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.     

An Evaluation of the Double Exponentially Weighted Moving Average Control Chart

In this article we perform a careful investigation of the double exponentially weighted moving average (DEWMA) chart performance for monitoring the process mean. We compare the performance of this chart to the usual EWMA control chart based on zero-state and worst-case average run length (ARL) measures. We also evaluate the signal resistance measure of the DEWMA chart and compare its maximum value to that of the EWMA chart. We show that the superiority of the DEWMA chart over the simpler standard EWMA chart based on zero-state ARL performance disappears when the smoothing constant of the EWMA chart is chosen to give weights to past observations closer to those given by the DEWMA chart. Moreover, our results show that the standard EWMA chart has much better performance than the DEWMA chart in terms of worst-case ARL values, especially when small smoothing constants are used. We also demonstrate using an illustrative example that the DEWMA chart can build up an exceedingly large amount of inertia when used to monitor the process mean.     

Evaluation of control charts under linear trend

The performance of several control charting schemes is studied when the process mean changes as a linear trend. The control charts considered include the Shewhart chart, the Shewhart chart supplemented with runs rules, the cumulative sum (CUSUM) chart, the exponentially weighted moving average (EWMA) chart, and a generalized control chart.     

MDEWMA chart: an efficient and robust alternative to monitor process dispersion

Control chart is the most important statistical process control tool used to monitor changes in process location and dispersion. In this study, an EWMA control chart is proposed for efficient and robust monitoring of process dispersion. The proposed chart, namely the MDEWMA chart, is based on estimating the process standard deviation (σ) using the mean absolute deviations (MD), taken from the sample median. The performance of the proposed chart has been compared with the EWMASR chart (a dispersion EWMA chart based on sample range) and MD chart (a Shewhart-type dispersion chart based on MD), under the existence and violation of normality assumption. It has been observed that the proposed MDEWMA chart is more efficient and robust when compared with both EWMASR and MD charts in terms of run length (RL) characteristics such as average RL, median RL and standard deviation of the RL distribution.     

An Improved Distribution-free EWMA Mean Chart

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 nonnormal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, should not be properly used here. In this article, we propose an improved asymmetric EWMA mean chart based on a simple statistic to monitor process mean shift. We explored the sampling properties of the new monitoring statistic and calculated the average run lengths of the proposed asymmetric EWMA mean chart. We recommend the proposed improved asymmetric EWMA mean chart because the average run lengths of the modified charts are more accurate and reasonable than those of the five existed mean charts. A numerical example of service times with a right skewed distribution from a service system of a bank branch is used to illustrate the application of the improved asymmetric EWMA mean chart and to compare it with the five existing mean charts. The proposed chart showed better detection performance than those of the five existing mean charts in monitoring and detecting shifts in the process mean.     

A New Adaptive Variable Sample Size Approach in EWMA Control Chart

Adaptive control charts have been developed for improving the capability of control charts in detecting small shifts. In this article, we propose a new exponential weighted moving average control chart with variable sample size, in which the sample size is determined as an integer linear function by EWMA statistic value. The performance of the proposed VSS EWMA control chart is compared with FSS EWMA as well as traditional VSS EWMA control charts. The results show the better performance of the proposed VSS strategy respect to the traditional one and fixed sample size.     

Design of a sign chart using a new EWMA statistic

Abstract

In this article, a new non parametric control chart based on the modified or controlled exponentially weighted moving average (EWMA) statistic is developed to monitor the process deviation from the target value. The proposed control chart is evaluated for different values of design parameters using the average run length as a performance criterion under various sample sizes. The proposed chart is compared with the existing non parametric EWMA sign control chart. It is observed that the proposed chart is better than the existing EWMA sign control chart in terms of run length characteristics. An empirical example is provided for the practical implementation of the proposed chart.     

An EWMA chart for monitoring process mean

In the statistical process control literature, there exists several improved quality control charts based on cost-effective sampling schemes, including the ranked set sampling (RSS) and median RSS (MRSS). A generalized cost-effective RSS scheme has been recently introduced for efficiently estimating the population mean, namely varied L RSS (VLRSS). In this article, we propose a new exponentially weighted moving average (EWMA) control chart for monitoring the process mean using VLRSS, named the EWMA-VLRSS chart, under both perfect and imperfect rankings. The EWMA-VLRSS chart encompasses the existing EWMA charts based on RSS and MRSS (named the EWMA-RSS and EWMA-MRSS charts). We use extensive Monte Carlo simulations to compute the run length characteristics of the EWMA-VLRSS chart. The proposed chart is then compared with the existing EWMA charts. It is found that, with either perfect or imperfect rankings, the EWMA-VLRSS chart is more sensitive than the EWMA-RSS and EWMA-MRSS charts in detecting small to large shifts in the process mean. A real dataset is also used to explain the working of the EWMA-VLRSS chart.     

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.     

Short run spc based upon the second order dynamic linear model for trend detection

Recently, several new applications of control chart procedures for short production runs have been introduced. Bothe (1989) and Burr (1989) proposed the use of control chart statistics which are obtained by scaling the quality characteristic by target values or process estimates of a location and scale parameter. The performance of these control charts can be significantly affected by the use of incorrect scaling parameters, resulting in either an excessive "false alarm rate," or insensitivity to the detection of moderate shifts in the process. To correct for these deficiencies, Quesenberry (1990, 1991) has developed the Q-Chart which is formed from running process estimates of the sample mean and variance. For the case where both the process mean and variance are unknown, the Q-chaxt statistic is formed from the standard inverse Z-transformation of a t-statistic. Q-charts do not perform correctly, however, in the presence of special cause disturbances at process startup. This has recently been supported by results published by Del Castillo and Montgomery (1992), who recommend the use of an alternative control chart procedure which is based upon a first-order adaptive Kalman filter model Consistent with the recommendations by Castillo and Montgomery, we propose an alternative short run control chart procedure which is based upon the second order dynamic linear model (DLM). The control chart is shown to be useful for the early detection of unwanted process trends. Model and control chart parameters are updated sequentially in a Bayesian estimation framework, providing the greatest degree of flexibility in the level of prior information which is incorporated into the model. The result is a weighted moving average control chart statistic which can be used to provide running estimates of process capability. The average run length performance of the control chart is compared to the optimal performance of the exponentially weighted moving average (EWMA) chart, as reported by Gan (1991). Using a simulation approach, the second order DLM control chart is shown to provide better overall performance than the EWMA for short production run applications     

A Double Moving Average Control Chart

The double exponentially weighted moving average (DEWMA) technique has been investigated in recent years for detecting shifts in the process mean and has been shown to be more efficient than the corresponding exponentially weighted moving average (EWMA) technique. In this article, we extend the DEWMA technique of performing exponential smoothing twice to the double moving average (DMA) technique by computing the moving average twice. Using simulation, we show that our proposed DMA chart improves upon the ARL performance of the moving average (MA) chart in detecting mean shifts of small to moderate magnitudes. It is also shown through simulation that, generally, the DMA charts with spans, w = 10 and 15 provide comparable average run length (ARL) performances to the EWMA and cumulative sum (CUSUM) charts, designed for detecting small shifts.     

A multivariate exponentially weighted moving average control chart for monitoring process variability

This paper introduces a new multivariate exponentially weighted moving average (EWMA) control chart. The proposed control chart, called an EWMA V-chart, is designed to detect small changes in the variability of correlated multivariate quality characteristics. Through examples and simulations, it is demonstrated that the EWMA V-chart is superior to the |S|-chart in detecting small changes in process variability. Furthermore, a counterpart of the EWMA V-chart for monitoring process mean, called the EWMA M-chart is proposed. In detecting small changes in process variability, the combination of EWMA M-chart and EWMA V-chart is a better alternative to the combination of MEWMA control chart (Lowry et al. , 1992) and |S|-chart. Furthermore, the EWMA M- chart and V-chart can be plotted in one single figure. As for monitoring both process mean and process variability, the combined MEWMA and EWMA V-charts provide the best control procedure.     

Statistical control charts for monitoring the mean of a stationary process

Recently statistical process control (SPC) methodologies have been developed to accommodate autocorrelated data. A primary method to deal with autocorrelated data is the use of residual charts. Although this methodology has the advantage that it can be applied to any autocorrelated data it needs time series modeling efforts. In addition for a X residual chart the detection capability is sometimes small compared to the X chart and EWMA chart. Zhang (1998) proposed the EWMAST chart which is constructed by charting the EWMA statistic for stationary processes to monitor the process mean. The performance of the EWMAST chart the X chart the X residual chart and other charts were compared in Zhang (1998). In this paper comparisons are made among the EWMAST chart the CUSUM residual chart and EWMA residual chart as well as the X residual chart and X chart via the average run length.     

A mixed GWMA–CUSUM control chart for monitoring the process mean

The memory-type control charts are widely used in the process and service industries for monitoring the production processes. The reason is their sensitivity to quickly react against the small process disturbances. Recently, a new cumulative sum (CUSUM) chart has been proposed that uses the exponentially weighted moving average (EWMA) statistic, called the EWMA–CUSUM chart. Similarly, in order to further enhance the sensitivity of the EWMA–CUSUM chart, we propose a new CUSUM chart using the generally weighted moving average (GWMA) statistic, called the GWMA–CUSUM chart, for efficiently monitoring the process mean. The GWMA–CUSUM chart encompasses the existing CUSUM and EWMA–CUSUM charts. Extensive Monte Carlo simulations are used to explore the run length profiles of the GWMA–CUSUM chart. Based on comprehensive run length comparisons, it turns out that the GWMA–CUSUM chart performs substantially better than the CUSUM, EWMA, GWMA, and EWMA–CUSUM charts when detecting small shifts in the process mean. An illustrative example is also presented to explain the implementation and working of the EWMA–CUSUM and GWMA–CUSUM charts.     

Robustness of the EWMA and the combined X¯–EWMA control charts with variable sampling intervals to non-normality

The exponentially weighted moving average (EWMA) control charts with variable sampling intervals (VSIs) have been shown to be substantially quicker than the fixed sampling intervals (FSI) EWMA control charts in detecting process mean shifts. The usual assumption for designing a control chart is that the data or measurements are normally distributed. However, this assumption may not be true for some processes. In the present paper, the performances of the EWMA and combined X¯–EWMA control charts with VSIs are evaluated under non-normality. It is shown that adding the VSI feature to the EWMA control charts results in very substantial decreases in the expected time to detect shifts in process mean under both normality and non-normality. However, the combined X¯–EWMA chart has its false alarm rate and its detection ability is affected if the process data are not normally distributed.     

A new adaptive EWMA control chart using auxiliary information for monitoring the process mean

The adaptive memory-type control charts, including the adaptive exponentially weighted moving average (EWMA) and cumulative sum (CUSUM) charts, have gained considerable attention because of their excellent speed in providing overall good detection over a range of mean shift sizes. In this paper, we propose a new adaptive EWMA (AEWMA) chart using the auxiliary information for efficiently monitoring the infrequent changes in the process mean. The idea is to first estimate the unknown process mean shift using an auxiliary information based mean estimator, and then adaptively update the smoothing constant of the EWMA chart. Using extensive Monte Carlo simulations, the run length profiles of the AEWMA chart are computed and explored. The AEWMA chart is compared with the existing control charts, including the classical EWMA, CUSUM, synthetic EWMA and synthetic CUSUM charts, in terms of the run length characteristics. It turns out that the AEWMA chart performs uniformly better than these control charts when detecting a range of mean shift sizes. An illustrative example is also presented to demonstrate the working and implementation of the proposed and existing control charts.     

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.     

Monitoring the mean of autocorrelated observations with one generally weighted moving average control chart

Traditionally, using a control chart to monitor a process assumes that process observations are normally and independently distributed. In fact, for many processes, products are either connected or autocorrelated and, consequently, obtained observations are autocorrelative rather than independent. In this scenario, applying an independence assumption instead of autocorrelation for process monitoring is unsuitable. This study examines a generally weighted moving average (GWMA) with a time-varying control chart for monitoring the mean of a process based on autocorrelated observations from a first-order autoregressive process (AR(1)) with random error. Simulation is utilized to evaluate the average run length (ARL) of exponentially weighted moving average (EWMA) and GWMA control charts. Numerous comparisons of ARLs indicate that the GWMA control chart requires less time to detect various shifts at low levels of autocorrelation than those at high levels of autocorrelation. The GWMA control chart is more sensitive than the EWMA control chart for detecting small shifts in a process mean.     

Monitoring Process Mean and Variability with One Non-central Chi-square Chart

Traditionally, an X-chart is used to control the process mean and an R-chart to control the process variance. However, these charts are not sensitive to small changes in process parameters. A good alternative to these charts is the exponentially weighted moving average (EWMA) control chart for controlling the process mean and variability, which is very effective in detecting small process disturbances. In this paper, we propose a single chart that is based on the non-central chi-square statistic, which is more effective than the joint X and R charts in detecting assignable cause(s) that change the process mean and/or increase variability. It is also shown that the EWMA control chart based on a non-central chi-square statistic is more effective in detecting both increases and decreases in mean and/or variability.     

Generally weighted moving average control charts with fast initial response features

The generally weighted moving average (GWMA) control chart is an extension model of exponentially weighted moving average (EWMA) control chart. Recently, some approaches have been proposed to modify EWMA charts with fast initial response (FIR) features. We introduce these approaches in GWMA-type charts. Via simulation, various control schemes are designed and then their average run lengths are computed and compared. Based on the overall performance, it is showed that the DGWMA chart is the best choice especially when the shift is moderate, and the GWMA charts provided with additional FIR feature have a good performance only in detecting large shifts during the initial stage.