A new synthetic control chart for monitoring process mean using auxiliary information

ABSTRACT

Quality control charts have been widely recognized as a potentially powerful statistical process monitoring tool in statistical process control because of their superior ability in detecting shifts in the process parameters. Recently, auxiliary-information-based control charts have been proposed and shown to have excellent speed in detecting process shifts than those based without it. In this paper, we design a new synthetic control chart that is based on a statistic that utilizes information from both the study and auxiliary variables. The proposed synthetic chart encompasses the classical synthetic chart. The construction, optimal design, run length profiles, and the performance evaluation of the new chart are discussed in detail. It turns out that the proposed synthetic chart performs uniformly better than the classical synthetic chart when detecting different kinds of shifts in the process mean under both zero-state and steady-state run length performances. Moreover, with reasonable assumptions, the proposed chart also surpasses the exponentially weighted moving average control chart. An application with a simulated data set is also presented to explain the implementation of the proposed control chart.     

A combined control scheme for monitoring the frequency and size of an attribute event

A traffic accident can be considered as an example of the attribute events, and the number of the injured in each accident is called the event size. Some control charts have been developed for monitoring either the time interval (T) between the occurrences of an event or the event size (C) in each occurrence. This article studies the statistical monitoring of the attribute events in which T and C are monitored simultaneously and C is an integer. Essentially, it integrates a T chart and a C chart, and is therefore referred to as a T&C scheme. Our studies show that the new chart is more effective than an individual T chart or C chart for detecting the out-of-control status of the event, in particular for detecting downward shifts (sparse occurrence and/or small size). Another desirable feature of the T&C scheme is that its detection effectiveness is more invariable against different types of shifts (i.e. T shift, C shift and joint shift in T&C) compared with an individual T or C chart. The improvement in performance is achieved due to the simultaneous monitoring of T and C. The T&C scheme can be applied in manufacturing systems and especially in non-manufacturing sectors (e.g. supply chain management, health care industry, disaster management and security control).     

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.     

Monitoring simple linear profiles using variable sample size schemes

ABSTRACT

Profile monitoring is one of the new research areas in statistical process control. Most of the control charts in this area are designed with fixed sampling rate which makes the control chart slow in detecting small to moderate shifts. In order to improve the performance of the conventional fixed control charts, adaptive features are proposed in which, one or more design parameters vary during the process. In this paper the variable sample size feature of EWMA₃ and MEWMA schemes are proposed for monitoring simple linear profiles. The EWMA₃ method is based on the combination of three exponentially weighted moving average (EWMA) charts for monitoring three parameters of a simple linear profile separately and the Multivariate EWMA (MEWMA) chart is based on the using a single chart to monitor the coefficients and variance of a general linear profile. Also a two-sided control chart is proposed for monitoring the standard deviation in the EWMA₃ method. The performance of the proposed charts is compared in terms of the average time to signal. Numerical examples show that using adaptive features increase the power of control charts in detecting the parameter shifts. Finally, the performance of the proposed variable sample size schemes is illustrated through a real case in the leather industry.     

Control charts for fraction nonconforming in a bivariate binomial process

Many multivariate quality control techniques are used for multivariate variable processes, but few work for multivariate attribute processes. To monitor multivariate attributes, controlling the false alarms (type I errors) and considering the correlation between attributes are two important issues. By taking into account these two issues, a new control chart is presented to monitor a bivariate binomial process. An example is illustrated for the proposed method. To evaluate the performance of the proposed method, a simulation study is conducted to compare the results with those using both the multivariate np chart and skewness reduction approaches. The results show that the correlation is taken into account in the designed chart and the overall false alarm is controlled at the nominal value. Moreover, the process shift can be quickly detected and the variable that is responsible for a signal can be determined.     

Multi-attribute unit and group runs control chart to identify the process deterioration

Gadre and Rattihalli [Gadre, M.P. and Rattihalli, R.N., 2005a, A unit and group runs based chart to identify increases in fraction nonconforming. Journal of Quality Technology, 37, 199–209.] proposed a control chart called the unit and group runs (UGR) control chart to identify increases in fraction non-conforming. In this article, the concept of UGR chart is extended to the multi-attribute case to detect the process deterioration. It is illustrated that in multi-attribute cases also, the UGR chart gives a remarkable reduction in out-of-control average time to signal when compared with the multi-attribute np chart, the multi-attribute synthetic chart and the multi-attribute group runs chart recently developed by Gadre and Rattihalli [Gadre, M.P. and Rattihalli, R.N., 2005b, Some group inspection based multi-attribute control charts. Economic Quality Control, 20, 191–204.]. The steady state performance of the multi-attribute UGR chart is also excellent. The procedure of identifying the attributes causing signal is also described and illustrated.     

Economic-statistical design of synthetic double sampling T2 chart

Abstract

An economic-statistical design of the synthetic double sampling (synDS) T² chart is presented in this study. The cost function is minimized to obtain the optimal design parameters of the synDS T² chart by incorporating the statistical constraints or the constraints on the average number of samples. An example is provided and a sensitivity analysis is conducted to study the effect of model parameters on the optimal solution of the design. The numerical comparison shows that the synDS T² chart performs better than the synthetic T² chart and the multivariate exponentially weighted moving average chart, in terms of the cost.     

Combined synthetic and |S| chart for monitoring process dispersion

This article proposes a multivariate control chart, the syn-|S| chart, which comprises a standard |S| subchart and a multivariate synthetic sample generalized variance |S| (synthetic |S|) subchart, for detecting shifts in the covariance matrix of a multivariate normally distributed process. A procedure for the optimal design of the syn-|S| chart by minimizing the average extra quadratic loss is provided. The syn-|S| chart has better overall performance compared to the synthetic |S| chart and the standard |S| chart, based on the zero-state and steady-state modes. An example is given to illustrate the operation of the synthetic |S| chart.     

Optimal designs of multivariate synthetic |S| control chart based on median run length

The multivariate synthetic generalized sample variance |S| (synthetic |S|) chart is a combination of the |S| sub-chart and the conforming run length sub-chart. A procedure for optimal designs of the synthetic |S| chart, based on the median run length (MRL), for both zero and steady-state modes are provided by minimizing the out-of-control MRL. The comparative results show that the synthetic |S| chart performs better than the standard |S| chart for detecting shifts in the covariance matrix of a multivariate normally distributed process, in terms of the MRL. An example is given to illustrate the operation of the synthetic |S| chart.     

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.     

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.     

A comparison study of effectiveness and robustness of robust economic designs of T2 chart using genetic algorithm

ABSTRACT

Recently, researchers have tried to design the T² chart economically to achieve the minimum possible quality cost; however, when T² chart is designed, it is important to consider multiple scenarios. This research presents the robust economic designs of the T² chart where there is more than one scenario. An illustrative example is used to demonstrate the effect of the model parameters on the optimal designs. The genetic algorithm optimization method is employed to obtain the optimal designs. Simulation studies show that the robust economic designs of T² chart are more effective than traditional economic design in practice.     

A binomial CUSUM chart for detecting large shifts in fraction nonconforming

This article studies a unique feature of the binomial CUSUM chart in which the difference (d _t ?d ₀) is replaced by (d _t ?d ₀)² in the formulation of the cumulative sum C _t (where d _t and d ₀ are the actual and in-control numbers of nonconforming units, respectively, in a sample). Performance studies are reported and the results reveal that this new feature is able to increase the detection effectiveness when fraction nonconforming p becomes three to four times as large as the in-control value p ₀. The design of the new binomial CUSUM chart is presented along with the calculation of the in-control and out-of-control Average Run Lengths (ARL₀ and ARL₁).     

Profile Monitoring Using Nonparametric Bootstrap T 2 Control Chart

In certain statistical process control applications, performance of a product or process can be monitored effectively using a linear profile or a linear relationship between a response variable and one or more explanatory variables. In this article, we design a nonparametric bootstrap control chart for monitoring simple linear profiles based on T ² statistic. We evaluate the performance of the proposed method in phase II. The average and standard deviation of the run length under different shifts in the intercept, slope, and standard deviation are considered as the performance measures. Simulation results show that the performance of the proposed bootstrap control chart improves as the size of the available data increases.     

Robustness of the EWMA and the combined X¯–EWMA control charts with variable sampling intervals to non-normality

The exponentially weighted moving average (EWMA) control charts with variable sampling intervals (VSIs) have been shown to be substantially quicker than the fixed sampling intervals (FSI) EWMA control charts in detecting process mean shifts. The usual assumption for designing a control chart is that the data or measurements are normally distributed. However, this assumption may not be true for some processes. In the present paper, the performances of the EWMA and combined X¯–EWMA control charts with VSIs are evaluated under non-normality. It is shown that adding the VSI feature to the EWMA control charts results in very substantial decreases in the expected time to detect shifts in process mean under both normality and non-normality. However, the combined X¯–EWMA chart has its false alarm rate and its detection ability is affected if the process data are not normally distributed.     

Economic design of non parametric sign control chart

An economic design of sign chart to control the median is proposed. Since the sign chart is distribution free, it can easily be applied to any process without prior knowledge of process quality distribution. The effect on loss cost observed for different shifts in location shows that the sign chart performs better for large shifts. The economic statistical performance study reveals that statistical performance of sign chart can be improved sufficiently for moderate shifts in the process. Sensitivity study shows that design is more sensitive for change in values of penalty loss cost and time required for search and repair of an assignable cause.     

A Multivariate Synthetic Control Chart for Monitoring Process Mean Vector

In this article, a multivariate synthetic control chart is developed for monitoring the mean vector of a normally distributed process. The proposed chart is a combination of the Hotelling's T ² chart and Conforming Run Length chart. The operation, design, and performance of the chart are described. Average run length comparisons between some other existing control charts and the synthetic T ² chart are presented. They indicate that the synthetic T ² chart outperforms Hotelling's T ² chart and T ² chart with supplementary runs rules.     

Sensitivity Analyses of the Economic and Economic Statistical Designs of the Multivariate Synthetic T2 Chart

This article performs a sensitivity analyses of the synthetic T² chart using fractional factorial design, which integrates the interaction effects. We are interested in the effects of the input parameters on the optimal cost, chart's parameters, and average run lengths. We also look at the input parameters responsible for the increase in cost and improvement in statistical performance under statistical constraints, and investigate how the input parameters influence the binding effect of the statistical constraints. The sensitivity analyses of the synthetic T² chart are compared with that of the Hotelling's T² chart, and parameters responsible for the cost advantage of the synthetic T² chart are identified.     

The Synthetic Mean Square Error Control Chart

A synthetic mean square error (MSE) control chart is presented in this study for monitoring the changes in the mean and standard deviation of a normally distributed process. The synthetic MSE control chart is a combination of the standard MSE control chart and the conforming run length (CRL) control chart. From the numerical comparisons, the synthetic MSE control chart is always more efficient than the standard MSE control chart in detecting shifts in the process mean and standard deviation. The synthetic MSE chart also performs better than the exponentially weighted moving average-semicircle (EWMA-SC) chart, except for some cases where the process mean shifts are small.     

Skewness Reduction Approach in Multi-Attribute Process Monitoring

Since the product quality of many industrial processes depends upon more than one dependent variable or attribute, they are either multivariate or multi-attribute in nature. Although multivariate statistical process control is receiving increased attention in the literature, little work has been done to deal with multi-attribute processes. In this article, we develop a new methodology to monitor multi-attribute processes. To do this, first we transform multi-attribute data in a way that their marginal probability distributions have almost zero skewness. Then, we estimate the transformed covariance matrix and apply the well-known T ² control chart. In order to illustrate the proposed method and evaluate its performance, we use two simulation experiments and compare the results with the ones from both MNP chart and the χ² control chart.