram can be made. From the statistics view, the first action is to check the process variability using control diagram of range (R chart). The limits on this control diagram are : Warning limit = D.975 R Control limit = D.999 R Where the constant D based on the sample size taken from the following table 5.3.2.

Table 5.3.2 Constants for determining the limits on the range control diagram

Size of sample D.975 D.999

2 3 4 5 6

2.81 2.17 1.93 1.81 1.72

4.12 2.99 2.58 2.36 2.22

After making the limits on the control diagram, it should be seen that whether the range values (of 10 sample) spread randomly below the warning limit. For example : for n = 4, R is 13.5 m Then : Warning limit = 1.93 R = 1.93 x 13.5 = 26 m Control limit = 2.58 R = 2.58 x 13.5 = 35 m The observation points and the limits on the control diagram is as follows.

Spreading of the points is the illustration of process variability. For an experienced one, the tendency of the observation points spreading can be recognize easily such that can determine the action should be taken for that production process. While that we can use the following aspects to determine whether the process can be said stable or not. A process considered not stable i.e. outside of the control if : -There is one point near or outside of the control limit -There are two points in ten sample taken near or outside of the warning limit. -There are 3 points in twenty sample taken near or outside of the warning limit.

- Before deciding the next action, sometimes it needs to ascertain the stability by taking one more sample. Based on this result, it will be known that whether the signal of instability caused by the measurement error only. -If in the interval 10 sample there is a point outside warning limits, but still far from the control limit, then the process is still considered to be stable when the next sample spreading below the warning limit. -If the range (R) is still outside the control, sample taking can be continued until the range back to the control. If the range still outside of the control, then it indicates that the process does not follow the characteristics of normal distribution. Therefore it needs to find the cause of that (material, machine or operator).

-Experience on the characteristics of machine or its construction much assist in the correction effort. If the range indicates the tendency to stability , then we can go to the next step that is the inspection of average process level using control diagram of mean value. Discussion will be divided into three level of precision, that are low, medium or high and special case where it needs high insurance. Before that, it needs to be warning that in all condition, the range should be stable (it needs continuous control) Note : A stable process does not mean satisfaction since for low RPI the process still results product outside of specification/tolerance.

5. Control Diagram of Mean value for Low Precision

For example, control diagram of mean value can be made using the data of example sheet (again written below)

No. of Sample Number Product 1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4

40 25

25 20 20 30 25 25

35

20

20 15 30

25 25

15

20

20 30 25 20 20 10 20 25 30

35 25 20 30 25 20

15 25 20 20

20 30 15 30

T 40 RPI = = 2.96 R 13.5

For n =4, counted as low precision

The limits of control diagram of mean value are calculated using the following equation : Warning limit = x A.975 R Control limit = x A.999 R Where the constant A is determined based on the sample size using the following table.

Table 5.3.3 Constants for determining the limits on the mean control diagram

Size of sample

.975

.999

2 3 4 5 6

1.23 0.67 0.48 0.38 0.32

1.94 1.05 0.75 0.59 0.50

For this example n =4, x = 23.5 m and R = 13.5 m, then Warning limit = 23.5 0.48 x 13.5 = 30 and 17 m Control limit = 23.5 0.75 x 13.5 = 34 and 13 m Observation data and mean control diagram is as follows

-The process is considered to be stable if observation points spread around warning limit. The process is considered unstable if the condition discuss in the range control above occurs. -Although the range and the mean value is still in the control, a process with low RPI will always result some of product outside the tolerance. The lower RPI the bigger group of product outside the tolerance. -Therefore, total measurement (100% inspection) must be done. As much as can RPI must be increased until the mid level by the following effort : - Wider the tolerance (agreed by the planner or customer ?) - Decrease the process variability, that is to lower av. Range If it can not be done, then the process must be stopped

5. Control Diagram of Mean value for Mid Precision

-If the RPI reach the mid value then the process is considered stable when the mean value of samples still in the warning limits. Correction should be done if the process tends to be unstable (if the observation points or mean of the sample tends to near the warning limits or there is a point near the control limits). - The warning and control limits are determined by the same procedure which has been discussed in range and mean control diagram. To bring the average process level to be inside the control, it needs knowledge about process characteristics. Generally the source of errors come from tool tips wearing or the error of machine set before the correction is done. As much as can, the RPI should be increased.

6. Control Diagram of Mean value for High Precision

-High RPI generally is the character of high precision machine. Usual machine can also reach the high RPI when produce the product with wide tolerance. In this case, since the process variability is narrow compared to the tolerance, then the change in average process level can be tolerated. (since the tail of distribution is far from the tolerance). -Therefore, the warning and control limits made by the equation above is no longer efficient, since those limits are far from the tolerance (If according to the control diagram the process becomes unstable, but the correction is not necessary to be done). Such that, determination of modified limits instead of usual limits is done as the following procedure.

Lower limits Modified warning limits Modified control limits L + A .975 R L + A .999 R

Upper limits H - A .975 R H - A .999 R

L = lower tolerance limits H = upper tolerance limits A = constant which is determined by the above table.

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