Monitoring Variability and Analyzing Multivariate Autocorrelated Processes

Traditional multivariate quality control charts are based on independent observations. In this paper, we explain how to extend univariate residual charts to multivariate cases and how to combine the traditional statistical process control (SPC) approaches to monitor changes in process variability in a dynamic environment. We propose using Alt's (1984) W chart on vector autoregressive (VAR) residuals to monitor the variability for multivariate processes in the presence of autocorrelation. We study examples jointly using the Hotelling T² chart on VAR residuals, the W chart, and the Portmanteau test to diagnose the types of shift in process parameters.     

Single Attribute Control Charts for a Markovian-Dependent Process

In a production process, sequence of observations related to the quality of a process need not be independent. In such situations, control charts based on the assumption of independence of the observations are not appropriate. When the characteristic under study is qualitative, the Markovian model serves as a simple model to account for the dependency of the observations. In this article, we develop two attribute control charts for a Markovian dependent process: the first is based on controlling the error probabilities; the second is based on minimizing the average time to get a correct signal.

The charts are developed under uniform sampling. Under uniform sampling, the two consecutive samples are far enough apart, so that for all practical purposes, two consecutive samples can be considered as if they are being independent. Optimal values of the design parameters of both the control charts are obtained. A procedure to estimate the values of the in-control parameters is also described. The chart's performance is evaluated using the probability of detecting shift. When we implement the proposed charts for the data simulated under given manufacturing environments, the charts exhibit the desired properties of error probabilities and average time to signal.     

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.     

Control charts for multivariate spatial autoregressive models

This paper deals with spatial detection of changes in model parameters of spatial autoregressive processes. The respective sequential testing problems are formulated. Moreover, we introduce characteristic quantities to monitor means or covariances of multivariate spatial autoregressive processes. Additionally, we also take into account the simultaneous surveillance of the mean vector and the covariance matrix. The aim is to apply control charts, important tools of sequential analysis, to these quantities. The considered control procedures are based on either cumulative sums or exponential smoothing. Further, we illustrate the methodology of statistical process control studying the spectrum of additive colors in a satellite photograph. Via simulation studies, the proposed control procedures are calibrated for a predefined average run length. In addition, we compare the performance of the control procedures considering the out-of-control situation. Eventually, the control charts are applied, and the signals of the different schemes are visualized. The final results are critically discussed.     

Parametric bootstrap process capability index control charts for both mean and dispersion

Abstract

Non-normal processes are common in practice. In this paper, we propose a novel approach to defining bootstrap process capability index (PCI) control charts to monitor the performance of in-control skew normal processes. We use a bootstrap method to calculate phase I control limits of the corresponding PCI control charts. The β-risk curves of the associated PCI control charts will be used to assess the performance of the PCI control charts. We use Monte-Carlo simulation to evaluate the performance of the proposed PCI control charts. A numerical example to illustrate the implementation of the proposed control charts.     

On increasing the sensitivity of mixed EWMA–CUSUM control charts for location parameter

Control chart is an important statistical technique that is used to monitor the quality of a process. Shewhart control charts are used to detect larger disturbances in the process parameters, whereas cumulative sum (CUSUM) and exponential weighted moving average (EWMA) are meant for smaller and moderate changes. In this study, we enhanced mixed EWMA–CUSUM control charts with varying fast initial response (FIR) features and also with a runs rule of two out of three successive points that fall above the upper control limit. We investigate their run-length properties. The proposed control charting schemes are compared with the existing counterparts including classical CUSUM, classical EWMA, FIR CUSUM, FIR EWMA, mixed EWMA–CUSUM, 2/3 modified EWMA, and 2/3 CUSUM control charting schemes. A case study is presented for practical considerations using a real data set.     

Effect of measurement error on exponentially weighted moving average control charts under ranked set sampling schemes

Control charts are a powerful statistical process monitoring tool often used to monitor the stability of manufacturing processes. In quality control applications, measurement errors adversely affect the performance of control charts. In this paper, we study the effect of measurement error on the detection abilities of the exponentially weighted moving average (EWMA) control charts for monitoring process mean based on ranked set sampling (RSS), median RSS (MRSS), imperfect RSS (IRSS) and imperfect MRSS (IMRSS) schemes. We also study the effect of multiple measurements and non-constant error variance on the performances of the EWMA control charts. The EWMA control chart based on simple random sampling is compared with the EWMA control charts based on RSS, MRSS, IRSS and IMRSS schemes. The performances of the EWMA control charts are evaluated in terms of out-of-control average run length and standard deviation of run lengths. It turns out that the EWMA control charts based on MRSS and IMRSS schemes are better than their counterparts for all measurement error cases considered here.     

A New Procedure to Monitor the Mean of a Quality Characteristic

The Shewhart, Bonferroni-adjustment, and analysis of means (ANOM) control charts are typically applied to monitor the mean of a quality characteristic. The Shewhart and Bonferroni procedure are utilized to recognize special causes in production process, where the control limits are constructed by assuming normal distribution for known parameters (mean and standard deviation), and approximately normal distribution regarding to unknown parameters. The ANOM method is an alternative to the analysis of variance method. It can be used to establish the mean control charts by applying equicorrelated multivariate non central t distribution. In this article, we establish new control charts, in phases I and II monitoring, based on normal and t distributions having as a cause a known (or unknown) parameter (standard deviation). Our proposed methods are at least as effective as the classical Shewhart methods and have some advantages.     

The effect of Phase I sample size on the run length performance of control charts for autocorrelated data

Traditional control charts assume independence of observations obtained from the monitored process. However, if the observations are autocorrelated, these charts often do not perform as intended by the design requirements. Recently, several control charts have been proposed to deal with autocorrelated observations. The residual chart, modified Shewhart chart, EWMAST chart, and ARMA chart are such charts widely used for monitoring the occurrence of assignable causes in a process when the process exhibits inherent autocorrelation. Besides autocorrelation, one other issue is the unknown values of true process parameters to be used in the control chart design, which are often estimated from a reference sample of in-control observations. Performances of the above-mentioned control charts for autocorrelated processes are significantly affected by the sample size used in a Phase I study to estimate the control chart parameters. In this study, we investigate the effect of Phase I sample size on the run length performance of these four charts for monitoring the changes in the mean of an autocorrelated process, namely an AR(1) process. A discussion of the practical implications of the results and suggestions on the sample size requirements for effective process monitoring are provided.     

An Improved Distribution-free EWMA Mean Chart

Control charts are effective tools for signal detection in both manufacturing processes and service processes. Much service data come from a process with variables having nonnormal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, should not be properly used here. In this article, we propose an improved asymmetric EWMA mean chart based on a simple statistic to monitor process mean shift. We explored the sampling properties of the new monitoring statistic and calculated the average run lengths of the proposed asymmetric EWMA mean chart. We recommend the proposed improved asymmetric EWMA mean chart because the average run lengths of the modified charts are more accurate and reasonable than those of the five existed mean charts. A numerical example of service times with a right skewed distribution from a service system of a bank branch is used to illustrate the application of the improved asymmetric EWMA mean chart and to compare it with the five existing mean charts. The proposed chart showed better detection performance than those of the five existing mean charts in monitoring and detecting shifts in the process mean.     

Distribution-free cumulative sum and exponentially weighted moving average control charts based on the Wilcoxon rank-sum statistic using ranked set sampling for monitoring mean shifts

ABSTRACT

Whenever a practitioner is not sure about the underlying process distribution, alternative monitoring schemes that may be used are called nonparametric charts. A nonparametric scheme mostly used to monitor the difference in the means of two samples is called the Wilcoxon rank-sum (WRS). In this paper, we propose nonparametric (or distribution-free) cumulative sum and exponentially weighted moving average charts based on the WRS using ranked set sampling. We thoroughly discuss the performance of the proposed control charts in terms of run-length properties through intensive simulations. Moreover, we conduct an overall performance comparison using the relative mean index and a variety of quality loss functions (for instance, the average extra quadratic loss, average ratio of the average run-length and performance comparison index). The newly proposed charts have very attractive run-length properties and they have better overall performance than their counterparts. An illustrative example is given, as well as an easy-to-use table with optimal design parameters to aid practical implementation.     

The effect of parameter estimation on the performance of one-sided Shewhart control charts for zero-inflated processes

ABSTRACT

Zero-inflated probability models are used to model count data that have an excessive number of zeros. Shewhart-type control charts have been proposed for the monitoring of zero-inflated processes. Usually their performance is evaluated under the assumption of known process parameters. However, in practice, their values are rarely known and they have to be estimated from an in-control historical Phase I sample. In the present paper, we investigate the performance of Shewhart-type control charts for zero-inflated processes with estimated parameters and propose practical guidelines for the statistical design of the examined charts, when the size of the preliminary sample is predetermined.     

New control charts for simultaneous monitoring of the mean vector and covariance matrix of multivariate multiple linear profiles

Simultaneous monitoring of the mean vector and covariance matrix in multivariate processes allows practitioners to avoid the inflated false alarm rate that results from using two independent control charts. In this paper, we extend exponentially weighted moving average semicircle and generally weighted moving average semicircle control charts to monitor the mean vector and covariance matrix of multivariate multiple linear regression profiles in Phase II simultaneously. These new control charts are compared with the existing control charts in the literature in terms of the average run length criterion. Finally, a case is considered to show the application of the proposed charts.     

INVERSE GAUSSIAN CONTROL CHARTS

Control charts typically used to monitor process centrality and dispersion either assume normally distributed output or appeal to the viability of the central limit theorem. This appeal to the central limit theorem is frequently made on behalf of samples consisting of 10 or fewer items. Control charts for centrality and dispersion are presented for processes with inverse Gaussian distributed output.     

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.     

Distribution-Free Quality Control Charts Based on Signed-Rank-Like Statistics

In this article we propose three distribution-free (or nonparametric) statistical quality control charts for monitoring a process center when an in-control target center is not specified. These charts are of the Shewhart-type, the exponentially moving average-type, and the cumulative sum-type. The constructions of the proposed charts require the availability of an initial reference sample taken when the process was operating in-control to calculate an estimator for the unknown in-control target process center. This estimated center is then used in the calculation of signed-rank-like statistics based on grouped observations taken periodically from the process output. As long as the in-control process underlying distribution is continuous and symmetric, the proposed charts have a constant in-control average run length and a constant false alarm rate irrespective of the process underlying distribution. Other advantages of the proposed distribution-free charts include their robustness against outliers and their superior efficiency over the traditional normal-based control charts when applied to processes with moderate- or heavy-tailed underlying distributions, such as the double exponential or the Cauchy distributions.     

ARL-unbiased control charts with alarm and warning lines for monitoring Weibull percentiles using the first-order statistic

This article discusses methodology for constructing control charts to monitor the percentiles of a Weibull process with known shape parameter. Periodic samples are censored at the smallest observed value. Charts with alarm and warning limits are studied, and these limits are derived using theoretical results based on the first-order statistic. The performance of the proposed charts is evaluated and compared using average run lengths. A numerical application concerning life tests of an electronic product is presented to illustrate the methods.     

Applying fast initial response features on GWMA control charts for monitoring autocorrelation data

ABSTRACT

A generally weighted moving average (GWMA) control chart with fast initial response (FIR) features is addressed to monitor an autoregressive process mean shift. Numerical simulations based on average run length (ARL) show that the GWMA control chart with additional FIR feature requires less time to detect small or moderate shifts than GWMA control chart at low level of autocorrelation; whereas these two control charts perform similarly at high level of autocorrelation. Regardless of any level of autocorrelation, GWMA control charts provided with additional FIR feature have a good performance in detecting large shifts during the initial stage.     

Control chart for monitoring the Weibull shape parameter under two competing risks

ABSTRACT

In this paper, we propose a control chart to monitor the Weibull shape parameter where the observations are censored due to competing risks. We assume that the failure occurs due to two competing risks that are independent and follow Weibull distribution with different shape and scale parameters. The control charts are proposed to monitor one or both of the shape parameters of competing risk distributions and established based on the conditional expected values. The proposed control chart for both shape parameters is used in certain situations and allows to monitor both shape parameters in only one chart. The control limits depend on the sample size, number of failures due to each risk and the desired stable average run length (ARL). We also consider the estimation problem of the target parameters when the Phase I sample is incomplete. We assumed that some of the products that fail during the life testing have a cause of failure that is only known to belong to a certain subset of all possible failures. This case is known as masking. In the presence of masking, the expectation-maximization (EM) algorithm is proposed to estimate the parameters. For both cases, with and without masking, the behaviour of ARLs of charts is studied through the numerical methods. The influence of masking on the performance of proposed charts is also studied through a simulation study. An example illustrates the applicability of the proposed charts.     

Applying State Space to SPC: Monitoring Multivariate Time Series

Monitoring cross-sectional and serially interdependent processes has become a new issue in statistical process control (SPC). In up-to-date SPC literature, Kalman filtering was reported to monitor univariate autocorrelated processes. This paper applies a Kalman filter or state-space method for SPC to monitoring multivariate time series. We use Aoki's approach to estimate the parameter matrices of a state-space model. Multivariate Hotelling T ² control charts are employed to monitor the residuals of the state-space. Examples of this approach are illustrated.