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.     

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.     

An exact method for designing Shewhart and S2 control charts to guarantee in-control performance

The in-control performance of Shewhart and S² control charts with estimated in-control parameters has been evaluated by a number of authors. Results indicate that an unrealistically large amount of Phase I data is needed to have the desired in-control average run length (ARL) value in Phase II. To overcome this problem, it has been recommended that the control limits be adjusted based on a bootstrap method to guarantee that the in-control ARL is at least a specified value with a certain specified probability. In this article we present simple formulas using the assumption of normality to compute the control limits and therefore, users do not have to use the bootstrap method. The advantage of our proposed method is in its simplicity for users; additionally, the control chart constants do not depend on the Phase I sample data.     

Moving range charts for monitoring the Weibull shape parameter with single observation samples

This paper proposes an approach to monitor shifts in the Weibull shape parameter bfβ via control charts based on the moving range of single‐point samples from a smallest extreme value distribution. The average run length (ARL) of the proposed charts are computed using Fredholm integral equations of the second kind. The derived control limits for one‐sided and two‐sided control charts are unbiased in the sense that the ARL when β has shifted is shorter than the desired stable‐process ARL. These control limits depend only on the desired stable‐process ARL and the stable value of β. The paper also discusses the sample size requirements for Phase I so that the run length distributions are similar under standards‐given scenario (β is given) and retrospective scenario (β is estimated from past data). The proposed methods are then applied to data on the breaking strengths of carbon fibers. The results suggest that one‐sided control charts can detect small shifts in β sooner than two‐sided charts. Copyright © 2011 John Wiley & Sons, Ltd.     

A comparative study of CCC and CUSUM charts

The cumulative count of conforming (CCC) chart is a new type of control chart used for the monitoring of high-quality processes. Instead of counting the number of non-conforming items in samples of fixed size, the cumulative number of conforming items between two non-conforming items is monitored. The CCC chart is convenient to use in a modern manufacturing environment where the product is inspected individually and automatically. The CCC chart has sometimes been confused with the cumulative sum (CUSUM) chart which has been shown to be more sensitive than the traditional Shewhart chart for small process shifts. In this paper the uses of these two types of charts are compared. It shown by numerical illustrations and analytical results that the two charts function in entirely different ways. However, the CUSUM concept can be applied to cumulative counts used in the CCC chart to improve its sensitivity for small process shifts when the process is producing at a very low non-conforming rate. © 1998 John Wiley & Sons, Ltd.     

EWMA control chart limits for first‐ and second‐order autoregressive processes

Today's manufacturing environment has changed since the time when control chart methods were originally introduced. Sequentially observed data are much more common. Serial correlation can seriously affect the performance of the traditional control charts. In this article we derive explicit easy‐to‐use expressions of the variance of an EWMA statistic when the process observations are autoregressive of order 1 or 2. These variances can be used to modify the control limits of the corresponding EWMA control charts. The resulting control charts have the advantage that the data are plotted on the original scale making the charts easier to interpret for practitioners than charts based on residuals. Copyright © 2008 John Wiley & Sons, Ltd.     

Percentile‐based control chart design with an application to Shewhart X̅ and S2 control charts

We present a method to design control charts such that in‐control and out‐of‐control run lengths are guaranteed with prespecified probabilities. We call this method the percentile‐based approach to control chart design. This method is an improvement over the classical and popular statistical design approach employing constraints on in‐control and out‐of‐control average run lengths since we can ensure with prespecified probability that the actual in‐control run length exceeds a desired magnitude. Similarly, we can ensure that the out‐of‐control run length is less than a desired magnitude with prespecified probability. Some numerical examples illustrate the efficacy of this design method.     

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.     

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.     

Monitoring the Weibull Shape Parameter by Control Charts for the Sample Range of Type II Censored Data

In this paper, we propose control charts to monitor the Weibull shape parameter β under type II (failure) censoring. This chart scheme is based on the sample ranges of smallest extreme value distributions derived from Weibull processes. We suggest one‐sided (high‐side or low‐side) and two‐sided charts, which are unbiased with respect to the average run length (ARL). The control limits for all types of charts depend on the sample size, the number of failures c under type II censoring, the desired stable‐process ARL, and the stable‐process value of β. This article also considers sample size requirements for phase I in retrospective charts. We investigate the effect of c on the out‐of‐control ARL. We discuss a simple approach to choosing c by cost minimization. The proposed schemes are then applied to data on the breaking strengths of carbon fibers. Copyright © 2011 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.     

A new approach to setting control limits of cumulative count of conforming charts for high‐yield processes

Cumulative count of conforming (CCC‐r) charts are usually used to monitor non‐conforming fraction p in high‐yield processes. Existing approaches to setting the control limits may cause non‐maximal or biased in‐control average run length (ARL). Non‐maximal in‐control ARL implies that the chart might not quickly detect the upward shift of p from its nominal value p₀. On the other hand, biased in‐control ARL means that both the in‐control and out‐of‐control ARLs are inflated. This paper develops a new approach to setting control limits for CCC‐r charts with near‐maximal and near‐unbiased in‐control ARL. Experimental results show that the proposed approach is effective in terms of the maximization and unbiasedness of in‐control ARL. Copyright © 2009 John Wiley & Sons, Ltd.     

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.     

Memory‐type multivariate control charts with auxiliary information for process mean

In statistical process control, it is a common practice to increase the sensitivity of a control chart with the help of an efficient estimator of the underlying process parameter. In this paper, we consider an efficient estimator that requires information on several study variables along with one or more auxiliary variables when estimating the mean of a multivariate normally distributed process. Using this auxiliary‐information‐based (AIB) process mean estimator, we propose new multivariate EWMA (MEWMA), double MEWMA (DMEWMA), and multivariate CUSUM (MCUSUM) charts for monitoring the process mean, denoted by the AIB‐MEWMA, AIB‐DMEWMA, and AIB‐MCUSUM charts, respectively. The run length characteristics of the proposed multivariate charts are computed using Monte Carlo simulations. The proposed charts are compared with their existing counterparts in terms of the run length characteristics. It turns out that the AIB‐MEWMA, AIB‐DMEWMA, and AIB‐MCUSUM charts are uniformly and substantially better than the MEWMA, DMEWMA, and MCUSUM charts, respectively, when detecting different shifts in the process mean. A real dataset is considered to explain the implementation of the proposed and existing multivariate control charts.     

About Shewhart control charts to monitor the Weibull mean

In this paper, a new reparametrization expressed in terms of the process mean for Weibull distribution is studied; thus, the monitoring of the process mean can be made directly. Additionally, we call attention that the asymptotic control limits for control chart by central limit theorem (CLT) may lead to a serious erroneous decision. Definitively, they can only be used to signal small/medium shifts in the process mean but with a very very large sample size. We present guidelines for practitioners about the minimum sample size needed to match out‐of‐control average run length (ARL₁) with the exact and asymptotic control limits in function of the shape parameter after an extensive simulation study. The proposed schemes are applied to monitoring the Weibull mean parameter of the strength distribution of a carbon fibber used in composite materials.     

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.     

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.     

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.