The economic design of multivariate binomial EWMA VSSI control charts

Since multi-attribute control charts have received little attention compared with multivariate variable control charts, this research is concerned with developing a new methodology to employ the multivariate exponentially weighted moving average (MEWMA) charts for m-attribute binomial processes; the attributes being the number of nonconforming items. Moreover, since the variable sample size and sampling interval (VSSI) MEWMA charts detect small process mean shifts faster than the traditional MEWMA, an economic design of the VSSI MEWMA chart is proposed to obtain the optimum design parameters of the chart. The sample size, the sampling interval, and the warning/action limit coefficients are obtained using a genetic algorithm such that the expected total cost per hour is minimized. At the end, a sensitivity analysis has been carried out to investigate the effects of the cost and the model parameters on the solution of the economic design of the VSSI MEWMA chart.     

Optimal Statistical Design of a Multivariate EWMA Chart Based on ARL and MRL

Statistical design is applied to a multivariate exponentially weighted moving average (MEWMA) control chart. The chart parameters are control limit H and smoothing constant r. The choices of the parameters depend on the number of variables p and the size of the process mean shift δ. The MEWMA statistic is modeled as a Markov chain and the Markov chain approach is used to determine the properties of the chart. Although average run length has become a traditional measure of the performance of control schemes, some authors have suggested other measures, such as median and other percentiles of the run length distribution to explain run length properties of a control scheme. This will allow a thorough study of the performance of the control scheme. Consequently, conclusions based on these measures would provide a better and comprehensive understanding of a scheme. In this article, we present the performance of the MEWMA control chart as measured by the average run length and median run length. Graphs are given so that the chart parameters of an optimal MEWMA chart can be determined easily.     

Multivariate EWMA Control Chart with Adaptive Sample Sizes

Standard multivariate control charts usually employ fixed sample sizes at equal sampling intervals to monitor a process. In this study, a multivariate exponential weighted moving average (MEWMA) chart with adaptive sample sizes is investigated. Performance measure of the adaptive-sample-size MEWMA chart is obtained through a Markov chain approach. The performance of the adaptive-sample-size MEWMA chart is compared with the fixed-sample-size control chart in terms of steady-state average run length for different magnitude of shifts in the process mean. It is shown that the adaptive-sample-size chart is more efficient than the fixed-sample-size MEWMA control chart in detecting shifts in the process mean.     

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.     

The effect of autocorrelation on the ewma maxmin tolerance limits

Amin et al. (1999) developed an exponentially weighted moving average (EWMA) control chart, based on the smallest and largest observations in each sample. The resulting plot of the extremes suggests that the MaxMin EWMA may also be viewed as smoothed tolerance limits. Tolerance limits are limits that include a specific proportion of the population at a given confidence level. In the context of process control, they are used to make sure that production will not be outside specifications. Amin and Li (2000) provided the coverages of the MaxMin EWMA tolerance limits for independent data. In this article, it is shown how autocorrelation affects the confidence level of MaxMin tolerance limits, for a specified level of coverage of the population, and modified smoothed tolerance limits are suggested for autocorrelated processes.     

A modified economic-statistical design of the T2 control chart with variable sample sizes and control limits

Recent studies have shown that using variable sampling size and control limits (VSSC) schemes result in charts with more statistical power than variable sampling size (VSS) when detecting small to moderate shifts in the process mean vector. This paper presents an economic-statistical design (ESD) of the VSSC T² control chart using the general model of Lorenzen and Vance [22]. The genetic algorithm approach is then employed to search for the optimal values of the six test parameters of the chart. We then compare the expected cost per unit of time of the optimally designed VSSC chart with optimally designed VSS and FRS (fixed ratio sampling) T² charts as well as MEWMA charts.     

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.     

Optimization of design parameters for control charts with multiple assignable causes

Duncan's economic model of Shewhart's original x¯ chart has established its optimal and economic application for processes with the Markovian failure characteristic. As the sample statistics show some indications of process variations, the variable-sampling-interval (VSI) control charts perform more effectively than the fixed sampling interval (FSI) ones due to a higher frequency in the sampling rate. Regarding the economic design of control charts, most studies have been dedicated to the FSI scheme. In 1998, Bai & Lee considered the production process with a single assignable cause and proposed an economic VSI design for a general x¯ control chart. However, in real cases, there are multiple assignable causes in the production process. Therefore, concerning the operation characteristics of the real industry, this research develops an economic model for the VSI control chart with multiple assignable causes based on stochastic and statistics theory and determines the optimal design parameters of the chart. A numerical example is also provided to demonstrate the effectiveness of the proposed model and the result indicates that VSI performs more effectively than a FSI control chart.     

Economic design based on a multivariate Bayesian VSI chart with a dual control limit

In this paper, a multivariate Bayesian variable sampling interval (VSI) control chart for the economic design and optimization of statistical parameters is designed. Based on the VSI sampling strategy of a multivariate Bayesian control chart with dual control limits, the optimal expected cost function is constructed. The proposed model allows the determination of the scheme parameters that minimize the expected cost per time of the process. The effectiveness of the Bayesian VSI chart is estimated through economic comparisons with the Bayesian fixed sampling interval and the Hotelling's T² chart. This study is an in-depth study on a Bayesian multivariate control chart with variable parameter. Furthermore, it is shown that significant cost improvement may be realized through the new model.     

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.     

Accounting for phase I sampling variability in the performance of the MEWMA control chart with estimated parameters

In this article, we assess the performance of the multivariate exponentially weighted moving average (MEWMA) control chart with estimated parameters while considering the practitioner-to-practitioner variability. We evaluate the chart performance in terms of the in-control average run length (ARL) distributional properties; mainly the average (AARL), the standard deviation (SDARL), and some percentiles. We show through simulations that using estimates in place of the in-control parameters may result in an in-control ARL distribution that almost completely lies below the desired value. We also show that even with the use of larger amounts of historical data, there is still a problem with the excessive false alarm rates. We recommend the use of a recently proposed bootstrap-based design technique for adjusting the control limits. The technique is quite effective in controlling the percentage of short in-control ARLs resulting from the estimation error.     

The Design of the Multivariate Synthetic Exponentially Weighted Moving Average Control Chart

A multivariate synthetic exponentially weighted moving average (MSEWMA) control chart is presented in this study. The MSEWMA control chart consists of a multivariate exponentially weighted moving average (MEWMA) control chart and a conforming run length control chart. The average run length of the MSEWMA control chart is obtained using a Markov chain approach. From the numerical comparisons, it is shown that the MSEWMA control chart is more efficient than the multivariate synthetic T ² control chart and the MEWMA control chart for detecting shifts in the process mean vector.     

On-line monitoring data quality of high-dimensional data streams

ABSTRACT

In recent years, effective monitoring of data quality has increasingly attracted attention of researchers in the area of statistical process control. Among the relevant research on this topic, none used multivariate methods to control the multidimensional data quality process, but instead relied on multiple univariate control charts. Based on a novel one-sided multivariate exponentially weighted moving average (MEWMA) chart, we propose a conditional false discovery rate-adjusted scheme to on-line monitor the data quality of high-dimensional data streams. With thousands of input data streams, the average run length loses its usefulness because one will likely have out-of-control signals at each time period. Hence, we first control the percentage of signals that are false alarms. Then, we compare the power of the proposed MEWMA scheme with that of two alternative methods. Compared with two competitors, numerical results show that the proposed MEWMA scheme has higher average power.     

A gradient approach to efficient design and analysis of multivariate EWMA control charts

Compared to the grid search approach to optimal design of control charts, the gradient-based approach is more computationally efficient as the gradient information indicates the direction to search the optimal design parameters. However, the optimal parameters of multivariate exponentially weighted moving average (MEWMA) control charts are often obtained by using grid search in the existing literature. Note that the average run length (ARL) performance of the MEWMA chart can be calculated based on a Markov chain model, making it feasible to estimate the ARL gradient from it. Motivated by this, this paper develops an ARL gradient-based approach for the optimal design and sensitivity analysis of MEWMA control charts. It is shown that the proposed method is able to provide a fast, accurate, and easy-to-implement algorithm for the design and analysis of MEWMA charts, as compared to the conventional design approach based on grid search.     

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 new economic scheme for CCC charts with run rules based on average number of inspected items

New statistical techniques and procedures have been developed to control high-yield processes along with looking for process improvement opportunities and minimizing production cost. Cumulative count of conforming control chart is generally a technique for high-quality processes, when nonconforming items are rarely produced. The objective of this study is to design control chart based on cumulative count of conforming items and run rules that develops an economic model based on the average number of inspected items to design m-of-m CCC chart in order to facilitate minimum average cost per item produced. The optimal design parameters for different values of nonconforming fraction and different cost parameters in each scenario are determined. Finally, to analyze the behavior of optimal economic solutions, sensitivity analysis of the model parameters is performed.     

A Multivariate Adaptive Exponentially Weighted Moving Average Control Chart

A multivariate extension of the adaptive exponentially weighted moving average (AEWMA) control chart is proposed. The new multivariate scheme can detect small and large shifts in the process mean vector effectively. The proposed scheme can be viewed as a smooth combination of a multivariate exponentially weighted moving average (MEWMA) chart and a Shewhart χ²-chart. The optimal design of the proposed chart is given according to a pre-specified in-control average run length and two shift sizes; a small and large shift each measured in terms of the non centrality parameter. The signal resistance of the newly proposed multivariate chart is also given. Comparisons among the new chart, the MEWMA chart, and the combined Shewhart-MEWMA (S-MEWMA) chart in terms of the standard and worst-case average run length profiles are presented. In addition, the three charts are compared with respect to their worst-case signal resistance values. The proposed chart gives somewhat better worst-case ARL and signal resistance values than the competing charts. It also gives better standard ARL performance especially for moderate and large shifts. The effectiveness of our proposed chart is illustrated through an example with simulated data set.     

Economic design of VSI X̄ control chart with correlated non-normal data under multiple assignable causes

It has been recently revealed that the Shewhart control charts with variable sampling interval (VSI) perform better than the traditional Shewhart chart with the fixed sampling interval in detecting shifts in the process. In most of these research works, the normality and independency of the process data or measurements are assumed and that the process is subjected to only one assignable cause. While, in practice, these assumptions usually do not hold, some recent studies are focused on working with only one or two of these violations. In this paper, the situation in which the process data are correlated and follow a non-normal distribution and that there is multiplicity of assignable causes in the process is considered. For this case, a cost model for the economic design of the VSI X? control chart is developed, where the Burr distribution is employed to represent the non-normal distribution of the process data. To obtain the optimal values of the design parameters, a genetic algorithm is employed in which the response surface methodology is applied. A numerical example is presented to show the applicability and effectiveness of the proposed methodology. Sensitivity analysis is also carried out to evaluate the effects of cost and input parameters on the performance of the chart.     

Economic design of &Xmacron; charts with variable parameters: the Markov chain approach

This paper presents an economic design of &Xmacron; control charts with variable sample sizes, variable sampling intervals, and variable control limits. The sample size n, the sampling interval h, and the control limit coefficient k vary between minimum and maximum values, tightening or relaxing the control. The control is relaxed when an &Xmacron; value falls close to the target and is tightened when an &Xmacron; value falls far from the target. A cost model is constructed that involves the cost of false alarms, the cost of finding and eliminating the assignable cause, the cost associated with production in an out-of-control state, and the cost of sampling and testing. The assumption of an exponential distribution to describe the length of time the process remains in control allows the application of the Markov chain approach for developing the cost function. A comprehensive study is performed to examine the economic advantages of varying the &Xmacron; chart parameters.