Control chart for monitoring multivariate COM-Poisson attributes

Statistical process control of multi-attribute count data has received much attention with modern data-acquisition equipment and online computers. The multivariate Poisson distribution is often used to monitor multivariate attributes count data. However, little work has been done so far on under- or over-dispersed multivariate count data, which is common in many industrial processes, with positive or negative correlation. In this study, a Shewhart-type multivariate control chart is constructed to monitor such kind of data, namely the multivariate COM-Poisson (MCP) chart, based on the MCP distribution. The performance of the MCP chart is evaluated by the average run length in simulation. The proposed chart generalizes some existing multivariate attribute charts as its special cases. A real-life bivariate process and a simulated trivariate Poisson process are used to illustrate the application of the MCP chart.     

Generally weighted moving average control charts using repetitive sampling

Abstract

Generally weighted moving average (GWMA) control charts have been validated for effective detection of small process shifts, and perform better than exponentially weighted moving average (EWMA) control charts. These charts are available based on single sampling; however, repetitive sampling charts have received less attention. Here, a GWMA control chart based on repetitive sampling (namely an RS-GWMA chart) is proposed for enhancing detectability of small process shifts. Simulations show that the proposed RS-GWMA chart with large design and small adjustment parameters outperforms existing hybrid EWMA (HEWMA) control charts based on repetitive sampling. An in-silico example is considered for demonstrating the applicability of the proposed RS-GWMA chart.     

A control chart for COM-Poisson distribution using a modified EWMA statistic

In this paper, a control chart has been developed for the Conway–Maxwell Poisson (COM-Poisson) distribution using the modified exponentially weighted moving average statistic. The proposed chart provides an efficient detection of smaller changes in the location parameter of the COM-Poisson distribution. The performance of the proposed control chart has been evaluated by the average and the standard deviation of the run length distribution for various parameters. Better detecting ability has also been compared with the existing control chart using EWMA statistic. Using simulation, we also showed the detecting ability over the traditional EWMA chart.     

A EWMA control chart based on an auxiliary variable and repetitive sampling for monitoring process location

ABSTRACT

This article develops an exponentially weighted moving average (EWMA) control chart using an auxiliary variable and repetitive sampling for efficient detection of small to moderate shifts in location. A EWMA statistic of a product estimator of the average (which utilities the information of auxiliary variables as well as repetitive sampling) is plotted on the proposed chart. The control chart coefficients of the proposed EWMA chart are determined for two strategic limits known as outer and inner control limits for the target in-control average run length. The performance of the proposed EWMA chart is studied using average run length when a shift occurs in the process average. The efficiency of the developed chart is compared with the competitive existing control charts. The results of the study revealed that proposed EWMA chart is more efficient than others to detect small changes in process mean.     

Design of an attribute np control chart for process monitoring based on repetitive group sampling under truncated life tests

In this paper, an attribute control chart under repetitive group sampling is designed for monitoring the production process where the lifetime of the product is considered as quality of the product. We assume that the lifetime follows the Pareto distribution of second kind with known shape parameter. The performance of the proposed chart is evaluated by average run length. The control limits coefficients as well as the repetitive group sampling parameter such as sample size are determined such that the in-control average run length is as close as to the specified average run length. Out-of-control average run length is also reported for different shift constants with corresponding optimal parameters. In addition, performance of proposed control chart is compared with the performance of existing chart. An economical designing of proposed control chart is also discussed.     

A control chart using an auxiliary variable and repetitive sampling for monitoring process mean

In this paper, a new control chart is proposed by using an auxiliary variable and repetitive sampling in order to enhance the performance of detecting a shift in process mean. The product-difference type estimator of the mean is plotted on the proposed control chart, which utilizes the information of an auxiliary variable correlated with the main quality variable. The proposed control chart is based on the outer and inner control limits so that repetitive sampling is allowed when the plotted statistic falls between the two limits. The average run length (ARL) of the proposed control chart is evaluated using the Monte Carlo simulation. The proposed control chart is compared with the Riaz M control chart and the results show the outperformance of the proposed control chart in terms of the ARL.     

On the improvement of one-sided S control charts

The most common charting procedure used for monitoring the variance of the distribution of a quality characteristic is the S control chart. As a Shewhart-type control chart, it is relatively insensitive in the quick detection of small and moderate shifts in process variance. The performance of the S chart can be improved by supplementing it with runs rules or by varying the sample size and the sampling interval. In this work, we introduce and study one-sided adaptive S control charts, supplemented or not with one powerful runs rule, for detecting increases or decreases in process variation. The properties of the proposed control schemes are obtained by using a Markov chain approach. Furthermore, a practical guidance for the choice of the most suitable control scheme is also provided.     

Copula-Based Bivariate ZIP Control Chart for Monitoring Rare Events

One difficulty with developing multivariate attribute control charts is the lack of the related joint distribution. So, if it would be possible to generate the joint distribution of two (or more) attribute characteristics, then a bivaraite (or multivariate) attribute control chart can be developed based on Types I and II errors. Copula function is a solution to the matter. In this article, applying the copula function approach, we achieve the joint distribution of two correlated zero inflated Poisson (ZIP) distributions. Then, using this joint distribution, we develop a bivaraite control chart which can be used for monitoring correlated rare events. This copula-based bivariate ZIP control chart is compared with the simultaneous use of two separate univariate ZIP control charts. Based on the average run length (ARL) measure, it is shown that the proposed control chart is much better than the simultaneous use of two separate univariate charts. In addition, a real case study related to the environmental air in a sterilization process is investigated to show the applicability of the developed control chart.     

Bootstrap-Based T 2 Multivariate Control Charts

Control charts have been used effectively for years to monitor processes and detect abnormal behaviors. However, most control charts require a specific distribution to establish their control limits. The bootstrap method is a nonparametric technique that does not rely on the assumption of a parametric distribution of the observed data. Although the bootstrap technique has been used to develop univariate control charts to monitor a single process, no effort has been made to integrate the effectiveness of the bootstrap technique with multivariate control charts. In the present study, we propose a bootstrap-based multivariate T ² control chart that can efficiently monitor a process when the distribution of observed data is nonnormal or unknown. A simulation study was conducted to evaluate the performance of the proposed control chart and compare it with a traditional Hotelling's T ² control chart and the kernel density estimation (KDE)-based T ² control chart. The results showed that the proposed chart performed better than the traditional T ² control chart and performed comparably with the KDE-based T ² control chart. Furthermore, we present a case study to demonstrate the applicability of the proposed control chart to real situations.     

Economic and economic–statistical designs of VSI Bayesian control chart using Monte Carlo method and ABC algorithm

The usual practice in using a Bayesian control chart to monitor a process is done by taking samples from the process with fixed sampling intervals. Recent studies on traditional control charts have shown that variable sampling interval (VSI) scheme compared to classical scheme (fixed ratio sampling, FRS) helps practitioners to detect process shifts more quickly. In this paper, the effectiveness of VSI scheme on performance of Bayesian control chart has been studied, based on economic (ED) and economic–statistical designs (ESD). Monte Carlo method and artificial bee colony algorithm have been utilized to obtain optimal design parameters of Bayesian control chart (sample size, sampling intervals, warning limit and control limit) since the statistic of this approach does not have any specified distribution. Finally, VSI Bayesian control chart has been compared to FRS Bayesian and VSI X-bar approaches based on ED and ESD, separately. According to the results, it has been found that the performance of VSI Bayesian scheme is better than FRS Bayesian and VSI X-bar approaches.     

Fast Initial Response Features for Poisson GWMA Control Charts

The Poisson GWMA (PGWMA) control chart is an extension model of Poisson EWMA chart. It is substantially sensitive to small process shifts for monitoring Poisson observations. Recently, some approaches have been proposed to modify EWMA charts with fast initial response (FIR) features. In this article, we employ these approaches in PGWMA charts and introduce a novel chart called Poisson double GWMA (PDGWMA) chart for comparison. Using simulation, various control schemes are designed and their average run lengths (ARLs) are computer and compared. It is shown that the PDGWMA chart is the first choice in detecting small shifts especially when the shifts are downward, and the PGWMA chart with adjusted time-varying control limits performs excellently in detecting great process shifts during the initial stage.     

The economic design of multivariate binomial EWMA VSSI control charts

Since multi-attribute control charts have received little attention compared with multivariate variable control charts, this research is concerned with developing a new methodology to employ the multivariate exponentially weighted moving average (MEWMA) charts for m-attribute binomial processes; the attributes being the number of nonconforming items. Moreover, since the variable sample size and sampling interval (VSSI) MEWMA charts detect small process mean shifts faster than the traditional MEWMA, an economic design of the VSSI MEWMA chart is proposed to obtain the optimum design parameters of the chart. The sample size, the sampling interval, and the warning/action limit coefficients are obtained using a genetic algorithm such that the expected total cost per hour is minimized. At the end, a sensitivity analysis has been carried out to investigate the effects of the cost and the model parameters on the solution of the economic design of the VSSI MEWMA chart.     

A control chart for monitoring process variation using multiple dependent state sampling

A control chart for monitoring process variation by using multiple dependent state (MDS) sampling is constructed in the present article. The operational formulas for in-control and out-of-control average run lengths (ARLs) are derived. Control constants are established by considering the target in-control ARL at a normal process. The extensive ARL tables are reported for various parameters and shifted values of process parameters. The performance of the proposed control chart has been evaluated with several existing charts in regard of ARLs, which empowered the presented chart and proved far better for timely detection of assignable causes. The application of the proposed concept is illustrated with a real-life industrial example and a simulation-based study to elaborate strength of the proposed chart over the existing concepts.     

A Multivariate Synthetic Control Chart for Monitoring the Process Mean Vector of Skewed Populations Using Weighted Standard Deviations

This article proposes a multivariate synthetic control chart for skewed populations based on the weighted standard deviation method. The proposed chart incorporates the weighted standard deviation method into the standard multivariate synthetic control chart. The standard multivariate synthetic chart consists of the Hotelling's T ² chart and the conforming run length chart. The weighted standard deviation method adjusts the variance–covariance matrix of the quality characteristics and approximates the probability density function using several multivariate normal distributions. The proposed chart reduces to the standard multivariate synthetic chart when the underlying distribution is symmetric. In general, the simulation results show that the proposed chart performs better than the existing multivariate charts for skewed populations and the standard T ² chart, in terms of false alarm rates as well as moderate and large mean shift detection rates based on the various degrees of skewnesses.     

Monitoring Process Variability with Individual Measurements Following Elliptically Contoured Distributions

An exponentially weighted moving average (EWMA) control chart of squared distance is developed by means of a double EWMA approach to monitor process dispersion with individual measurements distributed within the class of elliptically symmetric distributions. Several examples highlighting possible extensions of the control chart to multivariate processes are provided. In particular, for multivariate normal processes, an investigation on the detection power of the chart is carried out through Monte Carlo studies. The results show that the proposed control chart performs well, especially when a process has a small or moderate shift.     

A joint-adaptive np control chart with multiple dependent state sampling scheme

Although the classical Shewhart np control chart has been widely used to detect an out-of-control status of manufacturing process, it is static and there is lack of responsiveness to slight process changes. In this paper, an adaptive np control chart with a joint sampling strategy combining double sampling (DS) and variable sampling interval (VSI) is developed. The multiple dependent state sampling scheme is adopted to further improve the performance of the control chart. An economical design model to minimize the general cost of using the proposed chart is established and solved by a genetic algorithm. The numerical results show that comparing to traditional static np control chart, the proposed np chart yields better performance in terms of shorter time to signal an out-of-control process and less expected cost per unit of time. Comparisons are made to show the capability of the proposed chart in yielding average reductions of 5.01% and 8.89%, in the cost of the proposed model compared to situations in which either the DSVSI np chart or the traditional np chart is used.     

Economic design based on a multivariate Bayesian VSI chart with a dual control limit

In this paper, a multivariate Bayesian variable sampling interval (VSI) control chart for the economic design and optimization of statistical parameters is designed. Based on the VSI sampling strategy of a multivariate Bayesian control chart with dual control limits, the optimal expected cost function is constructed. The proposed model allows the determination of the scheme parameters that minimize the expected cost per time of the process. The effectiveness of the Bayesian VSI chart is estimated through economic comparisons with the Bayesian fixed sampling interval and the Hotelling's T² chart. This study is an in-depth study on a Bayesian multivariate control chart with variable parameter. Furthermore, it is shown that significant cost improvement may be realized through the new model.     

A new approach for monitoring process variance

ABSTRACT

Control charts are effective tools for signal detection in both manufacturing processes and service processes. Much service data come from a process with variables having non-normal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, should not be properly used in such circumstances. In this paper, we propose a new variance chart based on a simple statistic to monitor process variance shifts. We explore the sampling properties of the new monitoring statistic and calculate the average run lengths (ARLs) of the proposed variance chart. Furthermore, an arcsine transformed exponentially weighted moving average (EWMA) chart is proposed because the ARLs of this modified chart are more intuitive and reasonable than those of the variance chart. We compare the out-of-control variance detection performance of the proposed variance chart with that of the non-parametric Mood variance (NP-M) chart with runs rules, developed by Zombade and Ghute [Nonparametric control chart for variability using runs rules. Experiment. 2014;24(4):1683–1691], and the nonparametric likelihood ratio-based distribution-free exponential weighted moving average (NLE) chart and the combination of traditional exponential weighted moving average (EWMA) mean and EWMA variance (CEW) control chart proposed by Zou and Tsung [Likelihood ratio-based distribution-free EWMA control charts. J Qual Technol. 2010;42(2):174–196] by considering cases in which the critical quality characteristic has a normal, a double exponential or a uniform distribution. Comparison results showed that the proposed chart performs better than the NP-M with runs rules, and the NLE and CEW control charts. A numerical example of service times with a right-skewed distribution from a service system of a bank branch in Taiwan is used to illustrate the application of the proposed variance chart and of the arcsine transformed EWMA chart and to compare them with three existing variance (or standard deviation) charts. The proposed charts show better detection performance than those three existing variance charts in monitoring and detecting shifts in the process variance.     

Double moving average–EWMA control chart for exponentially distributed quality

A control chart is an ever-popular tool for monitoring the production process. The early detection of a process shift, if any, is the desire of the quality control personnel. In this article, an effective alternative control charting procedure has been developed for the monitoring of exponentially distributed quality characteristic using the double moving average combined with EWMA statistic. The performance of the proposed control chart is examined for different combinations of the shift constant, the EWMA smoothing parameter, the moving average span, and the target in-control average run lengths. It has been observed that the proposed control chart is more efficient in the detection of process shifts as compared to control chart suggested by Khoo and Wang for the same purpose. The proposed control chart is illustrated for practical usage with the help of a synthetic and a real dataset.     

Multiple dependent state repetitive sampling plans with or without auxiliary variable

In this article, a new variable acceptance sampling plan has been developed using the multiple dependent state repetitive sampling scheme for the normal distribution. The plan parameters have been determined so as to minimize the average sample number while satisfying the producer's and the consumer's risks under the operating characteristic function. The multiple dependent state repetitive sampling scheme has also been extended to the case of utilizing an auxiliary variable. The proposed sampling plans are compared with the existing sampling plans.