A new synthetic control chart for monitoring process mean using auxiliary information

ABSTRACT

Quality control charts have been widely recognized as a potentially powerful statistical process monitoring tool in statistical process control because of their superior ability in detecting shifts in the process parameters. Recently, auxiliary-information-based control charts have been proposed and shown to have excellent speed in detecting process shifts than those based without it. In this paper, we design a new synthetic control chart that is based on a statistic that utilizes information from both the study and auxiliary variables. The proposed synthetic chart encompasses the classical synthetic chart. The construction, optimal design, run length profiles, and the performance evaluation of the new chart are discussed in detail. It turns out that the proposed synthetic chart performs uniformly better than the classical synthetic chart when detecting different kinds of shifts in the process mean under both zero-state and steady-state run length performances. Moreover, with reasonable assumptions, the proposed chart also surpasses the exponentially weighted moving average control chart. An application with a simulated data set is also presented to explain the implementation of the proposed control chart.     

A side sensitive modified group runs control chart to detect shifts in the process mean

Gadre and Rattihalli [5 Gadre, M. P. and Rattihalli, R. N. 2006. Modified group runs control charts to detect increases in fraction non-conforming and shifts in the process mean. Commun. Stat. Simul. Comput., 35: 225–240. [Taylor & Francis Online], [Web of Science ®] [Google Scholar]] have introduced the Modified Group Runs (MGR) control chart to identify the increases in fraction non-conforming and to detect shifts in the process mean. The MGR chart reduces the out-of-control average time-to-signal (ATS), as compared with most of the well-known control charts. In this article, we develop the Side Sensitive Modified Group Runs (SSMGR) chart to detect shifts in the process mean. With the help of numerical examples, it is illustrated that the SSMGR chart performs better than the Shewhart's X¯ chart, the synthetic chart [12 Wu, Z. and Spedding, T. A. 2000. A synthetic control chart for detecting small shifts in the process mean. J. Qual. Technol., 32: 32–38. [Taylor & Francis Online], [Web of Science ®] [Google Scholar]], the Group Runs chart [4 Gadre, M. P. and Rattihalli, R. N. 2004. A group runs control chart for detecting shifts in the process mean. Econ. Qual. Control, 19: 29–43. [Crossref] [Google Scholar]], the Side Sensitive Group Runs chart [6 Gadre, M. P. and Rattihalli, R. N. 2007. A side sensitive group runs control chart for detecting shifts in the process mean. Stat. Methods Appl., 16: 27–37. [Crossref], [Web of Science ®] [Google Scholar]], as well as the MGR chart [5 Gadre, M. P. and Rattihalli, R. N. 2006. Modified group runs control charts to detect increases in fraction non-conforming and shifts in the process mean. Commun. Stat. Simul. Comput., 35: 225–240. [Taylor & Francis Online], [Web of Science ®] [Google Scholar]]. In some situations it is also superior to the Cumulative Sum chart p9 Page, E. S. 1954. Continuous inspection schemes. Biometrika, 41: 100–114. [Crossref], [Web of Science ®] [Google Scholar]] and the exponentially weighed moving average chart [10 Roberts, S. W. 1959. Control chart tests based on geometric moving averages. Technometrics, 1: 239–250. [Taylor & Francis Online] [Google Scholar]]. In the steady state also, its performance is better than the above charts.     

An improved mean deviation exponentially weighted moving average control chart to monitor process dispersion under ranked set sampling

Quality-control charts are widely used to monitor and detect shifts in the process mean and dispersion. Abbasi and Miller [MDEWMA chart: an efficient and robust alternative to monitor process dispersion, J Stat Comput Simul 2013;83:247–268] suggested a robust mean deviation exponentially weighted moving average (MDEWMA) control chart for monitoring process dispersion under simple random sampling. In this study, an improved MDEWMA (IMDEWMA) control chart is proposed under ranked set sampling to monitor process dispersion. Detailed Monte Carlo simulations are performed from symmetric and asymmetric populations to investigate the performances of the proposed and existing control charts in terms of average run length (ARL), median run length and standard deviation of run length. An application to real-life data is also presented to illustrate the use of the IMDEWMA control chart. It is observed that the IMDEWMA control chart indicates a shift in process dispersion substantially quicker than the MDEWMA control chart, while maintaining comparable ARLs when the process is in control.     

A new double sampling control chart for monitoring process mean using auxiliary information

Statistical quality control charts have been widely accepted as a potentially powerful process monitoring tool because of their excellent speed in tracking shifts in the underlying process parameter(s). In recent studies, auxiliary-information-based (AIB) control charts have shown superior run length performances than those constructed without using it. In this paper, a new double sampling (DS) control chart is constructed whose plotting-statistics requires information on the study variable and on any correlated auxiliary variable for efficiently monitoring the process mean, namely AIB DS chart. The AIB DS chart also encompasses the classical DS chart. We discuss in detail the construction, optimal design, run length profiles, and the performance evaluations of the proposed chart. It turns out that the AIB DS chart performs uniformly better than the DS chart when detecting different kinds of shifts in the process mean. It is also more sensitive than the classical synthetic and AIB synthetic charts when detecting a particular shift in the process mean. Moreover, with some realistic beliefs, the proposed chart outperforms the exponentially weighted moving average chart. An illustrative example is also presented to explain the working and implementation of the proposed chart.     

A binomial CUSUM chart for detecting large shifts in fraction nonconforming

This article studies a unique feature of the binomial CUSUM chart in which the difference (d _t ?d ₀) is replaced by (d _t ?d ₀)² in the formulation of the cumulative sum C _t (where d _t and d ₀ are the actual and in-control numbers of nonconforming units, respectively, in a sample). Performance studies are reported and the results reveal that this new feature is able to increase the detection effectiveness when fraction nonconforming p becomes three to four times as large as the in-control value p ₀. The design of the new binomial CUSUM chart is presented along with the calculation of the in-control and out-of-control Average Run Lengths (ARL₀ and ARL₁).     

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 nonparametric synthetic EWMA control chart for monitoring process mean

The exponentially weighted moving average (EWMA) control charts are widely used in chemical and process industries because of their excellent speed in catching small to moderate shifts in the process target. In usual practice, many data come from a process where the monitoring statistic is non-normally distributed or it follows an unknown probability distribution. This necessitates the use of distribution-free/nonparametric control charts for monitoring the deviations from the process target. In this paper, we integrate the existing EWMA sign chart with the conforming run length chart to propose a new synthetic EWMA (SynEWMA) sign chart for monitoring the process mean. The SynEWMA sign chart encompasses the synthetic sign and EWMA sign charts. Monte Carlo simulations are used to compute the run length profiles of the SynEWMA sign chart. Based on a comprehensive comparison, it turns out that the SynEWMA sign chart is able to perform substantially better than the existing EWMA sign chart. Both real and simulated data sets are used to explain the working and implementation of existing and proposed control charts.     

The RL2 chart versus the np chart for detecting upward shifts in fraction defective

The use of the np chart for monitoring fraction-defective is well-established, but there are a number of relatively simple alternatives based on run-lengths of conforming items. Here, the RL₂ chart, based on the moving sum of two successive conforming run-lengths, is investigated in order to provide SPC practitioners with clear-cut guidance on the comparative performance of these competing charts. Both sampling inspection and 100% inspection are considered here, and it is shown that the RL₂ chart can often be considerably more efficient than the np chart, but the comparative performance depends on the false-alarm rate used for the comparison. Graphs to aid parameter-choice for the RL₂ chart are also provided.     

Optimal design of the adaptive exponentially weighted moving average control chart over a range of mean shifts

The adaptive exponentially weighted moving average (AEWMA) control chart is a smooth combination of the Shewhart and exponentially weighted moving average (EWMA) control charts. This chart was proposed by Cappizzi and Masarotto (2003) to achieve a reasonable performance for both small and large shifts. Cappizzi and Masarotto (2003) used a pair of shifts in designing their control chart. In this study, however, the process mean shift is considered as a random variable with a certain probability distribution and the AEWMA control chart is optimized for a wide range of mean shifts according to that probability distribution and not just for a pair of shifts. Using the Markov chain technique, the results show that the new optimization design can improve the performance of the AEWMA control chart from an overall point of view relative to the various designs presented by Cappizzi and Masarotto (2003). Optimal design parameters that achieve the desired in-control average run length (ARL) are computed in several cases and formulas used to find approximately their values are given. Using these formulas, the practitioner can compute the optimal design parameters corresponding to any desired in-control ARL without the need to apply the optimization procedure. The results obtained by these formulas are very promising and would particularly facilitate the design of the AEWMA control chart for any in-control ARL value.     

A rational sequential probability ratio test control chart for monitoring process shifts in mean and variance

The sequential probability ratio test (SPRT) chart is a very effective tool for monitoring manufacturing processes. This paper proposes a rational SPRT chart to monitor both process mean and variance. This SPRT chart determines the sampling interval d based on the rational subgroup concept according to the process conditions and administrative considerations. Since the rational subgrouping is widely adopted in the design and implementation of control charts, the studies of the rational SPRT have a practical significance. The rational SPRT chart is designed optimally in order to minimize the index average extra quadratic loss for the best overall performance. A systematic performance study has also been conducted. From an overall viewpoint, the rational SPRT chart is more effective than the cumulative sum chart by more than 63%. Furthermore, this article provides a design table, which contains the optimal values of the parameters of the rational SPRT charts for different specifications. This will greatly facilitate the potential users to select an appropriate SPRT chart for their applications. The users can also justify the application of the rational SPRT chart according to the achievable enhancement in detection effectiveness.     

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 process mean and dispersion with one double generally weighted moving average control chart

Control charts are widely known quality tools used to detect and control industrial process deviations in Statistical Process Control. In the current paper, we propose a new single memory-type control chart, called the maximum double generally weighted moving average chart (referred as Max-DGWMA), that simultaneously detects shifts in the process mean and/or process dispersion. The run length performance of the proposed Max-DGWMA chart is compared with that of the Max-EWMA, Max-DEWMA, Max-GWMA and SS-DGWMA charts, using time-varying control limits, through Monte–Carlo simulations. The comparisons reveal that the proposed chart is more efficient than the Max-EWMA, Max-DEWMA and Max-GWMA charts, while it is comparable with the SS-DGWMA chart. An automotive industry application is presented in order to implement the Max-DGWMA chart. The goal is to establish statistical control of the manufacturing process of the automobile engine piston rings. The source of the out-of-control signals is interpreted and the efficiency of the proposed chart in detecting shifts faster is evident.     

An alternative approach to multivariate EWMA control chart

This Paper proposes a multivariate EWMA scheme that is alternative to the traditional EWMA-M. The distribution of the chart statistic is derived from Box quadratic form and the sensitivity of the chart is examined. The average run lengths of the M-EWMA scheme are numerically computed with the integral equation method. The exponential weight of 0.2 is found to be the optimal choice for the sensitive chart to detect assignable causes in the mean vector of processes.     

A synthetic control chart for monitoring the small shifts in a process mean based on an attribute inspection

Abstract

In this paper, a synthetic control chart is proposed by integrating the salient features of the np_x chart and the CRL chart. The synthetic chart achieves higher detection effectiveness on both small and large mean shifts while retaining the operational simplicity of the attribute charts owing to only using attribute inspection. Both statistical and economic design of the synthetic chart are considered and numerical tests have indicated that the synthetic chart has a higher power for detecting mean shifts than the np_x chart, MON chart and CUSUM chart. In addition, sensitivity analyses are also performed under both the statistical and economic design model.     

A new S2 control chart using repetitive sampling

A new S² control chart is presented for monitoring the process variance by utilizing a repetitive sampling scheme. The double control limits called inner and outer control limits are proposed, whose coefficients are determined by considering the average run length (ARL) and the average sample number when the process is in control. The proposed control chart is compared with the existing Shewhart S² control chart in terms of the ARLs. The result shows that the proposed control chart is more efficient than the existing control chart in detecting the process shift.     

Globally applicable control chart for online monitoring of stability of process mean

The shape features of run chart patterns of the most recent m observations arising from stable and unstable processes are different. Using this fact, a new monitoring statistic is defined whose value for given m depends on the pattern parameters but not on the process parameters. A control chart for this statistic for given m, therefore, will be globally applicable to normal processes. The simulation study reveals that the proposed statistic approximately follows normal distribution. The performances of the globally applicable control chart in terms of average run lengths (ARLs) are evaluated and compared with the X chart. Both in-control ARL and out-of-control ARLs with respect to different abnormal process conditions are found to be larger than the X chart. However, the proposed concept is promising because it can eliminate the burden of designing separate control charts for different quality characteristics or processes in a manufacturing set-up.     

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.