Attribute Charts for Zero-Inflated Processes

The classical Shewhart c-chart and p-chart which are constructed based on the Poisson and binomial distributions are inappropriate in monitoring zero-inflated counts. They tend to underestimate the dispersion of zero-inflated counts and subsequently lead to higher false alarm rate in detecting out-of-control signals. Another drawback of these charts is that their 3-sigma control limits, evaluated based on the asymptotic normality assumption of the attribute counts, have a systematic negative bias in their coverage probability. We recommend that the zero-inflated models which account for the excess number of zeros should first be fitted to the zero-inflated Poisson and binomial counts. The Poisson parameter λ estimated from a zero-inflated Poisson model is then used to construct a one-sided c-chart with its upper control limit constructed based on the Jeffreys prior interval that provides good coverage probability for λ. Similarly, the binomial parameter p estimated from a zero-inflated binomial model is used to construct a one-sided np-chart with its upper control limit constructed based on the Jeffreys prior interval or Blyth–Still interval of the binomial proportion p. A simple two-of-two control rule is also recommended to improve further on the performance of these two proposed charts.     

Synthetic exponential control charts with unknown parameter

The existing synthetic exponential control charts are based on the assumption of known in-control parameter. However, the in-control parameter has to be estimated from a Phase I dataset. In this article, we use the exact probability distribution, especially the percentiles, mean, and standard deviation of the conditional average run length (ARL) to evaluate the effect of parameter estimation on the performance of the Phase II synthetic exponential charts. This approach accounts for the variability in the conditional ARL values of the synthetic chart obtained by different practitioners. Since parameter estimation results in more false alarms than expected, we develop an exact method to design the adjusted synthetic charts with desired conditional in-control performance. Results of known and unknown in-control parameter cases show that the control limit of the conforming run length sub-chart of the synthetic chart should be as small as possible.     

Process monitoring of exponentially distributed characteristics through an optimal normalizing transformation

Many process characteristics follow an exponential distribution, and control charts based on such a distribution have attracted a lot of attention. However, traditional control limits may be not appropriate because of the lack of symmetry. In this paper, process monitoring through a normalizing power transformation is studied. The traditional individual measurement control charts can be used based on the transformed data. The properties of this control chart are investigated. A comparison with the chart when using probability limits is also carried out for cases of known and estimated parameters. Without losing much accuracy, even compared with the exact probability limits, the power transformation approach can easily be used to produce charts that can be interpreted when the normality assumption is valid.     

Control charts for attributes with maxima nominated samples

We develop quality control charts for attributes using the maxima nomination sampling (MNS) method and compare them with the usual control charts based on simple random sampling (SRS) method, using average run length (ARL) performance, the required sample size in detecting quality improvement, and non-existence region for control limits. We study the effect of the sample size, the set size, and nonconformity proportion on the performance of MNS control charts using ARL curve. We show that MNS control chart can be used as a better benchmark for indicating quality improvement or quality deterioration relative to its SRS counterpart. We consider MNS charts from a cost perspective. We also develop MNS attribute control charts using randomized tests. A computer program is designed to determine the optimal control limits for an MNS p-chart such that, assuming known parameter values, the absolute deviation between the ARL and a specific nominal value is minimized. We provide good approximations for the optimal MNS control limits using regression analysis. Theoretical results are augmented with numerical evaluations. These show that MNS based control charts can yield substantial improvement over the usual control charts based on SRS.     

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.     

Normalization of the origin-shifted exponential distribution for control chart construction

This study demonstrates that a location parameter of an exponential distribution significantly influences normalization of the exponential. The Kullback–Leibler information number is shown to be an appropriate index for measuring data normality using a location parameter. Control charts based on probability limits and transformation are compared for known and estimated location parameters. The probabilities of type II error (β-risks) and average run length (ARL) without a location parameter indicate an ability to detect an out-of-control signal of an individual chart using a power transformation similar to using probability limits. The β-risks and ARL of control charts with an estimated location parameter deviate significantly from their theoretical values when a small sample size of n≤50 is used. Therefore, without taking into account of the existence of a location parameter, the control charts result in inaccurate detection of an out-of-control signal regardless of whether a power or natural logarithmic transformation is used. The effects of a location parameter should be eliminated before transformation. Two examples are presented to illustrate these findings.     

CUSUM charts for monitoring the mean of a multivariate Gaussian process

In this paper control charts for the mean of a multivariate Gaussian process are considered. Using the generalized likelihood ratio approach and the sequential probability ratio test under an additional constraint on the magnitude of the change various types of CUSUM control charts are derived. It is analyzed under which conditions these schemes are directionally invariant. These charts are compared with several other control schemes proposed in literature. The performance of the charts is studied based on the maximum average delay.     

A simple,doubly robust,efficient estimator for survival functions using pseudo observations

Survival functions are often estimated by nonparametric estimators such as the Kaplan‐Meier estimator. For valid estimation, proper adjustment for confounding factors is needed when treatment assignment may depend on confounding factors. Inverse probability weighting is a commonly used approach, especially when there is a large number of potential confounders to adjust for. Direct adjustment may also be used if the relationship between the time‐to‐event and all confounders can be modeled. However, either approach requires a correctly specified model for the relationship between confounders and treatment allocation or between confounders and the time‐to‐event. We propose a pseudo‐observation–based doubly robust estimator, which is valid when either the treatment allocation model or the time‐to‐event model is correctly specified and is generally more efficient than the inverse probability weighting approach. The approach can be easily implemented using standard software. A simulation study was conducted to evaluate this approach under a number of scenarios, and the results are presented and discussed. The results confirm robustness and efficiency of the proposed approach. A real data example is also provided for illustration.     

Transforming the exponential by minimizing the sum of the absolute differences

This work presents an optimal value to be used in the power transformation to transform the exponential to normality for statistical process control (SPC) applications. The optimal value is found by minimizing the sum of absolute differences between two distinct cumulative probability functions. Based on this criterion, a numerical search yields a proposed value of 3.5142, so the transformed distribution is well approximated by the normal distribution. Two examples are presented to demonstrate the effectiveness of using the transformation method and its applications in SPC. The transformed data are almost normally distributed and the performance of the individual charts is satisfactory. Compared to charts that use the original exponential data and probability control limits, the individual charts constructed using the transformed distribution are superior in appearance, ease of interpretation and implementation by practitioners.     

Runs rules schemes for monitoring process variability

To increase the sensitivity of Shewhart control charts in detecting small process shifts sensitizing rules based on runs and scans are often used in practice. Shewhart control charts supplemented with runs rules for detecting shifts in process variance have not received as much attention as their counterparts for detecting shifts in process mean. In this article, we examine the performance of simple runs rules schemes for monitoring increases and/or decreases in process variance based on the sample standard deviation. We introduce one-sided S charts that overcome the weakness of high false-alarm rates when runs rules are added to a Shewhart control chart. The average run length performance and design aspects of the charts are studied thoroughly. The performance of associated two-sided control schemes is investigated as well.     

Multivariate CUSUM and EWMA Control Charts for Skewed Populations Using Weighted Standard Deviations

This article proposes a heuristic method of constructing multivariate cumulative sum and exponentially weighted moving average control charts for skewed populations based on the weighted standard deviation method which adjusts the variance–covariance matrix of quality characteristics and approximates the probability density function using several multivariate normal distributions. These control charts, however, reduce to the conventional control charts when the underlying distribution is symmetric. In-control and out-of-control average run lengths of the proposed control charts are compared with those of the conventional control charts for multivariate lognormal and Weibull distributions. Simulation results show that considerable improvements over the standard method can be achieved when the underlying distribution is skewed.     

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.     

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.     

On control charts for monitoring the variance of a time series

In this paper we derive control charts for the variance of a Gaussian process using the likelihood ratio approach, the generalized likelihood ratio approach, the sequential probability ratio method and a generalized sequential probability ratio procedure, the Shiryaev–Roberts procedure and a generalized modified Shiryaev–Roberts approach. Recursive presentations for the calculation of the control statistics are given for autoregressive processes of order 1. In an extensive simulation study these schemes are compared with existing control charts for the variance. In order to asses the performance of the schemes both the average run length and the average delay are used.     

A Comparison of the Performance of Phase II Simple Linear Profile Control Charts when Parameters are Estimated

The standard deviation of the average run length (SDARL) is an important performance metric in studying the performance of control charts with estimated in-control parameters. Only a few studies in the literature, however, have considered this measure when evaluating control chart performance. The current study aims at comparing the in-control performance of three phase II simple linear profile monitoring approaches; namely, those of Kang and Albin (2000), Kim et al. (2003), and Mahmoud et al. (2010). The comparison is performed under the assumption of estimated parameters using the SDARL metric. In general, the simulation results of the current study show that the method of Kim et al. (2003) has better overall statistical performance than the competing methods in terms of SDARL values. Some of the recommended approaches based solely on the usual average run length properties can have poor SDARL performance.     

Addressing the effect of parameter estimation on phase II monitoring of multivariate multiple linear profiles via a new cluster-based approach

Abstract

Profile monitoring is applied when the quality of a product or a process can be determined by the relationship between a response variable and one or more independent variables. In most Phase II monitoring approaches, it is assumed that the process parameters are known. However, it is obvious that this assumption is not valid in many real-world applications. In fact, the process parameters should be estimated based on the in-control Phase I samples. In this study, the effect of parameter estimation on the performance of four Phase II control charts for monitoring multivariate multiple linear profiles is evaluated. In addition, since the accuracy of the parameter estimation has a significant impact on the performance of Phase II control charts, a new cluster-based approach is developed to address this effect. Moreover, we evaluate and compare the performance of the proposed approach with a previous approach in terms of two metrics, average of average run length and its standard deviation, which are used for considering practitioner-to-practitioner variability. In this approach, it is not necessary to know the distribution of the chart statistic. Therefore, in addition to ease of use, the proposed approach can be applied to other type of profiles. The superior performance of the proposed method compared to the competing one is shown in terms of all metrics. Based on the results obtained, our method yields less bias with small-variance Phase I estimates compared to the competing approach.     

Using the predictive distribution to determine control limits for the Bayesian MEWMA chart

Bayesian control charts have been proposed for monitoring multivariate processes with the multivariate exponentially weighted moving average (MEWMA) statistic. It has been suggested that we use limits based on the predictive distribution of the MEWMA statistic. This analysis, however is based on the erroneous result that the average run length (ARL) is a function of the exceedance probability, that is, the probability that the first point exceeds the control limit. We show how this result can be corrected and we discuss how the Bayesian MEWMA chart with limits based on the predictive distribution compares with other multivariate control chart procedures.     

Integration of support vector machines and control charts for multivariate process monitoring

Statistical process control tools have been used routinely to improve process capabilities through reliable on-line monitoring and diagnostic processes. In the present paper, we propose a novel multivariate control chart that integrates a support vector machine (SVM) algorithm, a bootstrap method, and a control chart technique to improve multivariate process monitoring. The proposed chart uses as the monitoring statistic the predicted probability of class (PoC) values from an SVM algorithm. The control limits of SVM-PoC charts are obtained by a bootstrap approach. A simulation study was conducted to evaluate the performance of the proposed SVM–PoC chart and to compare it with other data mining-based control charts and Hotelling's T ² control charts under various scenarios. The results showed that the proposed SVM–PoC charts outperformed other multivariate control charts in nonnormal situations. Further, we developed an exponential weighed moving average version of the SVM–PoC charts for increasing sensitivity to small shifts.     

A non parametric approach to monitor simple linear profiles in phases I and II

In this paper, a non parametric approach is first proposed to monitor simple linear profiles with non normal error terms in Phase I and Phase II. In this approach, two control charts based on a transformation technique and decision on beliefs are designed in order to monitor the intercept and the slope, simultaneously. Then, some simulation experiments are performed in order to evaluate the performance of the proposed control charts in Phase II under both step and drift shifts in terms of out-of-control average run length (ARL₁). Besides, the performance of the proposed control charts is compared to the ones of seven other existing schemes in the literature. Simulation results show that the proposed control charts outperform the other control charts in detecting both the small step and small drift shifts of intercept. However, they have a weaker performance compared to other control charts in detecting both small step and small drift shifts of the slope. At the end, a real example from an electronic industry is used to illustrate the implementation of the proposed method.     

Construction of Fuzzy Control Charts Based on Weighted Possibilistic Mean

The problem of constructing control charts for fuzzy data has been considered in literature. The proposed transformation approaches and direct fuzzy approaches have their advantages and disadvantages. The representative values charts based on transformation methods are often recommended in practical application. For representing a fuzzy set by a crisp value, the weight of importance of the members assigned with some membership levels in a fuzzy set should be considered, and the possibility theory can be employed to deal with such problem. In this article, we propose to employ the weighted possibilistic mean (WPM), weighted interval valued possibilistic mean (WIVPM) of fuzzy number as a sort of representative values for the fuzzy attribute data, and establish new fuzzy control charts with WPM and WIVPM. The performance of the charts is compared to the existing fuzzy charts with a fuzzy c-chart example via newly defined average number of inspection for variation of control state.