Efficient bivariate EWMA charts for monitoring process dispersion

To ensure high quality standards of a process, the application of control charts to monitor process performance has become a regular routine. Multivariate charts are a preferred choice in the presence of more than one process variable. In this article, we proposed a set of bivariate exponentially weighted moving average (EWMA) charts for monitoring the process dispersion. These charts are formulated based on a variety of dispersion statistics considering normal and non-normal bivariate parent distributions. The performance of the different bivariate EWMA dispersion charts is evaluated and compared using the average run length and extra quadratic loss criteria. For the bivariate normal process, the comparisons revealed that the EWMA chart based on the maximum standard deviation (SMAX_E) was the most efficient chart when the shift occurred in one quality variable. It also performed well when the sample size is small and the shift occurred in both quality variables. The EWMA chart based on the maximum average absolute deviation from median (MDMAX_E) performed better than the other charts in most situations when the shift occurred in the covariance matrix for the bivariate non-normal processes. An illustrative example is also presented to show the working of the charts.     

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.     

Robustness properties of multivariate EWMA control charts

In this paper, the robustness of the multivariate exponentially weighted moving average (MEWMA) control chart to non‐normal data is examined. Two non‐normal distributions of interest are the multivariate distribution and the multivariate gamma distribution. Recommendations for constructing MEWMA control charts when the normality assumption may be violated are provided. Copyright © 2002 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.     

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.     

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.     

New memory‐type dispersion control charts

The exponentially weighted moving average (EWMA) control chart is a memory‐type process monitoring tool that is frequently used to monitor small and moderate disturbances in the process mean and/or process dispersion. In this study, we propose 2 new memory‐type control charts for monitoring changes in the process dispersion, namely, the generally weighted moving average and the hybrid EWMA charts. We use Monte Carlo simulations to compute the run length profiles of the proposed control charts. The run length comparisons of the proposed and existing charts reveal that the generally weighted moving average and hybrid EWMA charts provide better protection than the existing EWMA chart when detecting small to moderate shifts in the process dispersion. An illustrative dataset is also used to show the superiority of the proposed charts over the existing chart.     

Efficient homogeneously weighted dispersion control charts with an application to distillation process

Monitoring disturbances in process dispersion using control chart is mostly based on the assumption that the quality characteristic follows normal distribution, which is not the case in many real-life situations. This paper proposes a set of new dispersion charts based on the homogeneously weighted moving average (HWMA) scheme, for efficient detection of shifts in process standard deviation (σ). These charts are based on a variety of σ estimators and are investigated for normal as well as heavy tailed symmetric and skewed distributions. The shift detection ability of the charts is evaluated using different run length characteristics, such as average run length (ARL), extra quadratic loss (EQL), and relative ARL measures. The performance of the proposed HWMA control charts is also compared with the existing EWMA dispersion charts, using different design parameters. Furthermore, an illustrative example is presented to monitor the vapor pressure in a distillation process.     

A Bivariate Semiparametric Control Chart Based on Order Statistics

In this article, a new bivariate semiparametric Shewhart‐type control chart is presented. The proposed chart is based on the bivariate statistic (X_(r), Y_(s)), where X_(r) and Y_(s) are the order statistics of the respective X and Y test samples. It is created by considering a straightforward generalization of the well‐known univariate median control chart and can be easily applied because it calls for the computation of two single order statistics. The false alarm rate and the in‐control run length are not affected by the marginal distributions of the monitored characteristics. However, its performance is typically affected by the dependence structure of the bivariate observations under study; therefore, the suggested chart may be characterized as a semiparametric control chart. An explicit expression for the operating characteristic function of the new control chart is obtained. Moreover, exact formulae are provided for the calculation of the alarm rate given that the characteristics under study follow specific bivariate distributions. In addition, tables and graphs are given for the implementation of the chart for some typical average run length values and false alarm rates. The performance of the suggested chart is compared with that of the traditional χ² chart as well as to the nonparametric SN² and SR² charts that are based on the multivariate form of the sign test and the Wilcoxon signed‐rank test, respectively. Finally, in order to demonstrate the applicability of our chart, a case study regarding a real‐world problem related to winery production is presented. Copyright © 2016 John Wiley & Sons, Ltd.     

Dynamic probability control limits for CUSUM charts for monitoring proportions with time-varying sample sizes

We consider the problem of monitoring a proportion with time-varying sample sizes. Control charts are generally designed by assuming a fixed sample size or a priori knowledge of a sample size probability distribution. Sometimes, it is not possible to know, or accurately estimate, a sample size distribution or the distribution may change over time. An improper assumption for the sample size distribution could lead to undesirable performance of the control chart. To handle this problem, we propose the use of dynamic probability control limits (DPCLs) which are determined successively as the sample sizes become known. The method is based on keeping the conditional probability of a false alarm at a predetermined level given that there has not been any earlier false alarm. The control limits dynamically change, and the in-control performance of the chart can be controlled at the desired level for any sequence of sample sizes. The simulation results support this result showing that there is no need for any assumption of a sample size distribution with the use of this proposed approach.     

Adaptive control charts for skew‐normal distribution

The standard Shewhart‐type chart, named FSS‐ chart, has been widely used to detect the mean shift of process by implementing fixed sample and sampling frequency schemes. The FSS‐ chart could be sensitive to the normality assumption and is inefficient to catch small or moderate shifts in the process mean. To monitor nonnormally distributed variables, Li et al [Commun Stat‐Theory Meth. 2014; 43(23):4908‐4924] extended the study of Tsai [Int J Reliab Qual Saf Eng. 2007; 14(1):49‐63] to provide a new skew‐normal FSS‐ (SN FSS‐ ) chart with exact control limits for the SN distribution. To enhance the sensitivity of the SN FSS‐ chart on detecting small or moderate mean shifts in the process, adaptive charts with variable sampling interval (VSI), variable sample size (VSS), and variable sample size and sampling interval (VSSI) are introduced for the SN distribution in this study. The proposed adaptive control charts include the normality adaptive charts as special cases. Simulation results show that all the proposed SN VSI‐ , SN VSS‐ , and SN VSSI‐ charts outperform the SN FSS‐ chart on detecting small or moderate shifts in the process mean. The impact of model misspecification on using the proposed adaptive charts and the sample size impact for using the FSS‐ chart to monitor the mean of SN data are also discussed. An example about single hue value in polarizer manufacturing process is used to illustrate the applications of the proposed adaptive charts.     

Efficient shift detection using multivariate exponentially-weighted moving average control charts and principal components

This paper demonstrates the use of principal components in conjunction with the multivariate exponentially-weighted moving average (MEWMA) control procedure for process monitoring. It is demonstrated that the number of variables to be monitored is reduced through this approach, and that the average run length to detect process shifts or upsets is substantially reduced as well. The performance of the MEWMA applied to all the variables may be related to the MEWMA control chart that uses principal components through the non-centrality parameter. An average run length table demonstrates the advantages of the principal components MEWMA over the procedure that uses all of the variables. An illustrative example is provided.     

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.     

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.     

Optimization design of the CUSUM and EWMA charts for autocorrelated processes

The traditional control charts produce frequent false alarm signals in the presence of autocorrelation. The implementation of the modified chart scheme is a way of handling the problem of autocorrelation in control charts. In modified charts, the standard control limits of the traditional charts are adjusted to offset the influence because of the autocorrelation. The exponentially weighted moving average– and cumulative sum–modified charts are 2 widely used charts for monitoring autocorrelated data. These charts have design parameters in their formulation, and the choice of these parameters play significant roles in the detection of out‐of‐control situations. In reality, the magnitude of the mean shift is uncertain, and this leads to a difficulty in the choice of design parameters by the practitioner. The use of optimal parameters can enhance process performance in such situations. In this paper, we determine optimal design parameters for the charts using an exhaustive search procedure. In the optimization process, we determine the parameters that produce the smallest extra quadratic loss (EQL) value for each autocorrelation coefficient. This criterion measures the anticipated loss attributed to poor quality in the process. The loss in quality is lowered by minimizing the EQL and the combination of parameters in the chart that yields the smallest EQL has a better detection ability over the entire shift range. For the purpose of this work, we concentrate on autocorrelation that can be specifically modelled with autoregressive models. This article provides the practitioner with optimal parameters that can be used to enhance the overall effectiveness of the charts over an entire shift range.     

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.     

Approximate design and performance of the robust control charts for monitoring dispersion in Phase I

This article designs and studies the approximate performance of robust dispersion charts, namely, MAD chart, S_n chart, and Q_n chart, in Phase I analysis (recently developed in the literature). The proposed limits are based on false alarm probability for monitoring the dispersion of a process in Phase I analysis. The charting constants are determined to achieve the required nominal FAP (FAP₀). The performance of these structures is evaluated in (i) the attained false alarm rate and (ii) the probability of signals for out‐of‐control situations. The analysis shows that the proposed design of Phase I robust dispersion charts correctly controls the FAP and shows a good performance in detecting the shifts in the process variation. An illustrative example is used to explain the practical implementation of these limits.     

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.     

The effects of violations of the multivariate normality assumption in multivariate Shewhart and MEWMA control charts

A multivariate Shewhart and a multivariate exponentially weighted moving average control charts are types of multivariate control charts for monitoring the mean vector. For those control charts, a multivariate normal distribution is an important assumption that is used to describe a behavior of a set of quality characteristics of interest. This research explores the sensitivity of average run lengths and standard deviation of run lengths for the multivariate Shewhart and the multivariate exponentially weighted moving average control charts when the normality assumption is incorrect.