An Economic Approach to the Management of High‐Quality Processes

Modern manufacturing developments have forced researchers to investigate alternative quality control techniques for high‐quality processes. The cumulative count of conforming (CCC) control chart is a powerful alternative approach for monitoring high‐quality processes for which traditional control charts are inadequate. This study develops a mathematical model for the economic design of the CCC control chart and presents an application of the proposed model. On the basis of the results of the application, the economic and classical CCC control chart designs of the CCC control chart are compared. The optimal design parameters for different defective fractions are tabulated, and a sensitivity analysis of the model is presented for the CCC control chart user to determine the optimal economic design parameters and minimum hourly costs for one production run according to different defective fractions, cost, time, and process parameters. Copyright © 2012 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.     

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.     

Auxiliary-information-based efficient variability control charts for Phase I of SPC

The inclusion of correlated auxiliary variables into the monitoring scheme of quality characteristic of interest has gained notable attention in recent statistical process control (SPC) literature. Several authors have investigated the use of a correlated auxiliary variable for efficient monitoring of variability in Phase II of SPC. This phase is generally used to detect any shifts in the expected behavior of the process parameters which are often estimated from the historical in-control process in Phase I. However, no study has investigated the performance of auxiliary-based variability charts in Phase I of SPC. Here, we propose auxiliary-based dispersion control charts in Phase I of SPC. The auxiliary information is considered in the forms of regression, ratio, exponential, and power-ratio forms. The performance of the variability charts is evaluated and compared using probability to signal as a performance measure. An illustrative example is also provided to show the application of the charts. This study will provide practitioners with appropriate recommendations on the choice of dispersion charts for Phase I analysis.     

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.     

Using statistical control charts for software quality control

This paper describes the use of Shewhart U charts for controlling software quality while the software is under development. A parallel between the software development process and a complex manufacturing process is developed. This allows the use of statistical control charts to monitor the software development process. The general approach is to let observed defect data represent a sample of the true but unknown state of the entire software project. Software quality data so obtained can be used to derive a meaningful statistical interpretation of the state of the development project. Based upon this interpretation management can take action to improve the overall software quality while in the development stages.     

Improved one‐sided control charts for the mean of a positively skewed population using truncated saddlepoint approximations

This paper develops a truncated saddlepoint (TS) control chart for the mean of a population with a skewed density. This chart requires the estimation of only a few population cumulants from sample data and is relatively straightforward in construction. Performance is assessed at various levels of truncation in terms of type 1 and 2 error rates and compared with other heuristic control charts via the Monte Carlo simulation. The truncated saddlepoint (TS) chart is shown to generally outperform these charts, especially in cases with small sample sizes or high levels of population skewness. Copyright © 2011 John Wiley & Sons, Ltd.     

Improved design of robust exponentially weighted moving average control charts for autocorrelated processes

Residual‐based control charts for autocorrelated processes are known to be sensitive to time series modeling errors, which can seriously inflate the false alarm rate. This paper presents a design approach for a residual‐based exponentially weighted moving average (EWMA) chart that mitigates this problem by modifying the control limits based on the level of model uncertainty. Using a Bayesian analysis, we derive the approximate expected variance of the EWMA statistic, where the expectation is with respect to the posterior distribution of the unknown model parameters. The result is a relatively clean expression for the expected variance as a function of the estimated parameters and their covariance matrix. We use control limits proportional to the square root of the expected variance. We compare our approach to two other approaches for designing robust residual‐based EWMA charts and argue that our approach generally results in a more appropriate widening of the control limits. Copyright © 2010 John Wiley & Sons, Ltd.     

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.     

Model‐based control chart for autoregressive and correlated data

In recent years, statistical process control for autocorrelated processes has received a great deal of attention. This is due in part to the improvements in measurement and data collection that allow processes to be sampled at higher frequency rates and, hence, data autocorrelation. A method for monitoring autocorrelated processes based on regression adjustment is presented in this paper. The performance of the residual‐based control chart in terms of the average run length is compared to observation‐based control charts via Monte Carlo simulations. In general, the observation‐based control charts perform very poorly when data are correlated over time. Under the assumption that the model is correct, the residual‐based control charts are superior for all cases considered here. This suggests using a residual‐based control chart to detect the mean shift. This is recommended particularly for chemical processes where there are often cascade processes with several inputs but only a few outputs, and where many of the variables are highly autocorrelated. Copyright © 2002 John Wiley & Sons, Ltd.     

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.     

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.     

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.     

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.     

Improving the performance of CUSUM charts

The control chart is an important statistical technique that is used to monitor the quality of a process. Shewhart control charts are used to detect larger disturbances in the process parameters, whereas CUSUM and EWMA charts are meant for smaller and moderate changes. Runs rules schemes are generally used to enhance the performance of Shewhart control charts. In this study, we propose two runs rules schemes for the CUSUM charts. The performance of these two schemes is compared with the usual CUSUM, the weighted CUSUM, the fast initial response CUSUM and the usual EWMA schemes. The comparisons revealed that the proposed schemes perform better for small and moderate shifts, whereas they reasonably maintain their efficiency for large shifts as well. Copyright © 2010 John Wiley & Sons, Ltd.     

Control charts for traffic intensity monitoring of Markovian multiserver queues

A number of recent research studies have applied queueing theory as an approximate modeling tool to mathematically describe industrial systems, which include manufacturing, distribution, and service, for instance. Among the main observable characteristics in queues, the number of users in the system can be controlled to keep waiting times as minimal as possible. The design of efficient control charts is an attempt to monitor and control such systems. Control charts are proposed to monitor infinite queues with Markovian arrivals, exponential service times, and s identical parallel servers. The proposed charts monitor traffic intensities, which are the ratio between the arrival rate and the service rate, estimated through the number of users in the queueing system at random epochs. The effectiveness and efficiency of the proposed approaches in terms of the average run lengths are established by a comprehensive set of Monte Carlo simulations.     

An np‐control chart for inspection errors and repeated classifications

The np‐control chart has been used to monitor the conforming fraction in process production, and it is assumed that no classification errors occur during the inspection process. Increases in the sample size and/or the number of repeated classifications of the inspected items can reduce the impact of the classification errors. In this paper, an np ‐control chart is proposed, and the monitored statistics are based on the results of independent repeated classifications with classification errors during the inspection process. The aim of the proposed control chart is to have the same performance as a control chart without classification errors. Numerical examples illustrate the proposal. Copyright © 2011 John Wiley & Sons, Ltd.     

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.