Adaptive CUSUM and EWMA charts with auxiliary information and variable sampling intervals for monitoring the process mean

The variable sampling interval (VSI) feature enhances the sensitivity of a control chart that is based on fixed sampling interval (FSI). In this paper, we enhance the sensitivities of the auxiliary information-based (AIB) adaptive Crosier cumulative sum (CUSUM) (AIB-ACC) and adaptive exponentially weighted moving average (EWMA) (AIB-AE) charts using the VSI feature when monitoring a mean shift which is expected to lie within a given interval. The Monte Carlo simulations are used to compute zero-state and steady-state run length properties of these control charts. It is found that the AIB-ACC and AIB-AE charts with VSI feature are uniformly more sensitive than those based on FSI feature. Real datasets are also considered to demonstrate the implementation of these control charts.     

A survey on multivariate adaptive control charts: Recent developments and extensions

In the world of business, quality improvement is of high importance for the manufacturing industries. Statistical process control via control charts provides an online monitoring of the product's characteristic. The adaptive feature is being widely used in the design parameters of a control chart, which allows at least one of them to change during the process monitoring. Specifically, a control chart is considered adaptive if at least one of the chart's parameters (sample size, sampling interval, or control limit coefficient) is allowed to change in real time on the basis of the actual values of the sample statistics. In this paper, recent developments in the design of multivariate adaptive control schemes are presented and discussed.     

A multivariate CUSUM control chart for monitoring Gumbel's bivariate exponential data

Exponentially distributed data are commonly encountered in high-quality processes. Control charts dedicated to the univariate exponential distribution have been extensively studied by many researchers. In this paper, we investigate a multivariate cumulative sum (MCUSUM) control chart for monitoring Gumbel's bivariate exponential (GBE) data. Some tables are provided to determine the optimal design parameters of the proposed MCUSUM GBE chart. Furthermore, both zero-state and steady-state properties of the proposed MCUSUM GBE chart for the raw and the transformed GBE data are compared with the multivariate exponentially weighted moving average (MEWMA) chart and the paired individual cumulative sum (CUSUM) chart. The results show that the proposed MCUSUM GBE chart outperforms the other two types of control charts for most shift domains. In addition, an extension to Gumbel's multivariate exponential (GME) distribution is also investigated. Finally, an illustrative example is provided in order to explain how the proposed MCUSUM GBE chart can be implemented in practice.     

Evaluation of Phase I analysis scenarios on Phase II performance of control charts for autocorrelated observations

Phase I analysis of a control chart implementation comprises parameter estimation, chart design, and outlier filtering, which are performed iteratively until reliable control limits are obtained. These control limits are then used in Phase II for online monitoring and prospective analyses of the process to detect out-of-control states. Although a Phase I study is required only when the true values of the parameters of a process are unknown, this is the case in many practical applications. In the literature, research on the effects of parameter estimation (a component of Phase I analysis) on the control chart performance has gained importance recently. However, these studies consider availability of complete and clean data sets, without outliers and missing observations, for estimation. In this article, we consider AutoRegressive models of order 1 and study the effects of two extreme cases for Phase I analysis; the case where all outliers are filtered from the data set (parameter estimation from incomplete but clean data) and the case where all outliers remain in the data set during estimation. Performance of the maximum likelihood and conditional sum of squares estimators are evaluated and effects on the Phase II use are investigated. Results indicate that the effect of not detecting outliers in Phase I can be severe on the Phase II application of a control chart. A real-world example is provided to illustrate the importance of an appropriate Phase I analysis.     

Using economically designed Shewhart and adaptive ―X charts for monitoring the quality of tiles

This paper presents the economic design of ―X control charts for monitoring a critical stage of the main production process at a tile manufacturer in Greece. Two types of ―X charts were developed: a Shewhart‐type chart with fixed parameters and adaptive charts with variable sampling intervals and/or sample size. Our prime motivation was to improve the statistical control scheme employed for monitoring an important quality characteristic of the process with the objective of minimizing the relevant costs. At the same time we tested and confirmed the applicability of the theoretical models supporting the economic design of control charts with fixed and variable parameters in a practical situation. We also evaluated the economic benefits of moving from the broadly used static charts to the application of the more flexible and effective adaptive control charts. The main result of our study is that, by redesigning the currently employed Shewhart chart using economic criteria, the quality‐related cost is expected to decrease by approximately 50% without increasing the implementation complexity. Monitoring the process by means of an adaptive ―X chart with variable sampling intervals will increase the expected cost savings by about 10% compared with the economically designed Shewhart chart at the expense of some implementation difficulty. Copyright © 2006 John Wiley & Sons, Ltd.     

A comparison study on effectiveness and robustness of control charts for monitoring process mean and variance

This article compares the effectiveness and robustness of nine typical control charts for monitoring both process mean and variance, including the most effective optimal and adaptive sequential probability ratio test (SPRT) charts. The nine charts are categorized into three types (the type, CUSUM type and SPRT type) and three versions (the basic version, optimal version and adaptive version). While the charting parameters of the basic charts are determined by common wisdoms, the parameters of the optimal and adaptive charts are designed optimally in order to minimize an index average extra quadratic loss for the best overall performance. Moreover, the probability distributions of the mean shift δ_µ and standard deviation shift δ_σ are studied explicitly as the influential factors in a factorial experiment. The main findings obtained in this study include: (1) From an overall viewpoint, the SPRT‐type chart is more effective than the CUSUM‐type chart and type chart by 15 and 73%, respectively; (2) in general, the adaptive chart outperforms the optimal chart and basic chart by 16 and 97%, respectively; (3) the optimal CUSUM chart is the most effective fixed sample size and sampling interval chart and the optimal SPRT chart is the best choice among the adaptive charts; and (4) the optimal sample sizes of both the charts and the CUSUM charts are always equal to one. Furthermore, this article provides several design tables which contain the optimal parameter values and performance indices of 54 charts under different specifications. Copyright © 2011 John Wiley & Sons, Ltd.     

Phase II control charts for monitoring dispersion when parameters are estimated

Shewhart control charts are among the most popular control charts used to monitor process dispersion. To base these control charts on the assumption of known in-control process parameters is often unrealistic. In practice, estimates are used to construct the control charts and this has substantial consequences for the in-control and out-of-control chart performance. The effects are especially severe when the number of Phase I subgroups used to estimate the unknown process dispersion is small. Typically, recommendations are to use around 30 subgroups of size 5 each.

?We derive and tabulate new corrected charting constants that should be used to construct the estimated probability limits of the Phase II Shewhart dispersion (e.g., range and standard deviation) control charts for a given number of Phase I subgroups, subgroup size and nominal in-control average run-length (ICARL). These control limits account for the effects of parameter estimation. Two approaches are used to find the new charting constants, a numerical and an analytic approach, which give similar results. It is seen that the corrected probability limits based charts achieve the desired nominal ICARL performance, but the out-of-control average run-length performance deteriorate when both the size of the shift and the number of Phase I subgroups are small. This is the price one must pay while accounting for the effects of parameter estimation so that the in-control performance is as advertised. An illustration using real-life data is provided along with a summary and recommendations.     

Bivariate semiparametric control charts for simultaneous monitoring of process mean and variance

In the present article, two semiparametric bivariate control charts are presented, which use order statistics and are effective in jointly monitoring of possible shifts in the process mean and/or variance. To achieve that both the median location (or more generally the location of a specific order statistic) and the number of specific observations of the test sample lying between the control limits are taken into account. The false alarm rate and the in-control average run length are not affected by the marginal distributions, while the effect of the dependence structure on them is negligible; therefore, they can be used as fully nonparametric charts. A performance-comparison study is carried out, and an illustrative example is provided using a real-world data set.     

Monitoring the Weibull shape parameter by control charts for the sample range

In this paper, we propose control charts for monitoring changes in the Weibull shape parameter β. These charts are based on the range of a random sample from the smallest extreme value distribution. The control chart limits depend only on the sample size, the desired stable average run length (ARL), and the stable value of β. We derive control limits for both one‐ and two‐sided control charts. They are unbiased with respect to the ARL. We discuss sample size requirements if the stable value of βis estimated from past data. The proposed method is applied to data on the breaking strengths of carbon fibers. We recommend one‐sided charts for detecting specific changes in βbecause they are expected to signal out‐of‐control sooner than the two‐sided charts. Copyright © 2010 John Wiley & Sons, Ltd.     

A general class of nonparametric control charts

In this article, we introduce a new general class of nonparametric Shewhart‐type control charts using the lengths of runs of test sample observations between successive observations of a reference sample. Several control charts that have appeared in the literature are members of the new family. In addition, 3 new nonparametric control charts that belong to the class are introduced and studied. Numerical results depict that the proposed charts attain competitive in‐control and out‐of‐control performance as compared with existing nonparametric charts.     

High breakdown estimation methods for Phase I multivariate control charts

A goal of Phase I analysis of multivariate data is to identify multivariate outliers and step changes so that the Phase II estimated control limits are sufficiently accurate. High breakdown estimation methods based on the minimum volume ellipsoid (MVE) or the minimum covariance determinant (MCD) are well suited for detecting multivariate outliers in data. As a result of the inherent difficulties in their computation, many algorithms have been proposed to detect multivariate outliers. Due to their availability in standard software packages, we consider the subsampling algorithm to obtain the MVE estimators and the FAST‐MCD algorithm to obtain the MCD estimators. Previous studies have not clearly determined which of these two available estimation methods is best for control chart applications. The comprehensive simulation study presented in this paper gives guidance for the correct use of each estimator. Control limits are provided. High breakdown estimation methods based on the MCD and MVE approaches can be applied to a wide variety of multivariate quality control data. Copyright © 2006 John Wiley & Sons, Ltd.     

Bayesian np control charts with adaptive sample size for finite production runs

The design of a control chart requires the specification of three decision variables, namely the sample size, n, the sampling interval, h, and the action limit under which the process must be stopped for potential repair. In this paper, the Bayesian attribute control chart, namely the np chart for short run production, using a variable sample size is discussed. In a simulated experiment, optimal solutions of the static np chart, the basic Bayesian np chart, and the Bayesian scheme with adaptive sample size are presented. Results of the empirical study show that varying the sample size leads to more cost savings compared with the other two approaches. In order to detect how the input parameters affect decision variables, a regression analysis is conducted. It is obtained that the benefits of using the basic Bayesian np chart and the Bayesian chart with adaptive sample size instead of the static scheme are affected by the length of the production run. Copyright © 2008 John Wiley & Sons, Ltd.     

On a class of mixed EWMA-CUSUM median control charts for process monitoring

Monitoring of any manufacturing, production, or industrial process can be controlled and improved by removing these special cause of variations using control charts. Shewhart-type control charts are effective to control a large amount of special variations, whereas, cumulative sum (CUSUM) and exponentially weighted moving average (EWMA) charts detect small and moderate variations efficiently in the process parameters. Monitoring of location parameter can be done with mean control charts under the assumption that the parameters are known or correctly estimated from in-control samples and data are free from outliers (but in practice data occasionally have outliers). In this study, we have proposed generalized mixed EWMA-CUSUM median control charts structures for known and unknown parameters based on auxiliary variables for detecting shifts in process location parameter. The proposed charts are compared with the corresponding charts for the mean, based on contaminated and uncontaminated data. Different performance measures are used to evaluate the performance of proposed control charts and revealed through results that the median-based charts are more sensitive to detect a shift in process location parameter in the presence of outliers. An illustrative example using real data is also shown for practical consideration.     

面向质量目标的Q控制图设计

针对大批量生产开始阶段的过程监控,提出了一种基于预定质量目标的Q控制图监控方法.其基本思路是利用面向质量目标的统计公差技术与Q控制图相结合应用,以实现大批量过程开始阶段均值和方差未知时面向质量目标的过程监控.基于质量目标建立统计公差(CP*,k*),并将该统计公差转化为基于给定置信概率的对CP和k的估计值的判定条件.通过案例分析,面向质量目标的Q控制图能够在过程保持受控状态的前提下以一定置信概率保证质量目标.     

Phase I control charts for times between events

A count of the number of defects is often used to monitor the quality of a production process. When defects rarely occur in a process, it is often desirable to monitor the time between the occurrence of each defect rather than a count of the number of defects. An exponential distribution often provides a useful model of the time between defects. Phase I control charts for exponentially distributed processes are discussed. Methods for computing the control limits are given and the overall Type I error rates of these charts are evaluated. Copyright © 2002 John Wiley & Sons, Ltd.     

Design issues for adaptive control charts

Adaptive control charts allow the components of the quality‐monitoring scheme to vary in order to obtain improved performance over non‐adaptive control charts. Research has centered on components such as the sample size, time between samples, warning limits, and control limits and has recommended a variety of schemes, many of which are optimal in some sense. In practice, there are many other adaptive schemes that are near optimal, which will still yield considerable improvement over non‐adaptive control charts. In addition, the impact of parameter estimation on adaptive control chart performance must be taken into consideration. Based on the simulation results shown here, adaptive control charts should only be used for mature processes, where a sufficient amount of Phase I data have been obtained to ensure that the estimated control limits are accurate. When evaluating control chart performance, we consider initial state performance measures for simplicity and note that the conclusions obtained here apply to steady‐state performance measures. The evaluation of performance measures is easily handled by the Markov chain approach detailed in the Appendix. Copyright © 2008 John Wiley & Sons, Ltd.     

Optimal control limits for CCC charts in the presence of inspection errors

The control chart based on cumulative count of conforming (CCC) items between the occurrence of two non‐conforming ones, or the CCC chart, has been shown to be very useful for monitoring high‐quality processes. However, as in the implementation of other Shewhart‐type control charts, it is usually assumed that the inspection is free of error. This assumption may not be valid and this may have a significant impact on the interpretation of the control chart and the setting of control limits. This paper first investigates the effect of inspection errors and discusses the setting of control limits in such cases. Even if inspection errors are considered, the average time to alarm increases in the beginning when the process deteriorates. Since this is undesirable, the control limits in the presence of inspection errors should be set so as to maximize the average run length when the process is at the normal level. A procedure is presented for solving this problem. Copyright © 2003 John Wiley & Sons, Ltd.     

Economic cost models of integrated APC controlled SPC charts

In this paper, an economic cost model is proposed for processes integrating both automatic process control (APC) and statistical process control (SPC) for quality monitoring and control. Both the special cause and common cause variations are reduced by applying integrated APC and SPC. Traditionally, the integrated processes using APC and SPC are evaluated by the average run length (ARL). However, ARL may not be appropriate as a measurement of the economic design since it does not take into consideration the run length variation. Also, there are few studies that compare the cost models of such an integrated control system and the effect of cost parameters using different APC controllers. Therefore, we develop an economic cost model using non-homogenous Poisson process to describe the occurrence of an APC adjustment and develop a long run expected cost to investigate the use of different controllers in such integrated systems. Numerical examples are presented to demonstrate the applicability of the proposed model.