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.     

Optimal Designing of Variables Sampling Plan for Resubmitted Lots

This article proposes a variables sampling plan that can be applied for sampling inspection of resubmitted lots when the quality characteristic of interest follows the normal distribution. Resubmission of lots for inspection is allowed in some situations where the original inspection results are suspected or when the supplier or producer is allowed to opt for resampling as per the provisions of the contract, etc. The advantages of this proposed variables sampling plan over the existing single sampling variables plan are discussed. Tables are also constructed for the selection of optimal parameters of known and unknown standard deviation variables resampling scheme for specified two points on the operating characteristic curve, namely, the acceptable quality level and the limiting quality level along with the producer and consumer's risks. The optimization problem is formulated as a nonlinear programming where the objective function to be minimized is the average sample number and the constraints are related to lot acceptance probabilities at acceptable quality level and limiting quality level under the operating characteristic curve.     

Determination of a new mixed variable lot-size multiple dependent state sampling plan based on the process capability index

This article proposes a new mixed variable lot-size multiple dependent state sampling plan in which the attribute sampling plan can be used in the first stage and the variables multiple dependent state sampling plan based on the process capability index will be used in the second stage for the inspection of measurable quality characteristics. The proposed mixed plan is developed for both symmetric and asymmetric fraction non conforming. The optimal plan parameters can be determined by considering the satisfaction levels of the producer and the consumer simultaneously at an acceptable quality level and a limiting quality level, respectively. The performance of the proposed plan over the mixed single sampling plan based on C_pk and the mixed variable lot size plan based on C_pk with respect to the average sample number is also investigated. Tables are constructed for easy selection of plan parameters for both symmetric and asymmetric fraction non conforming and real world examples are also given for the illustration and practical implementation of the proposed mixed variable lot-size plan.     

Optimal designing of an SkSP-R double sampling plan

In this article, we propose a method of planning and determining the optimum parameters of a SkSP-R skip-lot sampling plan by using the attribute double sampling plan as the reference plan. The SkSP-R plan is a new type of skip-lot sampling plan which has a provision for re-inspecting the submitted lots. The optimal plan parameters of the suggested sampling plan are estimated with the target that the average sample number be minimized and satisfying both the specified producer's as well as the consumer's risks simultaneously. In order to obtain the optimum parameters, tables are also built for different combinations of the acceptable quality level and the limiting quality level in conjunctions with different producer's and consumer's risks. An illustrative example is provided for the implementation of the suggested plan. The advantages of the suggested plan over the existing conventional sampling plans and other existing skip-lot sampling plans are also described.     

Economic design of quick switching sampling system for resubmitted lots

This paper proposes a quick switching sampling system for the inspection of attributes quality characteristics for resubmitted lots. The optimal parameters for both fraction non conforming items and fraction non conformities of the proposed sampling system are determined using an optimization procedure so that producer’s risk and consumer’s risk are simultaneously satisfied. Tables are also constructed for the selection of parameters for specified AQL and LQL. The advantage of the proposed plan over the existing plan is discussed and illustrate. An economic design of the proposed sampling system is also discussed and shown that the proposed sampling system has minimum total cost and average total inspection compared to other existing sampling plans.     

Economic design of quick switching sampling system for assuring Weibull distributed mean life

In this paper, we propose the quick switching sampling system for assuring mean life of a product under time truncated life test where the lifetime of the product follows the Weibull distribution and the mean life is considered as the quality of the product. The optimal parameters of the proposed system are determined using two points on the operating characteristic curve approach for various combinations of consumer's risk and ratio of true mean life time and specified life time. Tables are constructed to determine the optimal parameters for specified acceptable quality level and limiting quality level along with the corresponding probabilities of acceptance. The proposed system is compared with other existing sampling plans under Weibull lifetime model. In addition, an economical design of the proposed system is also discussed.     

Bayesian Design of Special Type of Double Sampling Plans for Compliance Testing

Bayesian acceptance sampling plans, which utilize prior information on the process variation, can be employed as an alternative to conventional types of plans for taking decisions on the disposition of submitted lots. A special type of double sampling inspection plans by attributes with small acceptance numbers using Bayesian methodology is presented in this paper emphasizing its significance over small acceptance number single sampling plans. The procedures for designing such sampling plans for specified degree of discrimination which would ensure protection to the producer and consumer are discussed with illustrations under the conditions for the application of gamma-Poisson distribution.     

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.     

Acceptance sampling plan based on an exponentially weighted moving average statistic with the yield index for autocorrelation between polynomial profiles

Acceptance sampling plans based on process yield indices provide a proven resource for the lot-sentencing problem when the required fraction defective is very low. In this study, a new sampling plan based on the exponentially weighted moving average (EWMA) model with yield index for lot sentencing for autocorrelation between polynomial profiles is proposed. The advantage of the EWMA statistic is the accumulation of quality history from previous lots. In addition, the number of profiles required for lot sentencing is more economical than in the traditional single sampling plan. Considering the acceptable quality level (AQL) at the producer's risk and the lot tolerance percent defective (LTPD) at the consumer's risk, we proposed a new search algorithm to determine the optimal plan parameters. The plan parameters are tabulated for various combinations of the smoothing constant of the EWMA statistic, AQL, LTPD, and two risks. A comparison study and two numerical examples are provided to show the applicability of the proposed sampling plan.     

Predictive design of single sampling attribute plans

The design of a sampling inspection plan is usually based on the properties of the operating characteristic curve. This approach ensures that the plan has adequate power to discriminate a lot of acceptable quality from a lot rejectable quality. However, the designed plan need not necessarily have adequate predictive power when the sentenced lot is re-inspected using the same sampling plan. The paper introduces a new design approach for the single sampling attributes plan ensuring the decision of acceptance or rejection is consistent for both current and any future inspection of the lot. The proposed design controls the risks of a future sample leading to a contradictory decision of acceptance or rejection of the lot. An increase in sample size is required to achieve the required predictive power if the true lot quality fails to be at very low fraction non-conforming levels. A Bayesian analysis is also provided.     

A new sampling plan under the exponential distribution

This article considers a sampling plan when the quality characteristic follows the exponential distribution. We provide the exact approach and propose an approximated approach. In the proposed approximation, a new statistic combined with a Weibull transformation is used for the normal approximation. The plan parameters are obtained through the two-point approach at the acceptable quality level (AQL) and the limiting quality level (LQL). The tables for plan parameters are reported according to various values of the AQL and the LQL when the producer's and the consumer's risks are given. A real example is given to illustrate the proposed approximation approach.     

A Bayesian nonparametric model for Taguchi's on-line quality monitoring procedure for attributes

A Bayesian nonparametric model for Taguchi's on-line quality monitoring procedure for attributes is introduced. The proposed model may accommodate the original single shift setting to the more realistic situation of gradual quality deterioration and allows the incorporation of an expert's opinion on the production process. Based on the number of inspections to be carried out until a defective item is found, the Bayesian operation for the distribution function that represents the increasing sequence of defective fractions during a cycle considering a mixture of Dirichlet processes as prior distribution is performed. Bayes estimates for relevant quantities are also obtained.     

The Consumer’s Risk and Costs in Zero-Acceptance Number Sampling

The primary purpose of sampling inspection is the protection of consumer’s interests. Although under simple cost models, sampling inspection never serves the producer’s interest, some form of sampling inspection can be beneficial to the consumer under the same assumptions. We consider the case of isolated lot inspection and examine the consumer risk, economic sample design, and errors in the inspection process. Acceptance sampling is shown to be cost-effective to the consumer whenever the lot quality is less than perfect, and even for perfect lot quality in the presence of inspection errors.     

Design of a time-truncated double sampling plan for a general life distribution

A double sampling plan based on truncated life tests is proposed and designed under a general life distribution. The design parameters such as sample sizes and acceptance numbers for the first and the second samples are determined so as to minimize the average sample number subject to satisfying the consumer's and producer's risks at the respectively specified quality levels. The resultant tables can be used regardless of the underlying distribution as long as the reliability requirements are specified at two risks. In addition, Gamma and Weibull distributions are particularly considered to report the design parameters according to the quality levels in terms of the mean ratios.     

Attribute-variable Inspection Policy for Lots Using Resampling Based on EWMA

A new mixed sampling plan which is a combination of the attribute single sampling plan and variables resampling scheme based on EWMA statistic is proposed in this paper. The operating characteristic function of the proposed plan is derived and the plan parameters are determined such that the probability of acceptance of good lot is larger than the specified producer's confidence level and the bad lot acceptance probability is smaller than the consumer's confidence level. The efficiency and the advantages of the proposed plan are discussed over the existing attribute sampling plan. The extensive tables are provided for industrial applications. The use of tables is discussed with the help of a real-time industrial example.     

New acceptance sampling plans based on life tests for Birnbaum–Saunders distributions

In this paper, we consider the Birnbaum–Saunders distribution as a life model to develop various acceptance sampling schemes based on the truncated life tests. We develop the double sampling plan and determine the design parameters satisfying both the producer's and consumer's risks simultaneously for the specified reliability levels in terms of the mean ratio to the specified life. We also propose a group sampling plan and determine the parameters by the above-mentioned two-point method. Tables are constructed for the proposed sampling plans and results are explained with examples.     

Optimal designing of skip-lot sampling plan of type SkSP-2 with group acceptance sampling plan as reference plan under Burr-type XII distribution

In this paper, skip-lot sampling plan of type SkSP-2 with group acceptance sampling plans is proposed when the lifetime of the product follows the Burr-type XII distributions. The optimal parameters of the proposed plan are determined when two points on operating characteristics curve namely acceptable quality level and limiting quality level and the number of testers are specified. We also considered the Burr-type XII distribution to find the plan parameters. Several tables are given for practical use. We compare the results of proposed plan with the existing plans. Results are explained using real-world examples.     

A group acceptance sampling plan for truncated life test having Weibull distribution

In this paper, a group acceptance sampling plan for a truncated life test is proposed when a multiple number of items as a group can be tested simultaneously in a tester, assuming that the lifetime of a product follows the Weibull distribution with a known shape parameter. The design parameters such as the number of groups and the acceptance number will be determined by satisfying the producer's and the consumer's risks at the specified quality levels, while the termination time and the number of testers are specified. The results are explained with tables and examples.     

Optimal designing of two-level skip-lot sampling reinspection plan

Skip-lot sampling plan is often applied in industries for reducing the cost and effort of the inspection of the product having excellent quality history. Consequence of skip-lot sampling plans is to reduce the cost of inspection so which are more attractive in economical aspect. In this paper, we develop a sampling plan by incorporating the idea of resampling in two-level skip lot sampling plan and the new plan is designated as SkSP-2L.1-R. This paper presents the Markov chain formulation of the proposed plan along with the derivation of performance measures of the plan. We also provide the designing methodology to determine the optimal parameters of the SkSP-2L.1-R plan so as to minimize the average sample number by using two points on the operating characteristic curve approach. By contemplating various combinations of producer and consumer quality levels along with respective risks, a table is constructed to determine the optimal parameters. An industrial application of the proposed SkSP-2L.1-R plan is discussed. The SkSP-2L.1-R with single sampling plan as a reference plan is compared with the conventional single sampling plan, SkSP-2 plan and SkSP-2-R plan and proved that the proposed SkSP-2L.1-R plan outperforms these plans.KEYWORDS: Consumer quality level, average sample number, producer quality level, resampling scheme, skip-lot sampling     

Repeated screening with inspection error and no false positive results with application to pharmaceutical pill production

Summary.  Repeated screening is a 100% sampling inspection of a batch of items followed by removal of the defective items and further iterations of inspection and removal. The reason for repeating the inspection is that the detection of a defective item happens with probability p <1. A missed defective item is a false negative result. The no false positive result is contemplated in this paper, which is motivated by a problem coming from the production of pharmaceutical pills. Bayesian posterior distributions for the quality of the lot are obtained for the case of both p known and p unknown. Batch rejection and batch acceptance control limits for the number of defective items at subsequent iterations can then be calculated. Theoretical connections to the problem of estimating the number-of-trials parameter of a binomial distribution are drawn.