CUSUM Control Charts for Multivariate Poisson Distribution

A cumulative sum control chart for multivariate Poisson distribution (MP-CUSUM) is proposed. The MP-CUSUM chart is constructed based on log-likelihood ratios with in-control parameters, Θ₀, and shifts to be detected quickly, Θ₁. The average run length (ARL) values are obtained using a Markov Chain-based method. Numerical experiments show that the MP-CUSUM chart is effective in detecting parameter shifts in terms of ARL. The MP-CUSUM chart with smaller Θ₁ is more sensitive than that with greater Θ₁ to smaller shifts, but more insensitive to greater shifts. A comparison shows that the proposed MP-CUSUM chart outperforms an existing MP chart.     

A Parameter-Tuned Genetic Algorithm for Economic-Statistical Design of Variable Sampling Interval X-Bar Control Charts for Non-Normal Correlated Samples

Among innovations and improvements that occurred in the past two decades on the techniques and tools used for statistical process control (SPC), adaptive control charts have shown to substantially improve the statistical and/or economical performances. Variable sampling intervals (VSI) control charts are one of the most applied types of the adaptive control charts and have shown to be faster than traditional Shewhart control charts in identifying small changes of concerned quality characteristics. While in the designing procedure of the VSI control charts the data or measurements are assumed independent normal observations, in real situations the validity of these assumptions is under question in many processes. This article develops an economic-statistical design of a VSI X-bar control chart under non-normality and correlation. Since the proposed design consists of a complex nonlinear cost model that cannot be solved using a classical optimization method, a genetic algorithm (GA) is employed to solve it. Moreover, to improve the performances, response surface methodology (RSM) is employed to calibrate GA parameters. The solution procedure, efficiency, and sensitivity analysis of the proposed design are demonstrated through a numerical illustration at the end.     

A Simple Distribution for the Sum of Correlated,Exchangeable Binary Data

This article describes a generalization of the binomial distribution. The closed form probability function for the probability of k successes out of n correlated, exchangeable Bernoulli trials depends on the number of trials and its two parameters: the common success probability and the common correlation. The distribution is derived under the assumption that the common correlation between all pairs of Bernoulli trials remains unchanged conditional on successes in all completed trials. The distribution was developed to model bond defaults but may be suited to biostatistical applications involving clusters of binary data encountered in repeated measurements or toxicity studies of families of organisms. Maximum likelihood estimates for the parameters of the distribution are found for a set of binary data from a developmental toxicity study on litters of mice.     

Determining Optimal Number of Samples for Constructing Multivariate Control Charts

Normally, an average run length (ARL) is used as a measure for evaluating the detecting performance of a multivariate control chart. This has a direct impact on the false alarm cost in Phase II. In this article, we first conduct a simulation study to calculate both in-control and out-of-control ARLs under various combinations of process shifts and number of samples. Then, a trade-off analysis between sampling inspection and false alarm costs is performed. Both the simulation results and trade-off analysis suggest that the optimal number of samples for constructing a multivariate control chart in Phase I can be determined.     

A Combination of CUSUM Charts for Monitoring a Zero-Inflated Poisson Process

The Zero-inflated Poisson distribution (ZIP) is used to model the defects in processes with a large number of zeros. We propose a control charting procedure using a combination of two cumulative sum (CUSUM) charts to detect increases in the parameters of ZIP process, one is a conforming run length (CRL) CUSUM chart and another is a zero truncated Poisson (ZTP) CUSUM chart. The control limits of the control charts are obtained using both Markov chain-based methods and simulations. Simulation experiments show that the proposed method outperforms an existing method. Finally, a real example is presented.     

A Design of s Control Charts with a Combined Double Sampling and Variable Sampling Interval Scheme

In this paper, we propose new estimation techniques in connection with the system of S-distributions. Besides “exact” maximum likelihood (ML), we propose simulated ML and a characteristic function-based procedure. The “exact” and simulated likelihoods can be used to provide numerical, MCMC-based Bayesian inferences.     

On Statistical Design of the Cumulative Quantity Control Chart for Monitoring High Yield Processes

When dealing with high-yield processes, the cumulative quantity control chart (CQC chart) has been shown to be more suitable than the traditional c chart and u chart. However, the CQC chart shows an ARL-biased performance. In this article, we propose a design procedure to derive modified control limits for the CQC chart and the CQC chart with runs rules that can produce ARL-unbiased performance and maintain the predetermined false alarm rate. After extensive numerical work we have found that the proposed ARL-unbiased CQC chart is more sensitive than the conventional CQC chart in detecting process deteriorations.     

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.     

Economic-Statistical Design of EWMA Control Charts Based on Taguchi's Loss Function

This paper proposes an economic-statistical design of the EWMA chart with time-varying control limits in which the Taguchi's quadratic loss function is incorporated into the economic-statistical design based on Lorenzen and Vance's economical model. A nonlinear programming with statistical performance constraints is developed and solved to minimize the expected total quality cost per unit time. This model, which is divided into three parts, depends on whether production continues during the period when the assignable cause is being searched for and/or repaired. Through a computational procedure, the optimal decision variables, including the sample size, the sampling interval, the control limit width, and the smoothing constant, can be solved for by each model. It is showed that the optimal economic-statistical design solution can be found from the set of optimal solutions obtained from the statistical design, and both the optimal sample size and sampling interval always decrease as the magnitude of shift increases.     

The Economic Design of the MSE Control Chart

In this article, an economic design model of the MSE control chart is proposed. The formulated cost function includes the cost incurred in production process and the loss borne by customers because of the shift of means and the drift of variation. The economic bounds where the process is shut down if the search indicates the presence of an assignable cause are also being considered. A program written in Matlab 7.0 is used to determine the optimum parameters including the sample size n, the sample interval h and the width of the control limits k. Finally, an example is given to illustrate the proposed economic design and sensitivity analysis is carried out.     

Control Chart for Monitoring Autocorrelated Process with Multiple Exogenous Inputs

We propose to use AR-Sieve Bootstrap in the construction of a control chart of an autocorrelated process influenced by multiple exogenous inputs. The control charts are compared with Exponentially Weighted Moving Average (EWMA) control chart through a simulation study. AR-Sieve bootstrap control limits are narrower than EWMA control limits. While the proposed method yields a higher rate of false alarms, it is quick in detecting even minimal structural changes.     

A Robust Control Chart for Monitoring the Mean of an Autocorrelated Process

Residual control charts are frequently used for monitoring autocorrelated processes. In the design of a residual control chart, values of the true process parameters are often estimated from a reference sample of in-control observations by using least squares (LS) estimators. We propose a robust control chart for autocorrelated data by using Modified Maximum Likelihood (MML) estimators in constructing a residual control chart. Average run length (ARL) is simulated for the proposed chart when the underlying process is AR(1). The results show the superiority of the new chart under several situations. Moreover, the chart is robust to plausible deviations from assumed distribution of errors.     

Formulas for the Design of CUSUM Quality Control Charts

ABSTRACT

In the design of CUSUM control charts, it is common to use charts, tables, or software to find an appropriate critical threshold (h). This article provides an approximate formula to calculate the threshold directly from prespecified values of the reference value (k) and the in-control average run length (ARL₀). Formulas are also provided for choosing k and h from prespecified values of the in-control and out-of-control average run lengths.     

Monitoring foreclosure rates with a spatially risk-adjusted Bernoulli CUSUM chart for concurrent observations

Frequently in process monitoring, situations arise in which the order that events occur cannot be distinguished, motivating the need to accommodate multiple observations occurring at the same time, or concurrent observations. The risk-adjusted Bernoulli cumulative sum (CUSUM) control chart can be used to monitor the rate of an adverse event by fitting a risk-adjustment model, followed by a likelihood ratio-based scoring method that produces a statistic that can be monitored. In our paper, we develop a risk-adjusted Bernoulli CUSUM control chart for concurrent observations. Furthermore, we adopt a novel approach that uses a combined mixture model and kernel density estimation approach in order to perform risk-adjustment with regard to spatial location. Our proposed method allows for monitoring binary outcomes through time with multiple observations at each time point, where the chart is spatially adjusted for each Bernoulli observation's estimated probability of the adverse event. A simulation study is presented to assess the performance of the proposed monitoring scheme. We apply our method using data from Wayne County, Michigan between 2005 and 2014 to monitor the rate of foreclosure as a percentage of all housing transactions.     

On-Line Process Control using Attributes with Misclassification Errors: An Economical Design for Short-Run Production

On-line process control consists of inspecting a single item for every m (integer and m ≥ 2) produced items. Based on the results of the inspection, it is decided whether the process is in-control (the fraction of conforming items is p ₁; State I) or out-of-control (the fraction of conforming items is p ₂ < p ₁; State II). If the inspected item is non conforming, it is determined that the process is out-of-control, and the production process is stopped for an adjustment; otherwise, production continues. As most designs of on-line process control assume a long-run production, this study can be viewed as an extension because it is concerned with short-run production and the decision regarding the process is subject to misclassification errors. The probabilistic model of the control system employs properties of an ergodic Markov chain to obtain the expression of the average cost of the system per unit produced, which can be minimised as a function of the sampling interval, m. The procedure is illustrated by a numerical example.     

The Design of and R Control Charts for Skew Normal Distributed Data

The Shewhart-type control chart is traditionally developed under the normality assumption. In practice, however, this assumption may not hold. Because the skew normal distribution represents a broad distribution class and is more flexible than is the normal distribution, we propose two new control charts to monitor process mean and spread for skew normal distributed data. Moreover, to facilitate practical implementation, tables of charting constants are provided. We conducted simulation studies to compare the false alarm rates, and the results show that new proposed charts perform better than others as skewness increases. Finally, an illustrative example is provided.