Conditional design of the EWMA median chart with estimated parameters

The exponentially weighted moving average (EWMA) chart is often designed assuming the process parameters are known. In practice, the parameters are rarely known and need to be estimated from Phase I samples. Different Phase I samples are used when practitioners construct their own control chart's limits, which leads to the “Phase I between-practitioners” variability in the in-control average run length (ARL) of control charts. The standard deviation of the ARL (SDARL) is a good alternative to quantify this variability in control charts. Based on the SDARL metric, the performance of the EWMA median chart with estimated parameters is investigated in this paper. Some recommendations are given based on the SDARL metric. The results show that the EWMA median chart requires a much larger amount of Phase I data in order to reduce the variation in the in-control ARL up to a reasonable level. Due to the limitation of the amount of the Phase I data, the suggested EWMA median chart is designed with the bootstrap method which provides a good balance between the in-control and out-of-control ARL values.     

Run rules based phase II c and np charts when process parameters are unknown

Abstract

The performance of attributes control charts is usually evaluated under the assumption of known process parameters (i.e., the nominal proportion of non conforming units or the nominal average number of nonconformities). However, in practice, these process parameters are rarely known and have to be estimated from an in-control Phase I data set. The major contributions of this paper are (a) the derivation of the run length properties of the Run Rules Phase II c and np charts with estimated parameters, particularly focusing on the ARL, SDRL, and 0.05, 0.5, and 0.95 quantiles of the run length distribution; (b) the investigation of the number m of Phase I samples that is needed by these charts in order to obtain similar in-control ARLs to the known parameters case; and (c) the proposition of new specific chart parameters that allow these charts to have approximately the same in-control ARLs as the ones obtained in the known parameters case.     

Maximum likelihood analysis of masked series system lifetime data

Component lifetime parameters of a series system are estimated from system lifetimes and masked cause of failure observations. The time and cause of system failures are assumed to follow a competing risks model. The masking probabilities of the minimum random subsets are not subjected to the symmetry assumption. Sufficient regularity conditions are provided, justifying the maximum likelihood analysis. Maximum likelihood estimates of both the lifetime parameters and masking probabilities are generically computed via an EM algorithm. An appropriate set of asymptotically pivotal quantities are also derived. Such maximum likelihood based estimates are further refined by bootstrap. The developed techniques are illustrated by numerical examples of independent Weibull component lifetimes with distinct scale and shape parameters.     

A mixed control chart for monitoring failure times under accelerated hybrid censoring

In an accelerated hybrid censoring scheme several stress factors can be accelerated to make the products to respond to fail more quickly than under normal operating conditions. In such situations, the control charts available in the literature cover the attribute characteristics only to monitor the performance of the process over time. This study extends the idea by proposing an optimal mixed attribute-variable control chart for Weibull distribution under an accelerated hybrid censoring scheme keeping the advantages of both attribute and variable control charts. It first monitors the number of defectives under accelerated conditions and switches to the variable control chart to investigate the mean failure times when the process stability is dubious. The performance of the proposed chart is evaluated by using run-length characteristics, and the optimality of the design parameter is achieved by minimizing the out-of-control average run length. The simulation study depicted better performance of the proposed control chart than the traditional charts in detecting shifts in the process. A real-life application is also included.KEYWORDS: Mixed control chart, attribute chart, variable chart, Weibull distribution, accelerated hybrid censoring     

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.     

The performance of multivariate CUSUM control charts with estimated parameters

In this paper, we study the effect of estimating the vector of means and the variance–covariance matrix on the performance of two of the most widely used multivariate cumulative sum (CUSUM) control charts, the MCUSUM chart proposed by Crosier [Multivariate generalizations of cumulative sum quality-control schemes, Technometrics 30 (1988), pp. 291–303] and the MC1 chart proposed by Pignatiello and Runger [Comparisons of multivariate CUSUM charts, J. Qual. Technol. 22 (1990), pp. 173–186]. Using simulation, we investigate and compare the in-control and out-of-control performances of the competing charts in terms of the average run length measure. The in-control and out-of-control performances of the competing charts deteriorate significantly if the estimated parameters are used with control limits intended for known parameters, especially when only a few Phase I samples are used to estimate the parameters. We recommend the use of the MC1 chart over that of the MCUSUM chart if the parameters are estimated from a small number of Phase I samples.     

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.     

The ARL of modified Shewhart control charts for conditionally heteroskedastic models

In this article we consider the modified Shewhart control chart for ARCH processes and introduce it for threshold ARCH (TARCH) ones. For both charts, we determine bounds for the distribution of the in-control run length (RL) and, consequently, for its average (ARL), both depending only on the distribution of the generating white noise, the model parameters and the critical value. For the ARCH model, we compare our bounds with others available in literature and show how they improve the existing ones. We present a simulation study to assess the quality of the bounds calculated for the ARL.     

Progressive Variance Control Charts for Monitoring Process Dispersion

In a process, the deviation from location or scale parameters affects the quality of the process and waste resources. So it is essential to monitor such processes for possible changes due to any assignable causes. Control charts are the most famous tool used to meet this intention. It is useless to monitor process location until the assurance that process dispersion is in-control. This study proposes some new two-sided memory control charts named as progressive variance (PV) control charts which are based on sample variance to monitor changes in process dispersion assuming normality of quality characteristic to be monitored. Simulation studies are made, and an example is discussed to evaluate the performance of the proposed charts. The comparison of the proposed chart is made with exponentially weighted moving average- and cumulative sum-type charts for process dispersion. The study shows that performance of the proposed charts are uniformly better than its competitors for detecting positive shifts while for detecting negative shift in the variance their performance is better for small shifts and reasonably good for moderated shifts.     

An Extension of Economic Design of x-Bar Control Charts for Non Normally Distributed Data Under Weibull Shock Models

Three parameters—sample size, sampling intervals, and the control limits—must be determined when the x bar chart to monitor a manufacturing process. The constant sampling intervals were widely employed because of its administrative simplicity. However, the variable sampling interval (VSI) has recently been shown to give substantially faster detection of most process shifts than fixed-sampling-interval (FSI) for x-bar charts. In addition, these measurements in the subgroup are assumed to be normally distributed. That assumption may not be tenable. This investigation compares the economic design of x-bar control charts for non normal data under Weibull shock models with various sampling avenues.     

A non parametric approach to monitor simple linear profiles in phases I and II

In this paper, a non parametric approach is first proposed to monitor simple linear profiles with non normal error terms in Phase I and Phase II. In this approach, two control charts based on a transformation technique and decision on beliefs are designed in order to monitor the intercept and the slope, simultaneously. Then, some simulation experiments are performed in order to evaluate the performance of the proposed control charts in Phase II under both step and drift shifts in terms of out-of-control average run length (ARL₁). Besides, the performance of the proposed control charts is compared to the ones of seven other existing schemes in the literature. Simulation results show that the proposed control charts outperform the other control charts in detecting both the small step and small drift shifts of intercept. However, they have a weaker performance compared to other control charts in detecting both small step and small drift shifts of the slope. At the end, a real example from an electronic industry is used to illustrate the implementation of the proposed method.     

Comparison of different control charts for a Weibull process with type-I censoring

Some control charts have been proposed to monitor the mean of a Weibull process with type-I censoring. One type of control charts is to monitor changes in the scale parameter because it indicates changes in the mean. With this approach, we compare different control charts such as Shewhart-type and exponentially weighted moving average (EWMA) charts based on conditional expected value (CEV) and cumulative sum (CUSUM) chart based on likelihood-ratio. A simulation approach is employed to compute control limits and average run lengths. The results show that the CUSUM chart has the best performance. However, the EWMA-CEV chart is recommendable for practitioners with its competitive performance and ease of use advantage. An illustrative example is also provided.     

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.     

Improved R and s control charts for monitoring the process variance

The Shewhart R control chart and s control chart are widely used to monitor shifts in the process spread. One fact is that the distributions of the range and sample standard deviation are highly skewed. Therefore, the R chart and s chart neither provide an in-control average run length (ARL) of approximately 370 nor guarantee the desired type I error of 0.0027. Another disadvantage of these two charts is their failure in detecting an improvement in the process variability. In order to overcome these shortcomings, we propose the improved R chart (IRC) and s chart (ISC) with accurate approximation of the control limits by using cumulative distribution functions of the sample range and standard deviation. Simulation studies show that the IRC and ISC perform very well. We also compare the type II error risks and ARLs of the IRC and ISC and found that the s chart is generally more efficient than the R chart. Examples are given to illustrate the use of the developed charts.     

Design of adaptive s control charts

The Shewhart s chart has been widely used to monitor the standard deviation of a process. However, the main disadvantage of an s chart is its slowness to signal small increases in the variability. In this paper, ideas of adaptive control charts are extended to the Shewhart s chart for improving the efficiency in signalling increases in the standard deviation. A Markov chain model is applied to evaluate its performances and compares its performances with combined double sampling and variable sampling intervals s chart, variable parameters (VP) R chart, exponentially weighted moving average and Cusum charts. The statistical performances show that the VP s chart is more sensitive to increases in standard deviation.     

Generalized Control Charts for Non-Normal Data Using g-and-k Distributions

Statistical control charts are often used in industry to monitor processes in the interests of quality improvement. Such charts assume independence and normality of the control statistic, but these assumptions are often violated in practice. To better capture the true shape of the underlying distribution of the control statistic, we utilize the g-and-k distributions to estimate probability limits, the true ARL, and the error in confidence that arises from incorrectly assuming normality. A sensitivity assessment reveals that the extent of error in confidence associated with control chart decision-making procedures increases more rapidly as the distribution becomes more skewed or as the tails of the distribution become longer than those of the normal distribution. These methods are illustrated using both a frequentist and computational Bayesian approach to estimate the g-and-k parameters in two different practical applications. The Bayesian approach is appealing because it can account for prior knowledge in the estimation procedure and yields posterior distributions of parameters of interest such as control limits.     

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.     

A single-featured EWMA-X control chart for detecting shifts in process mean and standard deviation

The combined EWMA-X chart is a commonly used tool for monitoring both large and small process shifts. However, this chart requires calculating and monitoring two statistics along with two sets of control limits. Thus, this study develops a single-featured EWMA-X (called SFEWMA-X) control chart which has the ability to simultaneously monitor both large and small process shifts using only one set of statistic and control limits. The proposed SFEWMA-X chart is further extended to monitoring the shifts in process standard deviation. A set of simulated data are used to demonstrate the proposed chart's superior performance in terms of average run length compared with that of the traditional charts. The experimental examples also show that the SFEWMA-X chart is neater and easier to visually interpret than the original EWMA-X chart.     

Bayesian analysis for partially complete time and type of failure data

In this paper, we consider the Bayesian analysis of competing risks data, when the data are partially complete in both time and type of failures. It is assumed that the latent cause of failures have independent Weibull distributions with the common shape parameter, but different scale parameters. When the shape parameter is known, it is assumed that the scale parameters have Beta–Gamma priors. In this case, the Bayes estimates and the associated credible intervals can be obtained in explicit forms. When the shape parameter is also unknown, it is assumed that it has a very flexible log-concave prior density functions. When the common shape parameter is unknown, the Bayes estimates of the unknown parameters and the associated credible intervals cannot be obtained in explicit forms. We propose to use Markov Chain Monte Carlo sampling technique to compute Bayes estimates and also to compute associated credible intervals. We further consider the case when the covariates are also present. The analysis of two competing risks data sets, one with covariates and the other without covariates, have been performed for illustrative purposes. It is observed that the proposed model is very flexible, and the method is very easy to implement in practice.