The economic design of multivariate binomial EWMA VSSI control charts

Since multi-attribute control charts have received little attention compared with multivariate variable control charts, this research is concerned with developing a new methodology to employ the multivariate exponentially weighted moving average (MEWMA) charts for m-attribute binomial processes; the attributes being the number of nonconforming items. Moreover, since the variable sample size and sampling interval (VSSI) MEWMA charts detect small process mean shifts faster than the traditional MEWMA, an economic design of the VSSI MEWMA chart is proposed to obtain the optimum design parameters of the chart. The sample size, the sampling interval, and the warning/action limit coefficients are obtained using a genetic algorithm such that the expected total cost per hour is minimized. At the end, a sensitivity analysis has been carried out to investigate the effects of the cost and the model parameters on the solution of the economic design of the VSSI MEWMA chart.     

Economic and economic statistical design of T 2 control chart with two adaptive sample sizes

The Hotelling's T ² control chart, a direct analogue of the univariate Shewhart X¯ chart, is perhaps the most commonly used tool in industry for simultaneous monitoring of several quality characteristics. Recent studies have shown that using variable sampling size (VSS) schemes results in charts with more statistical power when detecting small to moderate shifts in the process mean vector. In this paper, we build a cost model of a VSS T ² control chart for the economic and economic statistical design using the general model of Lorenzen and Vance [The economic design of control charts: A unified approach, Technometrics 28 (1986), pp. 3–11]. We optimize this model using a genetic algorithm approach. We also study the effects of the costs and operating parameters on the VSS T ² parameters, and show, through an example, the advantage of economic design over statistical design for VSS T ² charts, and measure the economic advantage of VSS sampling versus fixed sample size sampling.     

A weibull process failure mechanism for the economic design of mewma control charts

The design parameters of the multivariate exponentially weighted moving average (MEWMA) control chart may be chosen according to economic and/or statistical considerations. The economic model proposed for the design of the'MEWMA chart assumes a Markovian process failure mechanism following an exponential distribution. We'assess the sensitivity of the resulting economic design for the MEWMA to deviations from this assumption. In particular, the generalization, from an exponential to a Weibull distribution of process failure, is used to study the selection of MEWMA chart parameters given process cost and time information. We conclude that the quality of the resulting design (in terms of expected cost) is not substantially affected by mis-specification of the distribution of process failure.     

Economic design based on a multivariate Bayesian VSI chart with a dual control limit

In this paper, a multivariate Bayesian variable sampling interval (VSI) control chart for the economic design and optimization of statistical parameters is designed. Based on the VSI sampling strategy of a multivariate Bayesian control chart with dual control limits, the optimal expected cost function is constructed. The proposed model allows the determination of the scheme parameters that minimize the expected cost per time of the process. The effectiveness of the Bayesian VSI chart is estimated through economic comparisons with the Bayesian fixed sampling interval and the Hotelling's T² chart. This study is an in-depth study on a Bayesian multivariate control chart with variable parameter. Furthermore, it is shown that significant cost improvement may be realized through the new model.     

A new economic scheme for CCC charts with run rules based on average number of inspected items

New statistical techniques and procedures have been developed to control high-yield processes along with looking for process improvement opportunities and minimizing production cost. Cumulative count of conforming control chart is generally a technique for high-quality processes, when nonconforming items are rarely produced. The objective of this study is to design control chart based on cumulative count of conforming items and run rules that develops an economic model based on the average number of inspected items to design m-of-m CCC chart in order to facilitate minimum average cost per item produced. The optimal design parameters for different values of nonconforming fraction and different cost parameters in each scenario are determined. Finally, to analyze the behavior of optimal economic solutions, sensitivity analysis of the model parameters is performed.     

The Variable Sampling Interval (VSI) in an Analysis of Taguchi's On-line Quality Monitoring Procedure for Variables

The procedure of on-line process control for variables proposed by Taguchi consists of inspecting the mth item (a single item) of every m items produced and deciding, at each inspection, whether the mean value is increased or not. If the value of the monitored statistic is outside of the control limits, one decides the process is out-of-control and the production is stopped for adjustment; otherwise, it continues. In this article, a variable sampling interval (with a longer L and a shorter m ≤ L) chart with two set of limits is used. These limits are the warning (±W) and the control (±C), where W ≤ C. The process is stopped for adjustment when an observation falls outside of the control limits or a sequence of h observations falls between the warning limits and the control limits. The longer sample interval is used after an adjustment or when an observation falls inside the warning limits; otherwise, the short sampling interval is used. The properties of an ergodic Markov chain are used to evaluate the time (in units) that the process remains in-control and out-of-control, with the aim of building an economic–statistical model. The parameters (the sampling intervals m and L, the control limits W and C and the length of run h) are optimized by minimizing the cost function with constraints on the average run lengths (ARLs) and the conformity fraction. The performance of the current proposal is more economical than the decision taken based on a sequence of length h = 1, L = m, and W = C, which is the model employed in earlier studies. A numerical example illustrates the proposed procedure.     

The robust economic statistical design of the Hotelling's T2 chart

ABSTRACT

Economic statistical designs aim at minimizing the cost of process monitoring when a specific scenario or a set of estimated process and cost parameters is given. But, in practice the process may be affected by more than one scenario which may lead to severe cost penalties if the wrong design is used. Here, we investigate the robust economic statistical design (RESD) of the T² chart in an attempt to reduce these cost penalties when there are multiple scenarios. Our method is to employ the genetic algorithm (GA) optimization method to minimize the total expected monitoring cost across all distinct scenarios. We illustrate the effectiveness of the method using two numerical examples. Simulation studies indicate that robust economic statistical designs should be encouraged in practice.     

On the Bivariate Kummer-Beta Type IV Distribution

Recent studies have shown the X-bar control chart with variable sampling interval detects shifts in the process mean faster than the traditional X-bar chart. These studies are usually based on the assumption that the process data are independently and normally distributed. However, many situations in practice violate these assumptions. In this study, a methodology is developed to economically design a variable sampling interval X-bar control chart that takes into consideration correlated non normal sample data. An example is provided to illustrate the solution procedure. A sensitivity analysis on the input parameters (i.e., the cost and the process parameters) is performed taking into account the non normality and the correlation on the optimal design of the chart.     

An economic statistical design of the Poisson EWMA control charts for monitoring nonconformities

An economic statistical model of the exponentially weighted moving average (EWMA) control chart for the average number of nonconformities in the sample is proposed. The statistical and economic performance of proposed design are evaluated using the average run length (ARL) and the hourly expected cost, respectively. A Markov chain approach is applied to derive expressions for ARL. The cost model is established based on the general cost function given in Lorenzen and Vance [The economic design of control charts: a unified approach. Technometrics. 1986;28:3–11]. An example is provided to illustrate the application of the proposed model. A sensitivity analysis is also carried out to investigate the effects of model parameters on the solution of the economic statistical design by using the design of experiments (DOE) technique.     

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.     

Economic design of VSI X̄ control chart with correlated non-normal data under multiple assignable causes

It has been recently revealed that the Shewhart control charts with variable sampling interval (VSI) perform better than the traditional Shewhart chart with the fixed sampling interval in detecting shifts in the process. In most of these research works, the normality and independency of the process data or measurements are assumed and that the process is subjected to only one assignable cause. While, in practice, these assumptions usually do not hold, some recent studies are focused on working with only one or two of these violations. In this paper, the situation in which the process data are correlated and follow a non-normal distribution and that there is multiplicity of assignable causes in the process is considered. For this case, a cost model for the economic design of the VSI X? control chart is developed, where the Burr distribution is employed to represent the non-normal distribution of the process data. To obtain the optimal values of the design parameters, a genetic algorithm is employed in which the response surface methodology is applied. A numerical example is presented to show the applicability and effectiveness of the proposed methodology. Sensitivity analysis is also carried out to evaluate the effects of cost and input parameters on the performance of the chart.     

Economic design of &Xmacron; charts with variable parameters: the Markov chain approach

This paper presents an economic design of &Xmacron; control charts with variable sample sizes, variable sampling intervals, and variable control limits. The sample size n, the sampling interval h, and the control limit coefficient k vary between minimum and maximum values, tightening or relaxing the control. The control is relaxed when an &Xmacron; value falls close to the target and is tightened when an &Xmacron; value falls far from the target. A cost model is constructed that involves the cost of false alarms, the cost of finding and eliminating the assignable cause, the cost associated with production in an out-of-control state, and the cost of sampling and testing. The assumption of an exponential distribution to describe the length of time the process remains in control allows the application of the Markov chain approach for developing the cost function. A comprehensive study is performed to examine the economic advantages of varying the &Xmacron; chart parameters.     

Economic and economic-statistical designs of the T2 control charts with SVSSI sampling scheme

Recent studies have shown that the adaptive T² chart with two different sampling interval and three sample sizes (SVSSI) shows a good performance in detecting small to large shifts in the process mean. This paper investigates the economic and economic statistical designs of the SVSSI T² charts. We use the Markov chain approach to developing the cost model proposed by Costa and Rahim (Journal of applied statistics 2001; 28: 875–885). A genetic algorithm approach is used to find the optimal solutions. Using numerical examples, we illustrate the performance of the proposed model and compare the statistical, economic, and economic statistical designs of the SVSSI T² chart with respect to the economic and statistical criteria. Furthermore, we compare the performance of the SVSSI T² chart with the other T² control schemes.     

A mean deviation-based approach to monitor process variability

The study proposes a Shewhart-type control chart, namely an MD chart, based on average absolute deviations taken from the median, for monitoring changes (especially moderate and large changes – a major concern of Shewhart control charts) in process dispersion assuming normality of the quality characteristic to be monitored. The design structure of the proposed MD chart is developed and its comparison is made with those of two well-known dispersion control charts, namely the R and S charts. Using power curves as a performance measure, it has been observed that the design structure of the proposed MD chart is more powerful than that of the R chart and is very close competitor to that of the S chart, in terms of discriminatory power for detecting shifts in the process dispersion. The non-normality effect is also examined on design structures of the three charts, and it has been observed that the design structure of the proposed MD chart is least affected by departure from normality.     

Economic Design of Cumulative Sum Control Charts for Monitoring a Process with Correlated Samples

The underlying assumption for the design of control charts is the measurements within a sample are independently distributed. However, there are many situations where the uncorrelation assumption may be unacceptable in practice. In this paper, the economic design of cumulative sum (CUSUM) control chart for correlated data within a sample is developed. The genetic algorithm is applied to find the optimal design parameters of the CUSUM control chart by minimizing the cost function. An illustrative example is given. A sensitivity analysis is then conducted to evaluate the effects of cost parameters, process parameters, and correlation coefficient on the economic design.     

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.     

A new Markov chain approach for the economic statistical design of the VSS T2 control chart

An economic statistical design model for a T² chart which uses a variable sample size (VSS) feature is developed in this article. This study mainly differs from the others conducted in the field. In that a new approach is offered to achieve closed form of some statistical criteria. In other words, the proposed formulas can be considered as a better alternative approach in designing the VSS control charts in terms of simplicity and yet providing the users with better optimal solutions.     

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.     

Double-objective economic statistical design of the VP T2 control chart: Wald's identity approach

Research has shown that applying the T² control chart by using a variable parameters (VP) scheme yields rapid detection of out-of-control states. In this paper, the problem of economic statistical design of the VP T²control chart is considered as a double-objective minimization problem with the statistical objective being the adjusted average time to signal and the economic objective being expected cost per hour. We then find the Pareto-optimal designs in which the two objectives are met simultaneously by using a multi-objective genetic algorithm. Through an illustrative example, we show that relatively large benefits can be achieved by applying the VP scheme when compared with usual schemes, and in addition, the multi-objective approach provides the user with designs that are flexible and adaptive.     

Designing Variables Sampling Plans with Process Loss Consideration

For the implementation of an acceptance sampling plan, a problem the quality practitioners have to deal with is the determination of the critical acceptance values and inspection sample sizes that provide the desired levels of protection to both vendors and buyers. Traditionally, most acceptance sampling plans focus on the percentage of defective products instead of considering the process loss, which doesn't distinguish among the products that fall within the specification limits. However, the quality between products that fall within the specification limits may be very different. So how to design an acceptance sampling plan with process loss consideration is necessary. In this article, a variables sampling plan based on L _e is proposed to handle processes requiring low process loss. The required sample sizes n and the critical acceptance value c with various combination of acceptance quality level are tabulated. The proposed sampling plan provides a feasible policy, which can be applied to products requiring low process loss where classical sampling plans cannot be applied.