Statistical Monitoring of Nominal Logistic Profiles in Phase II

Statistical analysis of profile monitoring, a relatively new sub-area of statistical process control due to its applications in different industries, have urged researchers and practitioners to contribute to the developments of new monitoring methods. A statistical profile is a relationship between a quality characteristic (a response) and one or more independent variables to characterize quality of a process or a product. In this article, statistical profiles based on nominal responses are studied, where logistic regression is used to model the responses. Three approaches including likelihood ratio test (LRT), multivariate exponentially weighted moving average (MEWMA), and support vector machines (SVM) approaches are proposed to monitor quality of a process or product in Phase II. Performances of the proposed approaches are evaluated and compared using a case study. Moreover, the effect of two important factors on average run length (ARL) performance, number of levels and number of covariates, has been considered. Results indicate that performance of all approaches depends on the number of covariates and levels. As the number of these factors increases, SVM performance improves while performance of the other approaches deteriorates.     

The effect of parameter estimation on phase II monitoring of poisson regression profiles

ABSTRACT

The effect of parameters estimation on profile monitoring methods has only been studied by a few researchers and only the assumption of a normal response variable has been tackled. However, in some practical situation, the normality assumption is violated and the response variable follows a discrete distribution such as Poisson. In this paper, we evaluate the effect of parameters estimation on the Phase II monitoring of Poisson regression profiles by considering two control charts, namely the Hotelling’s T² and the multivariate exponentially weighted moving average (MEWMA) charts. Simulation studies in terms of the average run length (ARL) and the standard deviation of the run length (SDRL) are carried out to assess the effect of estimated parameters on the performance of Phase II monitoring approaches. The results reveal that both in-control and out-of-control performances of these charts are adversely affected when the regression parameters are estimated.     

Control charts based on quasi-likelihood estimation for monitoring profiles

In some applications, the quality of the process or product is characterized and summarized by a functional relationship between a response variable and one or more explanatory variables. Profile monitoring is a technique for checking the stability of the relationship over time. Existing linear profile monitoring methods usually assumed the error distribution to be normal. However, this assumption may not always be true in practice. To address this situation, we propose a method for profile monitoring under the framework of generalized linear models when the relationship between the mean and variance of the response variable is known. Two multivariate exponentially weighted moving average control schemes are proposed based on the estimated profile parameters obtained using a quasi-likelihood approach. The performance of the proposed methods is evaluated by simulation studies. Furthermore, the proposed method is applied to a real data set, and the R code for profile monitoring is made available to users.     

Phase I monitoring of generalized linear model-based regression profiles

In some industrial applications, the quality of a process or product is characterized by a relationship between the response variable and one or more independent variables which is called as profile. There are many approaches for monitoring different types of profiles in the literature. Most researchers assume that the response variable follows a normal distribution. However, this assumption may be violated in many cases. The most likely situation is when the response variable follows a distribution from generalized linear models (GLMs). For example, when the response variable is the number of defects in a certain area of a product, the observations follow Poisson distribution and ignoring this fact will cause misleading results. In this paper, three methods including a T²-based method, likelihood ratio test (LRT) method and F method are developed and modified in order to be applied in monitoring GLM regression profiles in Phase I. The performance of the proposed methods is analysed and compared for the special case that the response variable follows Poisson distribution. A simulation study is done regarding the probability of the signal criterion. Results show that the LRT method performs better than two other methods and the F method performs better than the T²-based method in detecting either small or large step shifts as well as drifts. Moreover, the F method performs better than the other two methods, and the LRT method performs poor in comparison with the F and T²-based methods in detecting outliers. A real case, in which the size and number of agglomerates ejected from a volcano in successive days form the GLM profile, is illustrated and the proposed methods are applied to determine whether the number of agglomerates of each size is under statistical control or not. Results showed that the proposed methods could handle the mentioned situation and distinguish the out-of-control conditions.     

Identifying the time of a step change with multivariate single control charts

Change point estimation procedures simplify the efforts to search for and identify special causes in multivariate statistical process monitoring. After a signal is generated by the simultaneously used control charts or a single control chart, add-on change point procedure estimates the time of the change. In this study, multivariate joint change point estimation performance for simultaneous monitoring of both location and dispersion is compared under the assumption that various single charts are used to monitor the process. The change detection performance for several structural changes for the mean vector and covariance matrix is also discussed. It is concluded that choice of the control chart to obtain a signal may affect the change point detection performance.     

Addressing the effect of parameter estimation on phase II monitoring of multivariate multiple linear profiles via a new cluster-based approach

Abstract

Profile monitoring is applied when the quality of a product or a process can be determined by the relationship between a response variable and one or more independent variables. In most Phase II monitoring approaches, it is assumed that the process parameters are known. However, it is obvious that this assumption is not valid in many real-world applications. In fact, the process parameters should be estimated based on the in-control Phase I samples. In this study, the effect of parameter estimation on the performance of four Phase II control charts for monitoring multivariate multiple linear profiles is evaluated. In addition, since the accuracy of the parameter estimation has a significant impact on the performance of Phase II control charts, a new cluster-based approach is developed to address this effect. Moreover, we evaluate and compare the performance of the proposed approach with a previous approach in terms of two metrics, average of average run length and its standard deviation, which are used for considering practitioner-to-practitioner variability. In this approach, it is not necessary to know the distribution of the chart statistic. Therefore, in addition to ease of use, the proposed approach can be applied to other type of profiles. The superior performance of the proposed method compared to the competing one is shown in terms of all metrics. Based on the results obtained, our method yields less bias with small-variance Phase I estimates compared to the competing approach.     

Economic-statistical design of simple linear profiles with variable sampling interval

Control charts are statistical tools to monitor a process or a product. However, some processes cannot be controlled by monitoring a characteristic; instead, they need to be monitored using profiles. Economic-statistical design of profile monitoring means determining the parameters of a profile monitoring scheme such that total costs are minimized while statistical measures maintain proper values. While varying sampling interval usually increases the effectiveness of profile monitoring, economic-statistical design of variable sampling interval (VSI) profile monitoring is investigated in this paper. An extended Lorenzen–Vance function is used for modeling total costs in VSI model where the average time to signal is employed for depicting the statistical measure of the obtained profile monitoring scheme. Two sampling intervals; number of set points and the parameters of control charts that are used in profile monitoring are the variables that are obtained thorough the economic-statistical model. A genetic algorithm is employed to optimize the model and an experimental design approach is used for tuning its parameters. Sensitivity analysis and numerical results indicate satisfactory performance for the proposed model.     

Phase I Analysis of Multiple Linear Regression Profiles

This article considers the Phase I analysis of data when the quality of a process or product is characterized by a multiple linear regression model. This is usually referred to as the analysis of linear profiles in the statistical quality control literature. The literature includes several approaches for the analysis of simple linear regression profiles. Little work, however, has been done in the analysis of multiple linear regression profiles. This article proposes a new approach for the analysis of Phase I multiple linear regression profiles. Using this approach, regardless of the number of explanatory variables used to describe it, the profile response is monitored using only three parameters, an intercept, a slope, and a variance. Using simulation, the performance of the proposed method is compared to that of the existing methods for monitoring multiple linear profiles data in terms of the probability of a signal. The advantage of the proposed method over the existing methods is greatly improved detection of changes in the process parameters of linear profiles with high-dimensional space. The article also proposes useful diagnostic aids based on F-statistics to help in identifying the source of profile variation and the locations of out-of-control samples. Finally, the use of multiple linear profile methods is illustrated by a data set from a calibration application at National Aeronautics and Space Administration (NASA) Langley Research Center.     

A Bayesian way of monitoring the linear profiles using CUSUM control charts

In statistical process control applications, profiles functions are considered an efficient way of representing quality of products or processes. Classical and Bayesian thoughts are two chief sources of defining control charting structures for profiles monitoring. This Study introduces novel Bayesian CUSUM control structures for profiles monitoring. The comprehensive comparative study identifies that the proposed Bayesian CUSUM control charts under conjugate priors has better expected performance than competing methods. The implementation of Bayesian structures requires detailed information about process parameters which come up with considerable benefits. In addition, simulative example and case study further justified the superiority of proposed techniques.     

Statistical Monitoring of Autocorrelated Simple Linear Profiles Based on Principal Components Analysis

In this article, a transformation method using the principal component analysis approach is first applied to remove the existing autocorrelation within each profile in Phase I monitoring of autocorrelated simple linear profiles. This easy-to-use approach is independent of the autocorrelation coefficient. Moreover, since it is a model-free method, it can be used for Phase I monitoring procedures. Then, five control schemes are proposed to monitor the parameters of the profile with uncorrelated error terms. The performances of the proposed control charts are evaluated and are compared through simulation experiments based on different values of autocorrelation coefficient as well as different shift scenarios in the parameters of the profile in terms of probability of receiving an out-of-control signal.     

Phase I Monitoring of Polynomial Profiles

In some statistical process control applications, quality of a process or product is characterized by a relationship between two or more variables which is referred to as profile. In many practical situations, a profile can be modeled as a polynomial regression. In this article, three methods are developed for monitoring polynomial profiles in Phase I. Their performance is evaluated using power criterion. Furthermore, a method based on likelihood ratio test is developed to identify the location of shifts. Numerical simulation is used to evaluate the performance of the developed method.     

Profile Monitoring Using Nonparametric Bootstrap T 2 Control Chart

In certain statistical process control applications, performance of a product or process can be monitored effectively using a linear profile or a linear relationship between a response variable and one or more explanatory variables. In this article, we design a nonparametric bootstrap control chart for monitoring simple linear profiles based on T ² statistic. We evaluate the performance of the proposed method in phase II. The average and standard deviation of the run length under different shifts in the intercept, slope, and standard deviation are considered as the performance measures. Simulation results show that the performance of the proposed bootstrap control chart improves as the size of the available data increases.     

Testing homogeneity of difference of two proportions for stratified correlated paired binary data

In ophthalmologic or otolaryngologic study, each subject may contribute paired organs measurements to the analysis. A number of statistical methods have been proposed on bilateral correlated data. In practice, it is important to detect confounding effect by treatment interaction, since ignoring confounding effect may lead to unreliable conclusion. Therefore, stratified data analysis can be considered to adjust the effect of confounder on statistical inference. In this article, we investigate and derive three test procedures for testing homogeneity of difference of two proportions for stratified correlated paired binary data in the basis of equal correlation model assumption. The performance of proposed test procedures is examined through Monte Carlo simulation. The simulation results show that the Score test is usually robust on type I error control with high power, and therefore is recommended among the three methods. One example from otolaryngologic study is given to illustrate the three test procedures.     

On-line monitoring data quality of high-dimensional data streams

ABSTRACT

In recent years, effective monitoring of data quality has increasingly attracted attention of researchers in the area of statistical process control. Among the relevant research on this topic, none used multivariate methods to control the multidimensional data quality process, but instead relied on multiple univariate control charts. Based on a novel one-sided multivariate exponentially weighted moving average (MEWMA) chart, we propose a conditional false discovery rate-adjusted scheme to on-line monitor the data quality of high-dimensional data streams. With thousands of input data streams, the average run length loses its usefulness because one will likely have out-of-control signals at each time period. Hence, we first control the percentage of signals that are false alarms. Then, we compare the power of the proposed MEWMA scheme with that of two alternative methods. Compared with two competitors, numerical results show that the proposed MEWMA scheme has higher average power.     

Multivariate Quality Control Chart for Autocorrelated Processes

Traditional multivariate statistical process control (SPC) techniques are based on the assumption that the successive observation vectors are independent. In recent years, due to automation of measurement and data collection systems, a process can be sampled at higher rates, which ultimately leads to autocorrelation. Consequently, when the autocorrelation is present in the data, it can have a serious impact on the performance of classical control charts. This paper considers the problem of monitoring the mean vector of a process in which observations can be modelled as a first-order vector autoregressive VAR (1) process. We propose a control chart called Z-chart which is based on the single step finite intersection test (Timm, 1996). An important feature of the proposed method is that it not only detects an out of control status but also helps in identifying variable(s) responsible for the out of control situation. The proposed method is illustrated with the help of suitable illustrations.     

Monitoring simple linear profiles using variable sample size schemes

ABSTRACT

Profile monitoring is one of the new research areas in statistical process control. Most of the control charts in this area are designed with fixed sampling rate which makes the control chart slow in detecting small to moderate shifts. In order to improve the performance of the conventional fixed control charts, adaptive features are proposed in which, one or more design parameters vary during the process. In this paper the variable sample size feature of EWMA₃ and MEWMA schemes are proposed for monitoring simple linear profiles. The EWMA₃ method is based on the combination of three exponentially weighted moving average (EWMA) charts for monitoring three parameters of a simple linear profile separately and the Multivariate EWMA (MEWMA) chart is based on the using a single chart to monitor the coefficients and variance of a general linear profile. Also a two-sided control chart is proposed for monitoring the standard deviation in the EWMA₃ method. The performance of the proposed charts is compared in terms of the average time to signal. Numerical examples show that using adaptive features increase the power of control charts in detecting the parameter shifts. Finally, the performance of the proposed variable sample size schemes is illustrated through a real case in the leather industry.     

Phase II Monitoring of Nonlinear Profiles

In many practical cases, the quality of a product or process is characterized by multiple measurements constituting a line or curve that is referred to as a profile. In this article, we develop two approaches for monitoring process and product nonlinear profiles. The first approach consists of control chart methods to monitor nonlinear profiles using parametric estimates of regression model. In order to avoid the problems arising from complexity of coefficient estimation of nonlinear profiles, the second approach, which consists of using metrics to measure deviation from a reference curve, is proposed. The performance of the methods is evaluated through a numerical example using average run length criterion. The effect of sample size on the performance of both approaches is also investigated in this article.     

A semiparametric nonlinear mixed model approach to phase I profile monitoring

When process data follow a particular curve in quality control, profile monitoring is suitable and appropriate for assessing process stability. Previous research in profile monitoring focusing on nonlinear parametric (P) modeling, involving both fixed and random-effects, was made under the assumption of an accurate nonlinear model specification. Lately, nonparametric (NP) methods have been used in the profile monitoring context in the absence of an obvious linear P model. This study introduces a novel technique in profile monitoring for any nonlinear and auto-correlated data. Referred to as the nonlinear mixed robust profile monitoring (NMRPM) method, it proposes a semiparametric (SP) approach that combines nonlinear P and NP profile fits for scenarios in which a nonlinear P model is adequate over part of the data but inadequate of the rest. These three methods (P, NP, and NMRPM) account for the auto-correlation within profiles and treats the collection of profiles as a random sample with a common population. During Phase I analysis, a version of Hotelling’s T² statistic is proposed for each approach to identify abnormal profiles based on the estimated random effects and obtain the corresponding control limits. The performance of the NMRPM method is then evaluated using a real data set. Results reveal that the NMRPM method is robust to model misspecification and performs adequately against a correctly specified nonlinear P model. Control charts with the NMRPM method have excellent capability of detecting changes in Phase I data with control limits that are easily computable.     

Monitoring of autocorrelated general linear profiles

A collection of quality data represented by a functional relationship between response and explanatory variables is called a profile. In the literature, the errors of profiles are often assumed to be independent. However, quality data often exhibits time correlations in real applications. Therefore, in this paper, we investigate a general linear regression model with a between-profile autocorrelation. We propose a multivariate exponentially weighted moving average chart for monitoring shifts in the regression parameters, and an exponentially weighted moving average chart for monitoring shifts in the standard deviation. A simulation study reveals that our proposed schemes outperform competing existing schemes based on the average run length criterion. An example is used to illustrate the applicability of the proposed scheme.     

A Comparison of the Performance of Phase II Simple Linear Profile Control Charts when Parameters are Estimated

The standard deviation of the average run length (SDARL) is an important performance metric in studying the performance of control charts with estimated in-control parameters. Only a few studies in the literature, however, have considered this measure when evaluating control chart performance. The current study aims at comparing the in-control performance of three phase II simple linear profile monitoring approaches; namely, those of Kang and Albin (2000), Kim et al. (2003), and Mahmoud et al. (2010). The comparison is performed under the assumption of estimated parameters using the SDARL metric. In general, the simulation results of the current study show that the method of Kim et al. (2003) has better overall statistical performance than the competing methods in terms of SDARL values. Some of the recommended approaches based solely on the usual average run length properties can have poor SDARL performance.