Monitoring bivariate and trivariate mean vectors with a Shewhart chart

In this article, we propose the use of the mean chart to control multivariate processes. The basic idea is to control the mean vector of bivariate (X, Y) and trivariate (X, Y, Z) processes by alternating the charting statistic of the Shewhart chart. If the mean of X observations was the charting statistic to obtain the current sample point, then the mean of Y observations will be the charting statistic to obtain the next sample point (for the trivariate case, the mean of Z observations will be the charting statistic to obtain the sample point subsequent to the next one). As a Shewhart chart, the signal is given anytime a sample point is plotted beyond the control limits, independent of the charting statistic in use. A fair comparison between the proposed chart and the Hotelling chart is based on an equal number of measurements per sample. The Shewhart chart with alternated charting statistic (ACS) always outperforms the Hotelling chart, except for specific types of disturbances in quality characteristics highly correlated (ρ = 0.7). The ACS chart is substantially easier to operate and faster than the Hotelling chart in signaling changes in the mean vector of bivariate and trivariate processes. Even with fewer measurements per sample, the trivariate ACS chart outperforms the Hotelling chart.     

Bivariate Dispersion Control Charts for Monitoring Non‐Normal Processes

Multivariate control charts are well known to be more sensitive to the occurrence of variation in processes with two or more correlated quality variables than univariate charts. The use of separate univariate control charts to monitor multivariate process can be misleading as it ignores the correlation between the quality characteristics. The application of multivariate control charts allows for the simultaneous monitoring of the quality characteristics by forming a single chart. The charts operate on the assumption that process observations are normally distributed, but in practice this is not always the case. In this study, we examine and present multivariate dispersion control charts for detecting shifts in the covariance matrix of normal and non‐normal bivariate processes. These control charts, referred to as SMAX, QMAX, MDMAX and MADMAX, rely on dispersion estimates, such as the sample standard deviation (S), interquartile range (Q), average absolute deviation from median (MD) and median absolute deviation (MAD), respectively. We compare the performances of these charts to the existing multivariate generalized variance |S| and RMAX charts for bivariate processes using normal and non‐normal parent distributions. The average run length (ARL) measure is used for the evaluation and comparison of the charts. A real life and simulated datasets are used to demonstrate the application of the charts. Copyright © 2016 John Wiley & Sons, Ltd.     

Control Charts for Monitoring Correlated Poisson Counts with an Excessive Number of Zeros

The zero‐inflated Poisson distribution serves as an appropriate model when there is an excessive number of zeros in the data. This phenomenon frequently occurs in count data from high‐quality processes. Usually, it is assumed that these counts exhibit serial independence, while a more realistic assumption is the existence of an autocorrelation structure between them. In this work, we study control charts for monitoring correlated Poisson counts with an excessive number of zeros. Zero‐inflation in the process is captured via appropriate integer‐valued time series models. Extensive numerical results are provided regarding the performance of the considered charts in the detection of changes in the mean of the process as well as the effects of zero‐inflation on them. Finally, a real‐data practical application is given. Copyright © 2016 John Wiley & Sons, Ltd.     

Effects of Parameter Estimation on the Multivariate Distribution‐free Phase II Sign EWMA Chart

Multivariate nonparametric control charts can be very useful in practice and have recently drawn a lot of interest in the literature. Phase II distribution‐free (nonparametric) control charts are used when the parameters of the underlying unknown continuous distribution are unknown and can be estimated from a sufficiently large Phase I reference sample. While a number of recent studies have examined the in‐control (IC) robustness question related to the size of the reference sample for both univariate and multivariate normal theory (parametric) charts, in this paper, we study the effect of parameter estimation on the performance of the multivariate nonparametric sign exponentially weighted moving average (MSEWMA) chart. The in‐control average run‐length (ICARL) robustness and the out‐of‐control shift detection performance are both examined. It is observed that the required amount of the Phase I data can be very (perhaps impractically) high if one wants to use the control limits given for the known parameter case and maintain a nominal ICARL, which can limit the implementation of these useful charts in practice. To remedy this situation, using simulations, we obtain the “corrected for estimation” control limits that achieve a desired nominal ICARL value when parameters are estimated for a given set of Phase I data. The out‐of‐control performance of the MSEWMA chart with the correct control limits is also studied. The use of the corrected control limits with specific amounts of available reference sample is recommended. Otherwise, the performance the MSEWMA chart may be seriously affected under parameter estimation. Copyright © 2016 John Wiley & Sons, Ltd.     

Optimal Designs of the Variable Sample Size Chart Based on Median Run Length and Expected Median Run Length

The variable sample size (VSS) chart, devoted to the detection of moderate mean shifts, has been widely investigated under the context of the average run‐length criterion. Because the shape of the run‐length distribution alters with the magnitude of the mean shifts, the average run length is a confusing measure, and the use of percentiles of the run‐length distribution is considered as more intuitive. This paper develops two optimal designs of the VSS chart, by minimizing (i) the median run length and (ii) the expected median run length for both deterministic and unknown shift sizes, respectively. The 5th and 95th percentiles are also provided in order to measure the variation in the run‐length distribution. Two VSS schemes are considered in this paper, that is, when the (i) small sample size (n_S) or (ii) large sample size (n_L) is predefined for the first subgroup (n₁). The Markov chain approach is adopted to evaluate the performance of these two VSS schemes. The comparative study reveals that improvements in the detection speed are found for these two VSS schemes without increasing the in‐control average sample size. For moderate to large mean shifts, the optimal VSS chart with n₁ = n_L significantly outperforms the optimal EWMA chart, while the former is comparable to the latter when n₁ = n_S. Copyright © 2016 John Wiley & Sons, Ltd.     

Distribution‐free Lepage Type Circular‐grid Charts for Joint Monitoring of Location and Scale Parameters of a Process

In the last 5 years, research works on distribution‐free (nonparametric) process monitoring have registered a phenomenal growth. A Google Scholar database search on early September 2015 reveals 246 articles on distribution‐free control charts during 2000–2009 and 466 articles in the following years. These figures are about 1400 and 2860 respectively if the word ‘nonparametric’ is used in place of ‘distribution‐free’. Distribution‐free charts do not require any prior knowledge about the process parameters. Consequently, they are very effective in monitoring various non‐normal and complex processes. Traditional process monitoring schemes use two separate charts, one for monitoring process location and the other for process scale. Recently, various schemes have been introduced to monitor the process location and process scale simultaneously using a single chart. Performance advantages of such charts have been clearly established. In this paper, we introduce a new graphical device, namely, circular‐grid charts, for simultaneous monitoring of process location and process scale based on Lepage‐type statistics. We also discuss general form of Lepage statistics and show that a new modified Lepage statistic is often better than the traditional of Lepage statistic. We offer a new and attractive post‐signal follow‐up analysis. A detailed numerical study based on Monte‐Carlo simulations is performed, and some illustrations are provided. A clear guideline for practitioners is offered to facilitate the best selection of charts among various alternatives for simultaneous monitoring of location‐scale. The practical application of the charts is illustrated. Copyright © 2016 John Wiley & Sons, Ltd.     

Bridging the gap between theory and practice in basic statistical process monitoring

ABSTRACT

Some issues are discussed relative to the gap between theory and practice in the area of statistical process monitoring (SPM). Among other issues, it is argued that the collection and use of baseline data in Phase I needs a greater emphasis. Also, the use of sample ranges in practice to estimate process standard deviations deserves reconsideration. A discussion is given on the role of modeling in SPM. Then some work on profile monitoring and the effect of estimation error on Phase II chart performance is summarized. Finally, some ways that researchers could influence practice more effectively are discussed along with how SPM research could become more useful to practitioners.     

Bond behavior of GFRP and steel bars in ultra-high-performance fiber-reinforced concrete

The bond behavior of glass fiber-reinforced polymer (GFRP) and steel bars embedded in ultra-high-performance fiber-reinforced concrete (UHPFRC) was investigated according to embedment length and bar diameter. Post-peak bond stress-slip softening curve of the GFRP bars was obtained, and a wedging effect was quantitatively evaluated. Test results indicated that a normalized bond strength of 5 was applicable for steel bars embedded in UHPFRC, and the development lengths of normal- and high-strength steel bars were determined to be 2 and 2.5 times the bar diameter, respectively. The GFRP bars exhibited approximately 70% lower bond strength than the steel bars, and the bond stress additionally applied by the wedging effect increased almost linearly with respect to the slip. Based on dimensionless bond stress and slip parameters, an appropriate theoretical model for the bond stress and slip relationship of steel bars in UHPFRC was suggested, and it was verified through comparison with the test data.     

Monitoring of zero-inflated Poisson processes with EWMA and DEWMA control charts

The zero-inflated Poisson (ZIP) distribution is an extension of the ordinary Poisson distribution and is used to model count data with an excessive number of zeros. In ZIP models, it is assumed that random shocks occur with probability p, and upon the occurrence of random shock, the number of nonconformities in a product follows the Poisson distribution with parameter λ. In this article, we study in more detail the exponentially weighted moving average control chart based on the ZIP distribution (regarded as ZIP-EWMA) and we also propose a double EWMA chart with an upper time-varying control limit to monitor ZIP processes (regarded as ZIP-DEWMA chart). The two charts are studied to detect upward shifts not only in each parameter individually but also in both parameters simultaneously. The steady-state performance and the performance with estimated parameters are also investigated. The performance of the two charts has been evaluated in terms of the average and standard deviation of the run length, and compared with Shewhart-type and CUSUM schemes for ZIP distribution, it is shown that the proposed chart is very effective especially in detecting shifts in p when λ remains in control (IC) and in both parameters simultaneously. Finally, one real example is given to display the application of the ZIP charts on practitioners.     

Use of median-based estimator to construct Phase II exponential chart

The Shewhart-type exponential control chart is a popular and extensively used among all time-between-events control charts for its simplicity. When the parameter is unknown, Phase II control limits are constructed, and the success of its implementation depends to an extent on the estimated value of the parameter, obtained from Phase I dataset. However, when the Phase I data are contaminated with spurious observations/outliers, the performance of the chart is suspected to deviate from what is normally expected. Traditionally, maximum likelihood estimator (MLE) and minimum variance unbiased estimator (MVUE) are used to estimate the unknown process parameter. Both of estimators are the functions of sample mean. In this paper, the median-based estimator (MBE) that is a function of sample median is used to construct Phase II control limits. Moreover, performance of the proposed chart is examined when Phase I sample consists of contaminated observations/outliers. It is found that the proposed chart outperforms the existing charts whether the sample is contaminated or not.