A distribution-free CUSUM chart for joint monitoring of location and scale based on the combination of Wilcoxon and Mood statistics

We propose a distribution-free cumulative sum (CUSUM) chart for joint monitoring of location and scale based on a Lepage-type statistic that combines the Wilcoxon rank sum and the Mood statistics. Monte Carlo simulations were used to obtain control limits and examine the in-control and out-of-control performance of the new chart. A direct comparison of the new chart was made with the original CUSUM Lepage based on Wilcoxon rank sum and Ansari-Bradley statistics. The result is a more powerful chart in most of the considered scenarios and thus a more useful CUSUM chart. An example using real data illustrates how the proposed control chart can be implemented.     

Adaptive nonparametric CUSUM scheme for detecting unknown shifts in location

In this paper, we provide a sequential rank-based adaptive nonparametric cumulative sum control chart for detecting a range of shifts in the location parameter. This chart is a self-starting scheme, and thus can be used to monitor processes at the start-up stages rather than having to wait for the accumulation of sufficiently large calibration samples. It does not require any prior knowledge of the underlying distribution. The choice of the chart parameters is studied and a simulation study demonstrates that the proposed control chart not only performs robustly for different distributions, but also efficiently detects various magnitudes of shifts. An illustrative example is also given to introduce the implementation of this proposed control chart.     

An EWMA signed ranks control chart with reliable run length performances

During the design phase of a control chart, the determination of its exact run length properties plays a vital role for its optimal operation. Markov chain or integral equation methods have been extensively applied in the design phase of conventional control charts. However, for distribution-free schemes, due to the discrete nature of the statistics being used (such as the sign or the Wilcoxon signed rank statistics, for instance), it is impossible to accurately compute their run length properties. In this work, a modified distribution-free phase II exponentially weighted moving average (EWMA)-type chart based on the Wilcoxon signed rank statistic is considered and its exact run length properties are discussed. A continuous transformation of the Wilcoxon signed rank statistic, combined with the classical Markov chain method, is used for the determination of the average run length in the in- and out-of control cases. Moreover, its exact performance is derived without any knowledge of the distribution of sample observations. Finally, an illustrative example is provided showing the practical implementation of our proposed chart.     

Comparisons of Shewhart-type rank based control charts for monitoring location parameters of univariate processes

The nonparametric (distribution-free) control charts are robust alternatives to the conventional parametric control charts when the form of underlying process distribution is unknown or complicated. In this paper, we consider two new nonparametric control charts based on the Hogg–Fisher–Randle (HFR) statistic and the Savage rank statistic. These are popular statistics for testing location shifts, especially in right-skewed densities. Nevertheless, the control charts based on these statistics are not studied in quality control literature. In the current context, we study phase-II Shewhart-type charts based on the HFR and Savage statistics. We compare these charts with the Wilcoxon rank-sum chart in terms of false alarm rate, out-of-control average run-length and other run length properties. Implementation procedures and some illustrations of these charts are also provided. Numerical results based on Monte Carlo analysis show that the new charts are superior to the Wilcoxon rank-sum chart for a class of non-normal distributions in detecting location shift. New charts also provide better control over false alarm when reference sample size is small.     

A nonparametric double generally weighted moving average signed-rank control chart for monitoring process location

Most control charts have been developed based on the actual distribution of the quality characteristic of interest. However, in many applications, there is a lack of knowledge about the process distribution. Therefore, in recent years, nonparametric (or distribution-free) control charts have been introduced for monitoring the process location or scale parameter. In this article, a nonparametric double generally weighted moving average control chart based on the signed-rank statistic (referred as DGWMA-SR chart) is proposed for monitoring the location parameter. We provide the exact approach to compute the run-length distribution, and through an extensive simulation study, we compare the performance of the proposed chart with existing nonparametric charts, such as the exponentially weighted moving average signed-rank (EWMA-SR), the generally weighted moving average signed-rank (GWMA-SR), the double exponentially weighted moving average signed-rank (DEWMA-SR), and the double generally weighted moving average sign (DGWMA-SN) charts, as well as the parametric DGWMA- $\overline{X}$ chart for subgroup averages. The simulation results show that the DGWMA-SR chart (with suitable parameters) is more sensitive than the other competing charts for small shifts in the location parameter and performs as well as the other nonparametric charts for larger shifts. Finally, two examples are given to illustrate the application of the proposed chart.     

A new nonparametric double exponentially weighted moving average control chart

There are many practical situations where the underlying distribution of the quality characteristic either deviates from normality or it is unknown. In such cases, practitioners often make use of the nonparametric control charts. In this paper, a new nonparametric double exponentially weighted moving average control chart on the basis of the signed-rank statistic is proposed for monitoring the process location. Monte Carlo simulations are carried out to obtain the run length characteristics of the proposed chart. The performance comparison of the proposed chart with the existing parametric and nonparametric control charts is made by using various performance metrics of the run length distribution. The comparison showed the superiority of the suggested chart over its existing parametric and nonparametric counterparts. An illustrative example for the practical implementation of the proposed chart is also provided by using the industrial data set.     

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.     

A CUSUM scheme with variable sample sizes and sampling intervals for monitoring the process mean and variance

The adaptive control feature and CUSUM chart are two monitoring schemes that are much more effective than the traditional static Shewhart chart in detecting process shifts in mean and variance. However, the designs and analyses of the adaptive CUSUM chart are mathematically intractable and the operation is very laborious. This article proposes a VSSI WLC scheme, which is a weighted‐loss‐function‐based CUSUM (WLC) scheme using variable sample sizes and sampling intervals (VSSI). This scheme detects the two‐sided mean shift and increasing standard deviation shift based on a single statistic WL (the weighted loss function). Most importantly, the VSSI WLC scheme is much easier to operate and design than a VSSI CCC scheme which comprises three individual CUSUM charts (two of them monitoring the increasing and decreasing mean shifts and one monitoring the increasing variance shift). Overall, the VSSI WLC scheme is much more effective than the static &S charts (by 72.36%), the VSSI &S charts (by 30.97%) and the static WLC scheme (by 50.94%) for detection. It is even more effective than the complicated VSSI CCC scheme for most cases. Copyright © 2006 John Wiley & Sons, Ltd.     

Investigation and characterization of a control scheme for multivariate quality control

A new scheme for multivariate statistical quality control is investigated and characterized. The control scheme consists of three steps and it will identify any out-of-control samples, select the subset of variables that are out of control, and diagnose the out-of-control variables. A new control variable selection algorithm, the backward selection algorithm, and a new control variable diagnosis method, the hyperplane methods, are proposed. It is shown by simulation that the control scheme is useful in cases where the process variables are correlated and where they are uncorrelated.     

Nonparametric cost‐minimized Shewhart‐type process monitoring with restricted false alarm probability

Traditional Duncan‐type models for cost‐efficient process monitoring often inflate type I error probability. Nevertheless, controlling the probability of type I error or false alarms is one of the key issues in sequential monitoring of specific process characteristics. To this end, researchers often recommend economic‐statistical designs. Such designs assign an upper bound on type I error probability to avoid excessive false alarms while achieving cost optimality. In the context of process monitoring, there is a plethora of research on parametric approaches of controlling type I error probability along with the cost optimization. In the nonparametric setup, most of the existing works on process monitoring address one of the two issues but not both simultaneously. In this article, we present two distribution‐free cost‐efficient Shewhart‐type schemes for sequentially monitoring process location with restricted false alarm probability, based, respectively, on the sign and Wilcoxon rank‐sum statistics. We consider the one‐sided shift in location parameter in an unknown continuous univariate process. Nevertheless, one can easily extend our proposed schemes to monitor the two‐sided process shifts. We evaluate and compare the actual performance of the two monitoring schemes employing extensive computer simulation based on Monte Carlo. We investigate the effects of the size of the reference sample and the false alarm constraint. Finally, we provide two illustrative examples, each based on a realistic situation in the industry.     

Distribution-free double-sampling precedence monitoring scheme to detect unknown shifts in the location parameter

In most applications, parametric monitoring schemes are used to monitor the majority of industrial and nonindustrial processes in order to improve the quality of the outputs or services. However, parametric monitoring schemes are known to underperform when the normality assumption is not met or when there is not enough information about the symmetry or asymmetry nature of the process underlying distribution. Hence, in this paper, a new nonparametric Phase II Shewhart-type double-sampling (DS) monitoring scheme based on the precedence statistic is proposed in order to efficiently monitor quality processes when the underlying process distribution departs from normality. The performance is investigated using the average run length (ARL), standard deviation of the run length (SDRL), expected ARL (EARL) and expected average number of observations to signal (EANOS), and the average sample sizes (ASS) metrics. The latter metrics are computed using Monte Carlo simulation and exact formulae. In general, it is shown that the new DS precedence scheme outperforms the existing basic Shewhart precedence scheme with and without supplementary runs rules in many situations. A real-life illustrative example based on a filling process of milk bottles is provided to demonstrate the application and implementation of the new DS precedence monitoring scheme.     

On the design of control charts with guaranteed conditional performance under estimated parameters

When designing control charts the in-control parameters are unknown, so the control limits have to be estimated using a Phase I reference sample. To evaluate the in-control performance of control charts in the monitoring phase (Phase II), two performance indicators are most commonly used: the average run length (ARL) or the false alarm rate (FAR). However, these quantities will vary across practitioners due to the use of different reference samples in Phase I. This variation is small only for very large amounts of Phase I data, even when the actual distribution of the data is known. In practice, we do not know the distribution of the data, and it has to be estimated, along with its parameters. This means that we have to deal with model error when parametric models are used and stochastic error because we have to estimate the parameters. With these issues in mind, choices have to be made in order to control the performance of control charts. In this paper, we discuss some results with respect to the in-control guaranteed conditional performance of control charts with estimated parameters for parametric and nonparametric methods. We focus on Shewhart, exponentially weighted moving average (EWMA), and cumulative sum (CUSUM) control charts for monitoring the mean when parameters are estimated.     

Nonparametric triple exponentially weighted moving average signed-rank control chart for monitoring shifts in the process location

Nonparametric (or distribution-free) control charts are used for monitoring processes where there is a lack of knowledge about the underlying distribution. In this article, a triple exponentially weighted moving average control chart based on the signed-rank statistic (referred as TEWMA-SR chart) is proposed for monitoring shifts in the location parameter of an unknown, but continuous and symmetric, distribution. The run-length characteristics of the proposed chart are evaluated performing Monte Carlo simulations. A comparison study with other existing nonparametric control charts based on the signed-rank statistic, the TEWMA sign chart, and the parametric TEWMA-$\overline{X}$ chart indicates that the proposed chart is more effective in detecting small shifts, while it is comparable with the other charts for moderate and large shifts. Finally, two illustrative examples are provided to demonstrate the application of the proposed chart.     

Distribution-free triple EWMA control chart for monitoring the process location using the Wilcoxon rank-sum statistic with fast initial response feature

The exponentially weighted moving average (EWMA) control chart is a memory-type chart known to be more efficient in detecting small and moderate shifts in the process parameter. The double EWMA (DEWMA) chart is an extension of the EWMA chart that is more effective than the latter in the detection of small-to-moderate shifts. This paper proposes a new distribution-free (or nonparametric) triple EWMA (TEWMA) control chart based on the Wilcoxon rank-sum (W) statistic to improve the detection ability in the process location parameter. Moreover, a new fast initial response (FIR) feature is added to further improve the sensitivity of the new TEWMA chart. The performance of the proposed TEWMA chart with and without FIR features is compared to those of the existing EWMA and DEWMA W charts. It is observed that the TEWMA chart with and without FIR features is superior to the competing charts in most situations. A real-life illustration is provided to show the application and implementation of the new chart.     

Distribution-free composite Shewhart-GWMA Mann-Whitney charts for monitoring the process location

The Mann-Whitney (MW) statistic is one of the most recommended two-sample statistical tests when the assumption of normality fails to hold due to its robustness and fascinating properties especially when small sample sizes are involved. In order to improve the sensitivity of the generally weighted moving average (GWMA) monitoring scheme toward the detection of large shifts, in this paper, a new distribution-free phase II composite Shewhart-GWMA (CSG) scheme is proposed using the MW U statistic. The performance of the proposed scheme is investigated using the average run-length (ARL) and average extra quadratic loss (AEQL) values through extensive simulations. The performance of this newly proposed monitoring scheme is found to be superior when compared to numerous memory-type MW schemes (some existing and others introduced in this paper) in many situations. An illustrative example is given to demonstrate the implementation of the CSG MW U scheme using real-life data.     

A modified CUSUM control chart for monitoring industrial processes

Control charts are the most popular tool of statistical process control for monitoring variety of processes. The detection ability of these control charts can be improved by introducing various transformations. In this study, we have enhanced the performance of CUSUM charts by introducing a link relative variable transformation technique. Link relative variable converts the original process variable in a form which is relative to its mean. So, the link relative represents the relative positioning of the observations. Average run length (ARL ) is used to compare our technique with the previous studies. The comparison shows the overall good detection performance of our scheme for a span of shifts in the mean. A real‐world example from the electrical engineering process is also included to demonstrate the application of proposed control chart.     

Design and implementation issues for a class of distribution-free Phase II EWMA exceedance control charts

Distribution-free (nonparametric) control charts can play an essential role in process monitoring when there is dearth of information about the underlying distribution. In this paper, we study various aspects related to an efficient design and execution of a class of nonparametric Phase II exponentially weighted moving average (denoted by NPEWMA) charts based on exceedance statistics. The choice of the Phase I (reference) sample order statistic used in the design of the control chart is investigated. We use the exact time-varying control limits and the median run-length as the metric in an in-depth performance study. Based on the performance of the chart, we outline implementation strategies and make recommendations for selecting this order statistic from a practical point of view and provide illustrations with a data-set. We conclude with a summary and some remarks.     

A control scheme for monitoring the frequency and magnitude of an event

While many control charts have been developed for monitoring the time interval (t) between the occurrences of an event, many other charts are employed to examine the magnitude (x) of the event. These two types of control charts have usually been investigated and applied separately with limited syntheses in conventional statistical process control (SPC) methods. This article presents an SPC method for simultaneously monitoring the time interval t and magnitude x. It, essentially, combines a t chart and an x chart, and is therefore referred to as a t&x chart. The new chart is more effective than an individual t chart or individual x chart for detecting the out-of-control status of the event, in particular for detecting downward shifts (sparse occurrence and/or small magnitude). More profound is that, compared with an individual t or x chart, the detection effectiveness of the t&x chart is more invariable against different types of shifts, i.e. t shift, x shift and joint shift in t and x. The t&x chart has demonstrated its potential not only for manufacturing systems, but also for non-manufacturing sectors such as supply chain management, office administration and health care industry.     

Optimal initial production control period based on a quality growth model

The initial production phase of new products or the initial installation phase of new manufacturing facilities is often unstable because of inexperienced workers and many defective products. An initial production process control, in which the defects in design, production technologies and products are fully fixed and removed, is switched to a normal process control whenever it is ready for actual mass production. This paper discusses a method of deciding the optimal initial production control period, based on a quality growth model. It is determined by the number of products with the minimum expected total quality control cost. Finally a penalty cost due to unattainable loss to the quality goal is introduced in the quality control cost: the realized stabilization level of the initial production process control is lower than the original quality objective. Numerical illustrations of the optimal policy are also presented. Copyright © 1999 John Wiley & Sons, Ltd.