On Statistical Design of the Cumulative Quantity Control Chart for Monitoring High Yield Processes

When dealing with high-yield processes, the cumulative quantity control chart (CQC chart) has been shown to be more suitable than the traditional c chart and u chart. However, the CQC chart shows an ARL-biased performance. In this article, we propose a design procedure to derive modified control limits for the CQC chart and the CQC chart with runs rules that can produce ARL-unbiased performance and maintain the predetermined false alarm rate. After extensive numerical work we have found that the proposed ARL-unbiased CQC chart is more sensitive than the conventional CQC chart in detecting process deteriorations.     

A Study on EWMA charts with runs rules—the Markov chain approach

ABSTRACT

Runs rules are usually used with Shewhart-type charts to enhance the charts' sensitivities toward small and moderate shifts. Abbas et al. in 2011 took it a step further by proposing two runs rules schemes, applied to the exponentially weighted moving average (EWMA) chart and evaluated their average run length (ARL) performances using simulation. They showed that the proposed schemes are superior to the classical EWMA chart and other schemes being investigated. Besides pointing out some erroneous ARL and standard deviation of the run length (SDRL) computations in Abbas et al., this paper presents a Markov chain approach for computing the ARL, percentiles of the run length (RL) distribution and SDRL, for the two runs rules schemes of Abbas et al. Using Markov chain, we also propose two combined runs rules EWMA schemes to quicken the two schemes of Abbas et al. in responding to large shifts. The runs rules (basic and combined rules) EWMA schemes will be compared with some existing control charting methods, where the former charts are shown to prevail.     

ARL-Design of S Charts with k-of-k Runs Rules

The standard S chart signals an out-of-control condition when one point exceeds a control limit. It can be augmented with runs rules to improve its performance in detecting assignable causes. A commonly used rule signals when k consecutive points exceed a control limit. This rule can be used alone or to supplement the standard chart. In this article we derive ARL expressions for charts with the k-of-k runs rule. We show how to design S charts with this runs rule, compare their ARL performance, and make a control chart recommendation when it is important to monitor for both increases and decreases in process dispersion.     

CUSUM Chart with Transformed Exponential Data

Time Between Events (TBE) charts were proposed to monitor the time between events occur based on exponential distribution, and have been shown to be more effective than monitoring the fraction non conforming directly. In this article, we consider monitoring the TBE data with CUSUM scheme by transformation. The idea behind it is to transform the TBE data to normal, and then apply the CUSUM scheme for the approximate normal data. Several simple transformation methods are examined. The calculation of Average Run Length (ARL) with Markov chain approach is described. Comparative studies on the ARL performance show that the transformed CUSUM is superior to the X-MR (Moving Range) chart with transformation, the Cumulative Quantity Control (CQC) chart, and have comparable performance with exponential CUSUM charts. The design procedures of optimal CUSUM chart are also presented. This study provides another possible alternative for monitoring TBE data with easy design procedures and relatively good performance.     

Transition probabilities and ARL performance of Six Sigma zone control charts

In this article, Six Sigma zone control charts (SSZCCs) are proposed for world class organizations. The transition probabilities are obtained using the Markov chain approach. The Average Run Length (ARL) values are then presented. The ARL performance of the proposed SSZCCs and the standard Six Sigma control chart (SSCC) without zones or run rules is studied. The ARL performance of these charts is then compared with those of the other standard zone control charts (ZCCs), the modified ZCC and the traditional Shewhart control chart (SCC) with common run rules. As expected, it is shown that the proposed SSZCC outperforms the standard SSCC without zones or run rules for process shifts of any magnitude. When compared to the other standard ZCCs and the Shewhart chart with common run rules, it is observed that the proposed SSZCCs have much higher false alarm rates for smaller shifts and hence they prevent unwanted process disturbances. The application of the proposed SSZCC is illustrated using a real time example.     

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.     

The Run Sum R Chart with Fast Initial Response

A fast initial response (FIR) feature for the run sum R chart is proposed and its ARL performance estimated by a Markov chain representation. It is shown that this chart is more sensitive than several R charts with runs rules proposed by different authors. We conclude that the run sum R chart is simple to use and a very effective tool for monitoring increases and decreases in process dispersion.     

Optimal design of the adaptive exponentially weighted moving average control chart over a range of mean shifts

The adaptive exponentially weighted moving average (AEWMA) control chart is a smooth combination of the Shewhart and exponentially weighted moving average (EWMA) control charts. This chart was proposed by Cappizzi and Masarotto (2003) to achieve a reasonable performance for both small and large shifts. Cappizzi and Masarotto (2003) used a pair of shifts in designing their control chart. In this study, however, the process mean shift is considered as a random variable with a certain probability distribution and the AEWMA control chart is optimized for a wide range of mean shifts according to that probability distribution and not just for a pair of shifts. Using the Markov chain technique, the results show that the new optimization design can improve the performance of the AEWMA control chart from an overall point of view relative to the various designs presented by Cappizzi and Masarotto (2003). Optimal design parameters that achieve the desired in-control average run length (ARL) are computed in several cases and formulas used to find approximately their values are given. Using these formulas, the practitioner can compute the optimal design parameters corresponding to any desired in-control ARL without the need to apply the optimization procedure. The results obtained by these formulas are very promising and would particularly facilitate the design of the AEWMA control chart for any in-control ARL value.     

Variable Sampling Interval Cumulative Count of Conforming Chart with Runs Rules

The cumulative count of conforming (CCC) chart is effective in detecting very low fraction of nonconforming items for high yield manufacturing processes. In this study, a combination of runs rules and variable sampling interval feature is proposed to a lower sided CCC chart by inspecting the items one by one. The performance measures of the control chart are derived by using the Markov chain approach. The numerical comparisons show that the performance of the CCC chart can be improved by adding the runs rules and varying the sampling interval.     

CUSUM chart for detecting range shifts when monotonicity of likelihood ratio is invalid

It is often encountered in the literature that the log-likelihood ratios (LLR) of some distributions (e.g. the student t distribution) are not monotonic. Existing charts for monitoring such processes may suffer from the fact that the average run length (ARL) curve is a discontinuous function of control limit. It implies that some pre-specified in-control (IC) ARLs of these charts may not be reached. To guarantee the false alarm rate of a control chart lower than the nominal level, a larger IC ARL is usually suggested in the literature. However, the large IC ARL may weaken the performance of a control chart when the process is out-of-control (OC), compared with a just right IC ARL. To overcome it, we adjust the LLR to be a monotonic one in this paper. Based on it, a multiple CUSUM chart is developed to detect range shifts in IC distribution. Theoretical result in this paper ensures the continuity of its ARL curve. Numerical results show our proposed chart performs well under the range shifts, especially under the large shifts. In the end, a real data example is utilized to illustrate our proposed chart.     

Improving the performance of the zone control chart

A general model for the zone control chart is presented. Using this model, it is shown that there are score vectors for zone control charts which result in superior average run length performance in comparison to Shewhart charts with common runs rules.

A fast initial response (FIR) feature for the zone control chart is also proposed. Average run lengths of the zone control chart with this feature are calculated. It is shown that the FIR feature improves zone control chart performance by providing significantly earlier signals when the process is out of control.     

Moving range EWMA control charts for monitoring the Weibull shape parameter

In this article, we propose an exponentially weighted moving average (EWMA) control chart for the shape parameter β of Weibull processes. The chart is based on a moving range when a single measurement is taken per sampling period. We consider both one-sided (lower-sided and upper-sided) and two-sided control charts. We perform simulations to estimate control limits that achieve a specified average run length (ARL) when the process is in control. The control limits we derive are ARL unbiased in that they result in ARL that is shorter than the stable-process ARL when β has shifted. We also perform simulations to determine Phase I sample size requirements if control limits are based on an estimate of β. We compare the ARL performance of the proposed chart to that of the moving range chart proposed in the literature.     

A control chart for variance based on squared ranks

A nonparametric control chart for variance is proposed. The chart is constructed following the change-point approach through the recursive use of the squared ranks test for variance. It is capable of detecting changes in the behaviour of individual observations with performance similar to a self-starting CUSUM chart for scale when normality is assumed, and a relatively better power when assessing nonnormal observations. A comparison is also made with two equivalent nonparametric charts based on Mood and Ansari-Bradley statistics. When dealing with symmetrical distributions, the proposed chart shows smaller (better) out-of-control average run length (ARL), and a competing performance otherwise. In addition, sensitivity to changes in mean and variance at the same time was tested. Extensive Monte Carlo simulation was used to measure performance, and a practical example is provided to illustrate how the proposed control chart can be implemented in practice.     

A control chart using an auxiliary variable and repetitive sampling for monitoring process mean

In this paper, a new control chart is proposed by using an auxiliary variable and repetitive sampling in order to enhance the performance of detecting a shift in process mean. The product-difference type estimator of the mean is plotted on the proposed control chart, which utilizes the information of an auxiliary variable correlated with the main quality variable. The proposed control chart is based on the outer and inner control limits so that repetitive sampling is allowed when the plotted statistic falls between the two limits. The average run length (ARL) of the proposed control chart is evaluated using the Monte Carlo simulation. The proposed control chart is compared with the Riaz M control chart and the results show the outperformance of the proposed control chart in terms of the ARL.     

基于加权似然比检验的监控线性曲线的控制图

文章提出了一种基于加权似然比检验的阶段二监控线性曲线的控制图,称为WLRT图,并通过平均运行长度来衡量控制图的性能表现。模拟结果表明,WLRT图对于线性曲线的截距、斜率、标准差的变化及截距和斜率同时变化都具有很好的检测能力。通过与其他几种控制图的性能比较,得出WLRT图能较快地发现过程变化,而且设计简单、操作方便。     

A new approach for monitoring process variance

ABSTRACT

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 non-normal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, should not be properly used in such circumstances. In this paper, we propose a new variance chart based on a simple statistic to monitor process variance shifts. We explore the sampling properties of the new monitoring statistic and calculate the average run lengths (ARLs) of the proposed variance chart. Furthermore, an arcsine transformed exponentially weighted moving average (EWMA) chart is proposed because the ARLs of this modified chart are more intuitive and reasonable than those of the variance chart. We compare the out-of-control variance detection performance of the proposed variance chart with that of the non-parametric Mood variance (NP-M) chart with runs rules, developed by Zombade and Ghute [Nonparametric control chart for variability using runs rules. Experiment. 2014;24(4):1683–1691], and the nonparametric likelihood ratio-based distribution-free exponential weighted moving average (NLE) chart and the combination of traditional exponential weighted moving average (EWMA) mean and EWMA variance (CEW) control chart proposed by Zou and Tsung [Likelihood ratio-based distribution-free EWMA control charts. J Qual Technol. 2010;42(2):174–196] by considering cases in which the critical quality characteristic has a normal, a double exponential or a uniform distribution. Comparison results showed that the proposed chart performs better than the NP-M with runs rules, and the NLE and CEW control charts. A numerical example of service times with a right-skewed distribution from a service system of a bank branch in Taiwan is used to illustrate the application of the proposed variance chart and of the arcsine transformed EWMA chart and to compare them with three existing variance (or standard deviation) charts. The proposed charts show better detection performance than those three existing variance charts in monitoring and detecting shifts in the process variance.     

An economic statistical design of the Poisson EWMA control charts for monitoring nonconformities

An economic statistical model of the exponentially weighted moving average (EWMA) control chart for the average number of nonconformities in the sample is proposed. The statistical and economic performance of proposed design are evaluated using the average run length (ARL) and the hourly expected cost, respectively. A Markov chain approach is applied to derive expressions for ARL. The cost model is established based on the general cost function given in Lorenzen and Vance [The economic design of control charts: a unified approach. Technometrics. 1986;28:3–11]. An example is provided to illustrate the application of the proposed model. A sensitivity analysis is also carried out to investigate the effects of model parameters on the solution of the economic statistical design by using the design of experiments (DOE) technique.     

CUSUM Control Charts for Multivariate Poisson Distribution

A cumulative sum control chart for multivariate Poisson distribution (MP-CUSUM) is proposed. The MP-CUSUM chart is constructed based on log-likelihood ratios with in-control parameters, Θ₀, and shifts to be detected quickly, Θ₁. The average run length (ARL) values are obtained using a Markov Chain-based method. Numerical experiments show that the MP-CUSUM chart is effective in detecting parameter shifts in terms of ARL. The MP-CUSUM chart with smaller Θ₁ is more sensitive than that with greater Θ₁ to smaller shifts, but more insensitive to greater shifts. A comparison shows that the proposed MP-CUSUM chart outperforms an existing MP chart.     

Likelihood ratio test-based chart for monitoring the process variability

This article proposes a new chart with the generalized likelihood ratio (GLR) test statistics for monitoring the process variance of a normally distributed process. The new chart can be easily designed and constructed and the computation results show that it provides quite a satisfactory performance, including the detection of the decrease in the variance and the individual observation at the sampling point which are very important in many practical applications. Average run length (ARL) comparisons between other procedures and the new chart are presented. The optimal parameters that can be used as a design aid in selecting specific parameter values based on the ARL are described. The application of our proposed method is illustrated by a real data example from chemical process control.     

The Generally Weighted Moving Average Variance Chart

This article extends the generally weighted moving average (GWMA) technique for detecting changes in process variance. The proposed chart is called the generally weighted moving average variance (GWMAV) chart. Simulation is employed to evaluate the average run length (ARL) characteristics of the GWMAV and EWMA control charts. An extensive comparison of these control charts reveals that the GWMAV chart is more sensitive than the EWMA control charts for detecting small shifts in the variance of a process when the shifts are below 1.35 standard deviations. Additionally, the GWMAV control chart performs little better when the variance shifts are between 1.35 and 1.5 standard deviation, and the 2 charts performs similar when the variance shifts are above 1.5 standard deviation. The design of the GWMAV chart is also discussed.