Control charts for high-quality processes: MAX or CUMAX?

For attribute data with (very) small failure rates control charts were introduced which are based on subsequent groups of r   failure times, for some r≥1$r\ge 1$. Within this family, it was shown to be attractive to stop once the maximum of such a group is sufficiently small, because this choice allows a very satisfactory nonparametric adaptation. The question we address here is whether a cumulative approach offers even further improvement. Thus instead of fixed groups, we shall use the first sequence of r consecutive sufficiently small failure times to produce a signal. A further reason for considering this type of chart is the fact that it forms the nonparametric counterpart of the well-known sets method.     

The optimal choice of negative binomial charts for monitoring high-quality processes

Good control charts for high quality processes are often based on the number of successes between failures. Geometric charts are simplest in this respect, but slow in recognizing moderately increased failure rates p. Improvement can be achieved by waiting until r>1 failures have occurred, i.e. by using negative binomial charts. In this paper we analyze such charts in some detail. On the basis of a fair comparison, we demonstrate how the optimal r is related to the degree of increase of p. As in practice p will usually be unknown, we also analyze the estimated version of the charts. In particular, simple corrections are derived to control the nonnegligible effects of this estimation step.     

Robustness to non-normality and autocorrelation of individuals control charts

This paper studies the effects of non-normality and autocorrelation on the performances of various individuals control charts for monitoring the process mean and/or variance. The traditional Shewhart X chart and moving range (MR) chart are investigated as well as several types of exponentially weighted moving average (EWMA) charts and combinations of control charts involving these EWMA charts. It is shown that the combination of the X and MR charts will not detect small and moderate parameter shifts as fast as combinations involving the EWMA charts, and that the performana of the X and MR charts is very sensitive to the normality assumption. It is also shown that certain combinations of EWMA charts can be designed to be robust to non-normality and very effective at detecting small and moderate shifts in the process mean and/or variance. Although autocorrelation can have a significant effect on the in-control performances of these combinations of EWMA charts, their relative out-of-control performances under independence are generally maintained for low to moderate levels of autocorrelation.     

On residual lifetime of coherent systems after the rth failure

In this article we study the residual lifetime of a coherent system after the rth failure, i.e. the time elapsed from the rth failure until the system failure given that the system operates at the time of the rth failure. We provide a mixture representation for the corresponding residual lifetime distribution in terms of signature. We also obtain some stochastic ordering results for the residual lifetimes.     

Classification of difference matrices over cyclic groups

The existence of difference matrices over small cyclic groups is investigated in this computer-aided work. The maximum values of the parameters for which difference matrices exist as well as the number of inequivalent difference matrices in each case is determined up to the computational limit. Several new difference matrices have been found in this manner. The maximum number of rows is 9 for an r ×15 difference matrix over Z₃, 8 for an r ×15 difference matrix over Z₅, and 6 for an r ×12 difference matrix over Z₆; the number of inequivalent matrices with these parameters is 5, 2, and 7, respectively.     

Using p values to design statistical process control charts

Conventional Phase II statistical process control (SPC) charts are designed using control limits; a chart gives a signal of process distributional shift when its charting statistic exceeds a properly chosen control limit. To do so, we only know whether a chart is out-of-control at a given time. It is therefore not informative enough about the likelihood of a potential distributional shift. In this paper, we suggest designing the SPC charts using p values. By this approach, at each time point of Phase II process monitoring, the p value of the observed charting statistic is computed, under the assumption that the process is in-control. If the p value is less than a pre-specified significance level, then a signal of distributional shift is delivered. This p value approach has several benefits, compared to the conventional design using control limits. First, after a signal of distributional shift is delivered, we could know how strong the signal is. Second, even when the p value at a given time point is larger than the significance level, it still provides us useful information about how stable the process performs at that time point. The second benefit is especially useful when we adopt a variable sampling scheme, by which the sampling time can be longer when we have more evidence that the process runs stably, supported by a larger p value. To demonstrate the p value approach, we consider univariate process monitoring by cumulative sum control charts in various cases.     

Multistage bandit problems

Consider two or more treatments with dichotomous responses. The total number N of experimental units are to be allocated in a fixed number r of stages. The problem is to decide how many units to assign to each treatment in each stage. Responses from selections in previous stages are available and can be considered but responses in the current stage are not available until the next group of selections is made. Information is updated via the Bayes theorem after each stage. The goal is to maximize the overall expected number of successes in the N units.Two forms of prior information are considered: (i) All arms have beta priors, and (ii) prior distributions have continuous densities. Various characteristics of optimal decisions are presented. For example, in most cases of (i) and (ii), the rate of the optimal size of the first stage cannot be greater than √N when r = 2.     

Ordering conditional lifetimes of coherent systems

Consider a system of n components that has the property that there exists a number r  (r<n)$(r<n)$, such that if it is known that at most r components have failed, the system is still functioning with probability 1. Suppose that such a system is equipped with a warning light that comes up at the time of the failure of the rth component. The system is still working then, and we are interested in its residual life. In this paper we obtain some results which stochastically compare the residual lives of such systems with the same type, or with different types, of components. Some applications are given. In particular, we derive upper and lower bounds on the expected residual lives of such systems given that the warning light has not come up yet, and given that the component hazard rate functions are bounded from below or from above by a known constant.     

On empirical Bayes simultaneous selection procedures for comparing normal populations with a standard

In this paper, we derive statistical selection procedures to partition k normal populations into ‘good’ or ‘bad’ ones, respectively, using the nonparametric empirical Bayes approach. The relative regret risk of a selection procedure is used as a measure of its performance. We establish the asymptotic optimality of the proposed empirical Bayes selection procedures and investigate the associated rates of convergence. Under a very mild condition, the proposed empirical Bayes selection procedures are shown to have rates of convergence of order close to O(k^−1/2) where k is the number of populations involved in the selection problem. With further strong assumptions, the empirical Bayes selection procedures have rates of convergence of order O(k^{−α(r−1)/(2r+1)}), where 1<α<2 and r is an integer greater than 2.     

A note on ‘curable’ shock processes

In most conventional shock models, the events caused by an external shock are initiated at the moments of its occurrence. Recently, Cha and Finkelstein (2012) had considered the case when each shock from a nonhomogeneous Poisson processes can trigger a failure of a system not immediately, as in the classical shock models, but with delay of some random time. In this paper, we suggest the new type of shock models, where each delayed failure can be cured (repaired) with certain probabilities. These shock processes have not been considered in the literature before. We derive and analyze the corresponding survival and failure rate functions and consider a meaningful reliability example of the stress–strength model.     

Empirical Non-Parametric Control Charts: Estimation Effects and Corrections

Owing to the extreme quantiles involved, standard control charts are very sensitive to the effects of parameter estimation and non-normality. More general parametric charts have been devised to deal with the latter complication and corrections have been derived to compensate for the estimation step, both under normal and parametric models. The resulting procedures offer a satisfactory solution over a broad range of underlying distributions. However, situations do occur where even such a large model is inadequate and nothing remains but to consider non- parametric charts. In principle, these form ideal solutions, but the problem is that huge sample sizes are required for the estimation step. Otherwise the resulting stochastic error is so large that the chart is very unstable, a disadvantage that seems to outweigh the advantage of avoiding the model error from the parametric case. Here we analyse under what conditions non-parametric charts actually become feasible alternatives for their parametric counterparts. In particular, corrected versions are suggested for which a possible change point is reached at sample sizes that are markedly less huge (but still larger than the customary range). These corrections serve to control the behaviour during in-control (markedly wrong outcomes of the estimates only occur sufficiently rarely). The price for this protection will clearly be some loss of detection power during out-of-control. A change point comes in view as soon as this loss can be made sufficiently small.     

Improved Shewhart-type Runs-rules Nonparametric Sign Charts

Runs-rules are typically incorporated in control charts to increase their sensitivity to detect small process shifts. However, a drawback of this approach is that runs-rules charts are unable to detect large shifts quickly. In this article improved runs-rules are introduced to the nonparametric sign chart to address this limitation. Improved runs-rules are incorporated to maintain sensitivity to small process shifts, while having the added ability to detect large shifts in the process more efficiently. Performance comparisons between sign charts with runs-rules and sign charts with improved runs-rules illustrate that the improved runs-rules are superior in performance for large shifts in the process, while maintaining the same sensitivity in the detection of small shifts.     

An extension of Banerjee and Rahim model in economic and economic statistical designs for multivariate quality characteristics under Burr XII distribution

The design parameters of the economic and economic statistical designs of control charts depend on the distribution of process failure mechanism or shock model. So far, only a small number of failure distributions, such as exponential, gamma, and Weibull with fixed or increasing hazard rates, have been used as a shock model in the economic and economic statistical designs of the Hotelling T² control charts. Due to both theoretical and practical aspects, the lifetime of the process under study may not follow a distribution with fixed or increasing hazard rate. A proper alternative for this situation may be the Burr distribution, in which the hazard rate can be fixed, increasing, decreasing, single mode, or even U-shaped. In this research article, economic and economic statistical designs of the Hotelling T² control charts under the Burr XII shock models under two uniform and non uniform sampling schemes were proposed, constructed, and compared. The obtained design models were implemented by a numerical example, and a sensitivity analysis was conducted to evaluate the effect of changing parameters of shock model distribution on the optimum values of the proposed design models. The results showed that first the proposed designs under non uniform sampling scheme perform better and second the optimum values of the designs are not significantly sensitive to changing of the Burr XII distribution parameters. We showed that the obtained design models are also true for the beta Burr XII shock model.     

Nonparametric control charts based on runs and Wilcoxon-type rank-sum statistics

In this article, we introduce three new distribution-free Shewhart-type control charts that exploit run and Wilcoxon-type rank-sum statistics to detect possible shifts of a monitored process. Exact formulae for the alarm rate, the run length distribution, and the average run length (ARL) are all derived. A key advantage of these charts is that, due to their nonparametric nature, the false alarm rate (FAR) and in-control run length distribution is the same for all continuous process distributions. Tables are provided for the implementation of the charts for some typical FAR values. Furthermore, a numerical study carried out reveals that the new charts are quite flexible and efficient in detecting shifts to Lehmann-type out-of-control situations.     

Improved inference for a linear mixed-effects model when the subpopulation effects are clustered

We provide Bayesian methodology to relax the assumption that all subpopulation effects in a linear mixed-effects model have, after adjustment for covariates, a common mean. We expand the model specification by assuming that the m subpopulation effects are allowed to cluster into d groups where the value of d, 1?d?m, and the composition of the d groups are unknown, a priori. Specifically, for each partition of the m effects into d groups we only assume that the subpopulation effects in each group are exchangeable and are independent across the groups. We show that failure to take account of this clustering, as with the customary method, will lead to serious errors in inference about the variances and subpopulation effects, but the proposed, expanded, model leads to appropriate inferences. The efficacy of the proposed method is evaluated by contrasting it with both the customary method and use of a Dirichlet process prior. We use data from small area estimation to illustrate our method.     

A robust R control chart based on a two-step estimator of the process dispersion

ABSTRACT

Control charts are the frequently used tools for monitoring and controlling the processes. Classical control charts are sensitive to existing contaminated data which may be presented in the data collected from the processes. Thus, these charts are not able to control the processes precisely when the data are contaminated. Robust control charts are those which are less sensitive to contamination. Some robust control charts for monitoring the process variability were proposed in the past which are robust to some sorts of contamination. In this paper a new robust R control chart is proposed which is less sensitive to wide range of contaminations, i.e. general and local contaminations. Simulation studies are performed to compare the performance of the proposed control chart with some classical and robust control charts, using ARL and MSD as criteria for comparisons purposes. The simulation results show a very good performance of the proposed chart when both types of contaminations exist.     

An extension of the ranked set sampling theory

This paper is concerned with ranked set sampling theory which is useful to estimate the population mean when the order of a sample of small size can be found without measurements or with rough methods. Consider n sets of elements each set having size m. All elements of each set are ranked but only one is selected and quantified. The average of the quantified elements is adopted as the estimator. In this paper we introduce the notion of selective probability which is a generalization of a notion from Yanagawa and Shirahata (1976). Uniformly optimal unbiased procedures are found for some (n,m). Furthermore, procedures which are unbiased for all distributions and are good for symmetric distributions are studied for (n,m) which do not allow uniformly optimal unbiased procedures.     

Control chart for monitoring the Weibull shape parameter under two competing risks

ABSTRACT

In this paper, we propose a control chart to monitor the Weibull shape parameter where the observations are censored due to competing risks. We assume that the failure occurs due to two competing risks that are independent and follow Weibull distribution with different shape and scale parameters. The control charts are proposed to monitor one or both of the shape parameters of competing risk distributions and established based on the conditional expected values. The proposed control chart for both shape parameters is used in certain situations and allows to monitor both shape parameters in only one chart. The control limits depend on the sample size, number of failures due to each risk and the desired stable average run length (ARL). We also consider the estimation problem of the target parameters when the Phase I sample is incomplete. We assumed that some of the products that fail during the life testing have a cause of failure that is only known to belong to a certain subset of all possible failures. This case is known as masking. In the presence of masking, the expectation-maximization (EM) algorithm is proposed to estimate the parameters. For both cases, with and without masking, the behaviour of ARLs of charts is studied through the numerical methods. The influence of masking on the performance of proposed charts is also studied through a simulation study. An example illustrates the applicability of the proposed charts.     

Bounds for permutation arrays

A permutation array (P.A.) defined on an r-set of symbols V is a v×r array of rows each of which is a permutation of the symbols of V and such that any two distinct rows have at most (at least) λ common column entries. We list all known bounds for such arrays and make improvements in certain cases. We consider, at length, the case when every pair of distinct rows of the P.A. have precisely λ common column entries.