Economic-statistical design of X ¥ charts for non-normal data by considering quality loss

When the X ¥ control chart is used to monitor a process, three parameters should be determined: the sample size, the sampling interval between successive samples, and the control limits of the chart. Duncan presented a cost model to determine the three parameters for an X ¥ chart. Alexander et al. combined Duncan's cost model with the Taguchi loss function to present a loss model for determining the three parameters. In this paper, the Burr distribution is employed to conduct the economic-statistical design of X ¥ charts for non-normal data. Alexander's loss model is used as the objective function, and the cumulative function of the Burr distribution is applied to derive the statistical constraints of the design. An example is presented to illustrate the solution procedure. From the results of the sensitivity analyses, we find that small values of the skewness coefficient have no significant effect on the optimal design; however, a larger value of skewness coefficient leads to a slightly larger sample size and sampling interval, as well as wider control limits. Meanwhile, an increase on the kurtosis coefficient results in an increase on the sample size and wider control limits.     

Designing an economic rectifying sampling plan in the presence of two markets

In this paper, an optimization model is developed for the economic design of a rectifying inspection sampling plan in the presence of two markets. A product with a normally distributed quality characteristic with unknown mean and variance is produced in the process. The quality characteristic has a lower specification limit. The aim of this paper is to maximize the profit, which consists the Taguchi loss function, under the constraints of satisfying the producer's and consumer's risk in two different markets simultaneously. Giveaway cost per unit of sold excess material is considered in the proposed model. A case study is presented to illustrate the application of proposed methodology. In addition, sensitivity analysis is performed to study the effect of model parameters on the expected profit and optimal solution. Optimal process adjustment problem and acceptance sampling plan is combined in the economical optimization model. Also, process mean and standard deviation are assumed to be unknown value, and their impact is analyzed. Finally, inspection error is considered, and its impact is investigated and analyzed.     

A new policy for designing acceptance sampling plan based on Bayesian inference in the presence of inspection errors

The purpose of this article is to present a new policy for designing an acceptance sampling plan based on the minimum proportion of the lot that should be inspected in the presence of inspection errors. It is assumed that inspection is not perfect and every defective item cannot be detected with complete certainty. The Bayesian method is used for obtaining the probability distribution function of the number of defective items in the lot. To design this model, two constraints of producer risk and consumer risk are considered during the inspection process by using two specified points on operating characteristic curve. In order to illustrate the application of the proposed model, an example is presented. In addition, a sensitivity analysis is performed to analyze the model performance under different scenarios of process parameters and the results are elaborated. Finally, the efficiency of the proposed model is compared with the sampling method of Spencer and Kevan de Lopez (2017) at the same conditions.     

An economic inspection interval for control of defective items in a hot rolling mill

The article addresses a real-life problem on determining the optimum sampling interval for control of defective items in a hot rolling mill. Having observed that the pattern of appearance of mill defects indicates a geometric process failure mechanism, an economic model is developed in line with the method suggested by Taguchi and critically examined by Nayebpour & Woodall. An expression for the expected loss per product as a function of the sampling interval is derived and the optimum interval is obtained by minimizing this loss function. The practical issues involved in this exercise, such as estimation of various cost components, are also discussed and the effect of erroneous estimation of cost components is studied through a sensitivity analysis.     

A flexible sampling scheme for variables inspection with loss consideration

This article develops a variables sampling scheme for resubmitted lots by incorporating the concept of Taguchi loss function. The probability of lot acceptance is derived based on the exact sampling distribution and two-point condition on operating characteristic curve is used to determine the plan parameters that meet both the producer's and consumer's quality and risk requirements. Moreover, the performance of the proposed variables resubmitted sampling plan is investigated and compared with the classical variables single sampling plan. The results indicate that the developed resubmitted sampling plan can provide the same protection with less inspection when the submitted lot is good enough. Tables of the plan parameters under various conditions are provided and the use of the proposed plan is also illustrated with an example.     

Optimal acceptance sampling policy considering Bayesian risks

In this paper, we propose a sampling policy considering Bayesian risks. Various definitions of producer's risk and consumer's risk have been made. Bayesian risks for both producer and consumer are proven to give better information to decision-makers than classical definitions of the risks. So considering the Bayesian risk constraints, we seek to find optimal acceptance sampling policy by minimizing total cost, including the cost of rejecting the batch, the cost of inspection, and the cost of defective items detected during the operation. Proper distributions to construct the objective function of the model are specified. In order to demonstrate the application of the proposed model, we illustrate a numerical example. Furthermore, the results of the sensitivity analysis show that lot size, the cost of inspection, and the cost of one defective item are key factors in sampling policies. The acceptable quality level, the lot tolerance proportion defective, and Bayesian risks also affect the sampling policy, but variations of acceptable quality level and producer Bayesian risks, for values more than a specified value, cause no changes in sampling policy.     

Designing an economically optimal repetitive group-sampling plan based on loss functions

Acceptance sampling is a quality assurance tool, which provides a rule for the producer and the consumer to make acceptance or rejection decision about a lot. This paper attempts to develop a more efficient sampling plan, variables repetitive group sampling plan, based on the total loss to the producer and consumer. To design this model, two constraints are considered to satisfy the opposing priorities and requirements of the producer and the consumer by using Acceptable quality level (AQL) and Limiting quality level (LQL) points on operating characteristic (OC) curve. The objective function of this model is constructed based on the total expected loss. In order to illustrate the application of the proposed model, an example is presented. In addition, the effects of process parameters on the optimal solution and the total expected loss are studied by performing a sensitivity analysis. Finally, the efficiency of the proposed model is compared with the variables single sampling plan, the variables double sampling plan and the repetitive group sampling plan of Balamurali and Jun (2006) in terms of average sample number, total expected loss and its difference with ideal OC curve.     

The probabilistic tolerance design for a subsystem using taguchi's quadratic loss function

Taguchi (1984,1987) has derived tolerances for subsystems, subcomponents, parts and materials. However, he assumed that the relationship between a higher rank and a lower rank quality characteristic is deterministic. The basic structure of the above tolerance design problem is very similar to that of the screening problem. Tang (1987) proposed three cost models and derived an economic design for the screening problem of “the-bigger-the-better” quality characteristic in which the optimal specification limit ( or tolerance ) for a screening variable ( or a lower rank quality characteristic ) was obtained by minimizing the expected total cost function.Tang considered that the quality cost incurred only when the quality characteristic is out of specification while Taguchi considered that the quality cost incurred whenever the quality characteristic deviates from its nominal value. In this paper, a probabilistic relationship, namely, a bivariate normal distribution between the above two qualy characteristics as in a screening problem as well as Taguchi's quadratic loss function are considered together to develop a closed form solution of the tolerance design for a subsystem.     

Designing a variable sampling plan based on Taguchi's loss function

This paper discusses the problem of designing a new variable sampling plan. Suppose that the lot quality characteristic obeys an exponential distribution. Adopting Taguchi's loss function, the objective is to design a plan under which the producer's risk of rejecting a lot that has a specified average loss per item is no greater than alpha, and the consumer's risk of accepting a lot that has a specified average loss per item is no greater than beta. The method of designing this plan is an extension of the method used by Derman and Ross.     

A median loss control chart for monitoring quality loss under skewed distributions

The quality and loss of products are crucial factors separating competitive companies in global market. Firms widely employ a loss function to measure the loss caused by a deviation of the quality variable from the target value. Monitoring this deviation from the process target value is important from the view of Taguchi’s philosophy. In reality, there are many situations where the distribution of the quality variable may not be normal but skewed. This paper aims at developing a median loss (ML) control chart for monitoring quality loss under skewed distributions. Both the cases with fixed and variable sampling intervals are considered. Numerical results show that the ML chart with (optimal) variable sampling intervals performs better than the ML chart in detecting small to moderate shifts in the process loss centre or in the difference of mean and target and/or variance of a process variable. The ML chart and the ML chart with variable sampling intervals also illustrate the best performance in detection out-of-control process for a process quality variable with a left-skewed distribution. A numerical example illustrates the application of the proposed control chart.     

Optimal designing of a new mixed variable lot-size chain sampling plan based on the process capability index

In this paper, a new mixed sampling plan based on the process capability index (PCI) C_pk is proposed and the resultant plan is called mixed variable lot-size chain sampling plan (ChSP). The proposed mixed plan comprises of both attribute and variables inspections. The variable lot-size sampling plan can be used for inspection of attribute quality characteristics and for the inspection of measurable quality characteristics, the variables ChSP based on PCI will be used. We have considered both symmetric and asymmetric fraction non conforming cases for the variables ChSP. Tables are developed for determining the optimal parameters of the proposed mixed plan based on two points on the operating characteristic (OC) approach. In order to construct the tables, the problem is formulated as a non linear programming where the average sample number function is considered as an objective function to be minimized and the lot acceptance probabilities at acceptable quality level and limiting quality level under the OC curve are considered as constraints. The practical implementation of the proposed mixed sampling plan is explained with an illustrative real time example. Advantages of the proposed sampling plan are also discussed in terms of comparison with other existing sampling plans.     

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.     

Double and group acceptance sampling plan for truncated life test based on inverse log-logistic distribution

This paper introduces a double and group acceptance sampling plans based on time truncated lifetimes when the lifetime of an item follows the inverse log-logistic (ILL) distribution with known shape parameter. The operating characteristic function and average sample number (ASN) values of the double acceptance sampling inspection plan are provided. The values of the minimum number of groups and operating characteristic function for various quality levels are obtained for a group acceptance sampling inspection plan. A comparative study between single acceptance sampling inspection plan and double acceptance sampling inspection plan is carried out in terms of sample size. One simulated example and four real-life examples are discussed to show the applicability of the proposed double and group acceptance sampling inspection plans for ILL distributed quality parameters.     

The reflected normal loss function

The use of loss functions in quality assurance has grown steadily with the introduction of Taguchi's philosophy. The quadratic loss function has been used by decision-theoretic statisticians and economists for many years. Taguchi uses a modified form of the quadratic loss function to demonstrate the need to consider proximity to the target while assessing quality. Several authors have suggested that the traditional quadratic loss function is inadequate for assessing quality and quality improvement. A new, easily understood loss function, based on a reflection of the normal density function, is presented, and some associated statistical properties discussed.     

Economic statistical design of X‾-control charts: Modified version of Rahim and Banerjee (1993) model

Rahim and Banerjee considered a constant integral of the hazard function for all sampling intervals. This led the sampling intervals to depend on the extended first sampling interval (h₁). Since this limitation might not lead to an optimal situation, we first showed that elimination of the mentioned restriction did not cause any significant change in the average quality cycle cost. So if one is looking for an ideal cost and the simplicity of the process, the approach taken in Rahim and Banerjee’s study is the best procedure to adopt. Moreover, in many cases of non-uniform sampling method the first sampling interval becomes so large and this can sometimes lead the production system to the out-of-control state due to unexpected failures that might happen during that time. Therefore, we proposed a new model of uniform and non-uniform sampling intervals combination that allows us to confine the value of h₁ without undergoing high costs. The proposed model showed that the quality cycle cost of the proposed model is lower than Rahim and Banerjee’s model in the economic-statistical state. For more illustration, we conducted sensitivity analysis and gave numerical examples.     

Optimum reliability acceptance sampling plans under progressive type-I interval censoring with random removal using a cost model

A reliability acceptance sampling plan (RASP) is a variable sampling plan, which is used for lot sentencing based on the lifetime of the product under consideration. If a good lot is rejected then there is a loss of sales, whereas if a bad lot is accepted then the post sale cost increases and the brand image of the product is affected. Since cost is an important decision-making factor, adopting an economically optimal RASP is indispensable. This work considers the determination of an asymptotically optimum RASP under progressive type-I interval censoring scheme with random removal (PICR-I). We formulate a decision model for lot sentencing and a cost function is proposed that quantifies the losses. The cost function includes the cost of conducting the life test and warranty cost when the lot is accepted, and the cost of batch disposition when it is rejected. The asymptotically optimal RASP is obtained by minimizing the Bayes risk in a set of decision rules based on the maximum likelihood estimator of the mean lifetime of the items in the lot. For numerical illustration, we consider that lifetimes follow exponential or Weibull distributions.     

On designing an acceptance sampling plan for the Pareto lifetime model

In this paper, the design of reliability sampling plans for the Pareto lifetime model under progressive Type-II right censoring is considered. Sampling plans are derived using the decision theoretic approach with a suitable loss or cost function that consists of sampling cost, rejection cost, and acceptance cost. The decision rule is based on the estimated reliability function. Plans are constructed within the Bayesian context using the natural conjugate prior. Simulations for evaluating the Bayes risk are carried out and the optimal sampling plans are reported for various sample sizes, observed number of failures and removal probabilities.     

Online control by attributes in the presence of classification errors with variable inspection interval

ABSTRACT

The procedure for online control by attribute consists of inspecting a single item at every m items produced (m ≥ 2). On each inspection, it is determined whether the fraction of the produced conforming items decreased. If the inspected item is classified as non conforming, the productive process is adjusted so that the conforming fraction returns to its original status. A generalization observed in the literature is to consider inspection errors and vary the inspection interval. This study presents an extension of this model by considering that the inspected item can be rated independently r (r ≥ 1) times. The process is adjusted every time the number of conforming classifications is less than a, 1 ≤ a ≤ r. This method uses the properties of an ergodic Markov chain to obtain the expression for the average cost of this control system. The genetic algorithm methodology is used to search for the optimal parameters that minimize the expected cost. The procedure is illustrated by a numerical example.     

A recursive approach for lot sentencing problem in the presence of inspection errors

In this paper, a new sequential acceptance sampling plans in the presence of inspection errors is developed. A suitable profit objective function is employed for optimizing the lot sentencing problem. A backward recursive approach is applied for obtaining the profit of different decisions in each stage of sampling. Required probabilities are obtained using Bayesian rule. A case study is solved for illustrating the application of proposed models and sensitivity analysis are carried out on the parameters of the proposed methodologies and the behaviour of models by changing the parameters are investigated.     

An improved sampling plan by variables inspection with consideration of process yield and quality loss

Repetitive group sampling (RGS) plan, a modified version of single sampling (SS) plan, has been shown to be more efficient than the SS plan for lot sentencing. However, because it does not consider the valuable sample information from preceding lots, that could reduce its sampling efficiency and discriminatory power. Therefore, this study proposes a modified-RGS plan by considering the quality history of preceding lots based on the C_pmk index. Additionally, the mathematical model for the plan parameters is formulated such that the objective function is to minimize the average sample number (ASN), and the required quality levels and risks as specified by producer and consumer are satisfied. The performance of the proposed plan is examined and compared with traditional sampling plans. Finally, an example is presented to illustrate its applicability.