A comparison of formulas for the design of cumulative sum control charts

A conventional cumulative sum control chart has a V‐mask where each arm makes an angle θ with the horizontal and has a lead distance d. These parameters are usually related to h (=dA tan(?), A is a scaling factor) and k(=A tan(?)). Two systems of formulas are examined for deriving h and k for selected values of the in control and out of control average run lengths. This is the first time an exhaustive comparison has been made. Copyright © 2009 John Wiley & Sons, Ltd.     

A mixed cumulative sum homogeneously weighted moving average control chart for monitoring process mean

The homogeneously weighted moving average (HWMA) control chart is famous to identify small deviations in the process mean. The plotting statistic of the HWMA chart assigns equal weight among the previous samples as compared to the plotting statistic of the exponentially weighted moving average chart. We propose a new HWMA chart that uses the plotting statistic of the cumulative sum chart. The run length performance of the proposed chart is measured in terms of the average, the standard deviation, some percentile points, and compared with some existing counterparts' charts. The comparison shows that the proposed chart performs superior to their existing counterparts. An application based on a real-life dataset is also presented.     

Advanced multivariate cumulative sum control charts based on principal component method with application

Existing multivariate cumulative sum (MCUSUM) control charts involve entire associated variables of a process to monitor variations in the mean vector. In this study, we have offered MCUSUM control charts with principal component method (PCM). The proposed MCUSUM control charts with PCM capture the whole process variations using fewer latent variables (principal components) while preserving as much data variability as possible. To show the significance of proposed MCUSUM control charts with PCM, various performance measures are considered including average run length, extra quadratic loss, relative average run length, and performance comparison index. Furthermore, performance measures are calculated through advanced Monte Carlo simulation method to explore the behavior of proposed MCUSUM control charts and to conduct comparative analysis with existing models. Results revealed that proposed MCUSUM control charts with PCM are efficient to detect variations timely by involving smaller number of principal components instead of considering entire associated variables. Also, proposed MCUSUM control charts have the ability to accommodate the features of existing control charts, which are illustrated as the special cases. Besides, to highlight the implementation mechanism and advantages of proposed MCUSUM control charts with PCM, a real-life example from wind turbine process is included.     

EWMA and DEWMA Control Charts for Poisson‐Exponential Distribution: Conditional Median Approach for Censored Data

Exponentially weighted moving average (EWMA) control charts are consistently used for the detection of small shifts contrary to Shewhart charts, which are commonly used for the detection of large shifts in the process. There are many interesting features of EWMA charts that have been studied for complete data in the literature. The aim of present study is to introduce and compare the double exponentially weighted moving average (DEWMA) and EWMA control charts under type‐I censoring for Poisson‐exponential distribution. The monitoring of mean level shifts using censored data is of a great interest in many applied problems. Moreover, a new idea of conditional median is introduced and further compared with the existing conditional expected values approach for monitoring the small mean level shifts. The performance of the DEWMA and EWMA charts is evaluated using the average run length, expected quadratic loss, and performance comparison index measures. The optimum sample size comparisons for the specified and unspecified parameters are also part of this study. Two applications for practical considerations are also discussed. It is observed that different censoring rates and the size of shifts significantly affect the performance of the EWMA and DEWMA charts. Copyright © 2016 John Wiley & Sons, Ltd.     

Optimal design of one-sided exponential cumulative sum charts with known and estimated parameters based on the median run length

As a useful tool in statistical process control (SPC), the exponential control chart is more and more popular for monitoring high-quality processes. Considering both known and estimated parameter cases, the one-sided exponential cumulative sum (CUSUM) charts are studied in this paper through a Markov chain approach. Because the shape of the run length (RL ) distribution of the one-sided exponential CUSUM charts is skewed and it also changes with the mean shift size and the number of Phase I samples used to estimate the process parameter, the median run length (MRL ) is employed as a good alternative performance measure for the charts. The optimal design procedures based on MRL of the one-sided exponential CUSUM charts with known and estimated parameters are discussed. By comparing the MRL performance of the chart with known parameters with the one of the chart with estimated parameters, we investigate the effect of estimated process parameters on the properties of the chart. Finally, an application is illustrated to show the implementation of the chart.     

A note on the average run length of cumulative sum control charts for count data

This note presents preliminary results on the average run length (ARL) of a Cumulative Sum Control Chart (CUSUM) used to monitor defects or counts, when the count distribution is Neyman Type-A. The ARL for this distribution is contrasted to the more customary Poisson model for counts or defects. We show that the ARL curve of a Neyman Type-A CUSUM always lies below the ARL curve of a Poisson CUSUM.     

Weighted adaptive multivariate CUSUM control charts

An adaptive multivariate cumulative sum (AMCUSUM) control chart has received considerable attention because of its ability to dynamically adjust the reference parameter whereby achieving a better performance over a range of mean shifts than the conventional multivariate cumulative sum (CUSUM) charts. In this paper, we introduce a progressive mean–based estimator of the process mean shift and then use it to devise new weighted AMCUSUM control charts for efficiently monitoring the process mean. These control charts are easy to design and implement in a computerized environment compared with their existing counterparts. Monte Carlo simulations are used to estimate the run‐length characteristics of the proposed control charts. The run‐length comparison results show that the weighted AMCUSUM charts perform substantially and uniformly better than the classical multivariate CUSUM and AMCUSUM charts in detecting a range of mean shifts. An example is used to illustrate the working of existing and proposed multivariate CUSUM control charts.     

SUBJECTS INDEX

Exponentially weighted moving average (EWMA) control charts are very widely used for the detection of small shifts. Another similar charting structure is double EWMA (DEWMA) control chart for the improved detection of the shifts. Many interesting features of EWMA and DEWMA have been described in the literature. This study intends to investigate EWMA and DEWMA control charts under Type-I censoring for gamma-distributed lifetimes. The idea of conditional expected values is used to monitor the mean level. The performance evaluations are carried out using average run length as a measure in this study. The optimum sample size comparisons for the specified and unspecified parameter are also part of the study. To assess the overall performance of the control charts, we also used extra quadratic loss and it is found DEWMA is an efficient chart for the detection of shift in scale parameter. Moreover, an illustrative example for practical considerations is included in the study. It is observed that varying censoring rates affect the performance of the chart depending upon the type of chart, the method of estimation, and the amount of shift.     

New control charts for monitoring the Weibull percentiles under complete data and Type‐II censoring

In this paper, we propose 3 new control charts for monitoring the lower Weibull percentiles under complete data and Type‐II censoring. In transforming the Weibull distribution to the smallest extreme value distribution, Pascaul et al (2017) presented an exponentially weighted moving average (EWMA) control chart, hereafter referred to as EWMA‐SEV‐Q, based on a pivotal quantity conditioned on ancillary statistics. We extended their concept to construct a cumulative sum (CUSUM) control chart denoted by CUSUM‐SEV‐Q. We provide more insights of the statistical properties of the monitoring statistic. Additionally, in transforming a Weibull distribution to a standard normal distribution, we propose EWMA and CUSUM control charts, denoted as EWMA‐YP and CUSUM‐YP, respectively, based on a pivotal quantity for monitoring the Weibull percentiles with complete data. With complete data, the EWMA‐YP and CUSUM‐YP control charts perform better than the EWMA‐SEV‐Q and CUSUM‐SEV‐Q control charts in terms of average run length. In Type‐II censoring, the EWMA‐SEV‐Q chart is slightly better than the CUSUM‐SEV‐Q chart in terms of average run length. Two numerical examples are used to illustrate the applications of the proposed control charts.     

An enhanced approach for the progressive mean control charts

To maintain and improve the quality of the processes, control charts play an important role for reduction of variation. To detect large shifts in the process parameters, Shewhart control charts are commonly applied but for small shifts, exponentially weighted moving averages (EWMA), cumulative sum (CUSUM), double exponentially weighted moving average (DEWMA), double CUSUM, moving average (MA), double moving average (DMA), and progressive mean (PM) control charts, are used. This study proposes double progressive mean (DPM) and optimal DPM control charts to enhance the performance of the PM chart. As the proposed DPM control charts use information sequentially, hence their performance is compared with natural competitors EWMA, CUSUM, DEWMA, double CUSUM, MA, DMA, and PM control charts. Run length and its different properties are evaluated to compare the performance of the proposed charts and counterparts. Results reveal that proposed optimal DPM outperforms the other charts. An example related to voltage on fixed capacitance level is also provided to illustrate the proposed charts.     

Shewhart-type Phase II control charts for monitoring times to an event with a guaranteed in-control and good out-of-control performance

Monitoring time to event (failure) data is important in many applications. Proper monitoring and control can make the production process more efficient and provide economic advantages. In this paper, we consider the efficacy of a class of Shewhart-type control charts for monitoring time to event data following an exponential distribution with an unknown mean, which is estimated from a class of estimators. An estimator is chosen within this class, so that the in-control performance is maximized with respect to a number of popular criteria in the recent literature, and the proposed optimal charts are compared on the basis of their in-control and out-of-control performance. The comparisons include the traditional Phase II exponential Shewhart chart using the maximum likelihood estimator. Improved in-control and out-of-control performances of these charts can enhance the quality and productivity of manufacturing processes. Since no chart is best under all the criteria, a ranking system is used to choose a chart to use in practice with a good overall performance. Two illustrative examples using real data are given; summary and conclusions are offered.     

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.     

Conditional Control Charts for Weibull Quantiles Under Type II Censoring

In this article, we propose control charts for the quantiles of the Weibull distribution, for type II censored data, based on the distribution of a pivotal quantity conditioned on ancillary statistics. These control charts must be considered as alternatives to bootstrap type control charts. We derive an analytical form of the conditional distribution function of the monitored statistic and we use this function to propose ARL‐unbiased control limits. We further demonstrate that the proposed conditional chart have a general analytical form for the ARL that can be evaluated numerically without use of simulations and we also show that these charts perform at least as well as the bootstrap type ones. We finally apply the conditional charts to a dataset on the strength of carbon fibers to detect shifts in a specified Weibull quantile. Copyright © 2014 John Wiley & Sons, Ltd.     

New EWMA control charts for monitoring process dispersion using auxiliary information

The exponentially weighted moving average (EWMA) control chart is a well‐known statistical process monitoring tool because of its exceptional pace in catching infrequent variations in the process parameter(s). In this paper, we propose new EWMA charts using the auxiliary information for efficiently monitoring the process dispersion, named the auxiliary‐information–based (AIB) EWMA (AIB‐EWMA) charts. These AIB‐EWMA charts are based on the regression estimators that require information on the quality characteristic under study as well as on any related auxiliary characteristic. Extensive Monte Carlo simulation are used to compute and study the run length profiles of the AIB‐EWMA charts. The proposed charts are comprehensively compared with a recent powerful EWMA chart—which has been shown to be better than the existing EWMA charts—and an existing AIB‐Shewhart chart. It turns out that the proposed charts perform uniformly better than the existing charts. An illustrative example is also given to explain the implementation and working of the AIB‐EWMA charts.     

On moving average control charts and their conditional average run lengths

Moving average control charts have been presented in the Quality Control literature in the past 75 years; however, their conditional average run lengths have not been obtained. The objective of this article is to derive the autocorrelation function between two moving averages, and then make application of the bivariate normal distribution to compute the conditional type II error probability at the future time, t +1, given that a manufacturing process is in statistical control at the present time t. Our Tables 3 through 8 show that the values of Shewhart's average run length and the corresponding conditional first-order moving average run lengths are almost the same after one standard deviation shift from the target of a normal process mean. Our conclusion section 6 describes that the comparisons of the two average run lengths are not on a valid statistical basis.     

Bayesian EWMA control charts based on Exponential and transformed Exponential distributions

In this paper, we proposed the Bayesian exponentially weighted moving average (EWMA) control charts for mean under the nonnormal life time distributions. We used the time between events data which follow the Exponential distribution and proposed the Bayesian EWMA control charts for Exponential distribution and transformed Exponential distributions into Inverse Rayleigh and Weibull distributions. In order to develop the control charts, we used a uniform prior under five different symmetric and asymmetric loss functions (LFs), namely, squared error loss function (SELF), precautionary loss function (PLF), general entropy loss function (GELF), entropy loss function (ELF), and weighted balance loss function (WBLF). The average run length (ARL) and the standard deviation of run length (SDRL) are used to check the performance of the proposed Bayesian EWMA control charts for Exponential and transformed Exponential distributions. An extensive simulation study is conducted to evaluate the proposed Bayesian EWMA control chart for nonnormal distributions. It is observed from the results that the proposed control chart with the Weibull distribution produces the best results among the considered distributions under different LFs. A real data example is presented for implementation purposes.     

The performance of EWMA median and CUSUM median control charts for a normal process with measurement errors

Measurement error is often occurred in statistical process control. The effect of a linearly covariate error model on the exponentially weighted moving average (EWMA) median and cumulative sum (CUSUM) median charts is investigated. The results indicate that the EWMA median and CUSUM median charts are significantly affected in the presence of measurement errors. We compared the performance of the EWMA median and CUSUM median charts by using Markov chain method in the average run length and the standard deviation of the run length. We concluded that the CUSUM median chart for small shifts and the EWMA median chart for larger shifts are recommended. Two examples are provided to illustrate the application of the EWMA and CUSUM median charts with measurement errors.     

EWMA Control Chart for Poisson–Exponential Lifetime Distribution Under Type I Censoring

Exponentially weighted moving average (EWMA) control charts are widely used for the detection of small shifts as opposed to Shewhart charts, which are commonly used for the detection of large‐size shifts in a process. Many interesting features of EWMA charts are available in literature mainly for complete data. This study intends to investigate the EWMA control charts under Type‐I censoring for Poisson–exponential distributed lifetimes. The two commonly used sampling schemes, that is, simple random sampling and rank set sampling, are used in this study. The monitoring of mean level shifts using censored data is of a great interest in many applied problems. The idea of conditional expected values is employed in the monitoring of small mean level shifts in the current study. The performance of the EWMA charts is evaluated using the average run length extra quadratic loss and performance comparison index measures. The optimum sample‐size comparisons for the specified and unspecified parameter are also part of this study. Moreover, an illustrative example and a case study for practical considerations are also discussed. It is observed that varying censoring rates affect the performance of the chart depending upon the type of sampling scheme and the amount of shifts. Copyright © 2015 John Wiley & Sons, Ltd.     

Control charts for monitoring the median parameter of Birnbaum-Saunders distribution

In this paper, we propose control charts for monitoring the Birnbaum-Saunders (BS) median parameter (scale parameter) on the basis of three estimators. Comparison of the control charts in terms of average run length using probability control limits and those based on asymptotic distribution of three estimators for the median parameter is developed. We also present guidelines for practitioners about the minimum sample size needed to match out-of-control average run length with the asymptotic control limits in function of the median parameter after an extensive simulation study. Numerical example illustrates the applied monitoring of BS median parameter.     

Risk‐based metrics for performance evaluation of control charts

Control charts are commonly evaluated in terms of their average run length (ARL). However, since run length distributions are typically strongly skewed, the ARL gives a very limited impression about the actual run length performance. In this study, it is proposed to evaluate a control chart's performance using risk metrics, specifically the value at risk and the tail conditional expectation. When a control chart is evaluated for an in‐control performance, the risk is an early occurrence of a false alarm, whereas in an out‐of‐control state, there is a risk of a delayed detection. For these situations, risk metric computations are derived and exemplified for diverse types of control charts. It is demonstrated that the use of such risk metrics leads to important new insights into a control chart's performance. In addition to the cases of known process parameters for control chart design, these risk metrics are further used to analyze the estimation uncertainty in evaluating a control chart's performance if the design parameters rely on a phase 1 analysis. Benefits of the risk‐based metrics are discussed thoroughly, and these are recommended as supplements to the traditional ARL metric.