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.     

The effect of serial correlation on the in-control average run length of cumulative score charts

The cumulative sum (CUSUM) technique is well-established in theory and practice of process control. For a variant of the CUSUM technique, the cumulative score chart, we investigate the effect of serial correlation on the in-control average run length (ARL). The Shewhart chart is a special case of the cumulative score chart. Using the fact that the cumulative score statistic is a correlated random walk with a reflecting and an absorbing barrier, we derive an approximate but closed-form expression for the ARL of a control variable that follows a first-order autoregressive process with normally distributed disturbances. We also give an expression for the asymptotic (large in-control ARL) case. Our method of approximation gives ARL values that are in good agreement with Monte Carlo estimates of the true values. For positive serial correlation the ARL decreases with increasing value of the correlation coefficient. For increasing negative serial correlation, the ARL may decrease or increase depending on the choice of the parameters of the chart; parameterizations can be found which are rather insensitive for negative serial correlation. We use our results to give recommendations on how to modify the control chart procedure in the presence of serial correlation.     

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.     

A control chart for monitoring process variation using multiple dependent state sampling

A control chart for monitoring process variation by using multiple dependent state (MDS) sampling is constructed in the present article. The operational formulas for in-control and out-of-control average run lengths (ARLs) are derived. Control constants are established by considering the target in-control ARL at a normal process. The extensive ARL tables are reported for various parameters and shifted values of process parameters. The performance of the proposed control chart has been evaluated with several existing charts in regard of ARLs, which empowered the presented chart and proved far better for timely detection of assignable causes. The application of the proposed concept is illustrated with a real-life industrial example and a simulation-based study to elaborate strength of the proposed chart over the existing concepts.     

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.     

A Robust Control Chart for Monitoring the Mean of an Autocorrelated Process

Residual control charts are frequently used for monitoring autocorrelated processes. In the design of a residual control chart, values of the true process parameters are often estimated from a reference sample of in-control observations by using least squares (LS) estimators. We propose a robust control chart for autocorrelated data by using Modified Maximum Likelihood (MML) estimators in constructing a residual control chart. Average run length (ARL) is simulated for the proposed chart when the underlying process is AR(1). The results show the superiority of the new chart under several situations. Moreover, the chart is robust to plausible deviations from assumed distribution of errors.     

Conditional design of the CUSUM median chart for the process position when process parameters are unknown

In practice, different practitioners will use different Phase I samples to estimate the process parameters, which will lead to different Phase II control chart's performance. Researches refer to this variability as between-practitioners-variability of control charts. Since between-practitioners-variability is important in the design of the CUSUM median chart with estimated process parameters, the standard deviation of average run length (SDARL) will be used to study its properties. It is shown that the CUSUM median chart requires a larger amount of Phase I samples to sufficiently reduce the variation in the in-control ARL of the CUSUM median chart. Considering the limitation of the amount of the Phase I samples, a bootstrap approach is also used here to adjust the control limits of the CUSUM median chart. Comparisons are made for the CUSUM and Shewhart median charts with estimated parameters when using the adjusted- and unadjusted control limits and some conclusions are made.     

Properties and performance of the c-chart for attributes data

The effects of parameter estimation are examined for the well-known c-chart for attributes data. The exact run length distribution is obtained for Phase II applications, when the true average number of non-conformities, c, is unknown, by conditioning on the observed number of non-conformities in a set of reference data (from Phase I). Expressions for various chart performance characteristics, such as the average run length (ARL), the standard deviation of the run length (SDRL) and the median run length (MDRL) are also obtained. Examples show that the actual performance of the chart, both in terms of the false alarm rate (FAR) and the in-control ARL, can be substantially different from what might be expected when c is known, in that an exceedingly large number of false alarms are observed, unless the number of inspection units (the size of the reference dataset) used to estimate c is very large, much larger than is commonly used or recommended in practice. In addition, the actual FAR and the in-control ARL values can be very different from the nominally expected values such as 0.0027 (or ARL₀=370), particularly when c is small, even with large amounts of reference data. A summary and conclusions are offered.     

An ARL-unbiased design of time-between-events control charts with runs rules

In this paper, we consider incorporating the runs rules into the cumulative quantity control (CQC) chart for monitoring time-between-events data. We propose a simple and effective procedure to design a CQC chart coupled with runs rules that can yield average run length (ARL)-unbiased performance and meet the required in-control ARL. The proposed design involves determining a relation between the upper side and lower side false alarm probabilities. A Markov chain approach is used to evaluate the ARL performance of various control schemes studied in this paper. An extensive numerical comparison shows that the proposed design approach can result in a significant reduction in ARL for detecting increases in the occurrence rate of the event in comparison with the basic CQC charts.     

An Evaluation of the Double Exponentially Weighted Moving Average Control Chart

In this article we perform a careful investigation of the double exponentially weighted moving average (DEWMA) chart performance for monitoring the process mean. We compare the performance of this chart to the usual EWMA control chart based on zero-state and worst-case average run length (ARL) measures. We also evaluate the signal resistance measure of the DEWMA chart and compare its maximum value to that of the EWMA chart. We show that the superiority of the DEWMA chart over the simpler standard EWMA chart based on zero-state ARL performance disappears when the smoothing constant of the EWMA chart is chosen to give weights to past observations closer to those given by the DEWMA chart. Moreover, our results show that the standard EWMA chart has much better performance than the DEWMA chart in terms of worst-case ARL values, especially when small smoothing constants are used. We also demonstrate using an illustrative example that the DEWMA chart can build up an exceedingly large amount of inertia when used to monitor the process mean.     

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.     

The Effect of Methods for Handling Missing Values on the Performance of the MEWMA Control Chart

This article is concerned with the effect of the methods for handling missing values in multivariate control charts. We discuss the complete case, mean substitution, regression, stochastic regression, and the expectation–maximization algorithm methods for handling missing values. Estimates of mean vector and variance–covariance matrix from the treated data set are used to build the multivariate exponentially weighted moving average (MEWMA) control chart. Based on a Monte Carlo simulation study, the performance of each of the five methods is investigated in terms of its ability to obtain the nominal in-control and out-of-control average run length (ARL). We consider three sample sizes, five levels of the percentage of missing values, and three types of variable numbers. Our simulation results show that imputation methods produce better performance than case deletion methods. The regression-based imputation methods have the best overall performance among all the competing methods.     

A weighted likelihood ratio test-based chart for monitoring process mean and variability

In this paper, a new single exponentially weighted moving average (EWMA) control chart based on the weighted likelihood ratio test, referred to as the WLRT chart, is proposed for the problem of monitoring the mean and variance of a normally distributed process variable. It is easy to design, fast to compute, and quite effective for diverse cases including the detection of the decrease in variability and individual observation case. The optimal parameters that can be used as a design aid in selecting specific parameter values based on the average run length (ARL) and the sample size are provided. The in-control (IC) and out-of-control (OC) performance properties of the new chart are compared with some other existing EWMA-type charts. Our simulation results show that the IC run length distribution of the proposed chart is similar to that of a geometric distribution, and it provides quite a robust and satisfactory overall performance for detecting a wide range of shifts in the process mean and/or variability.     

Zone control charts with estimated parameters for detecting prespecified changes in linear profiles

ABSTRACT

In profile monitoring, control charts are proposed to detect unanticipated changes, and it is usually assumed that the in-control parameters are known. However, due to the characteristics of a system or process, the prespecified changes would appear in the process. Moreover, in most applications, the in-control parameters are usually unknown. To overcome these issues, we develop the zone control charts with estimated parameters to detect small shifts of these prespecified changes. The effects of estimation error have been investigated on the performance of the proposed charts. To account for the practitioner-to-practitioner variability, the expected average run length (ARL) and the standard deviation of the average run length (SDARL) is used as the performance metrics. Our results show that the estimation error results in the significant variation in the ARL distribution. Furthermore, in order to adequately reduce the variability, more phase I samples are required in terms of the SDARL metric than that in terms of the expected ARL metric. In addition, more observations on each sampled profile are suggested to improve the charts' performance, especially for small phase I sample sizes. Finally, an illustrative example is given to show the performance of the proposed zone control charts.     

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 distribution-free multivariate CUSUM control chart using dynamic control limits

In modern quality control, it is becoming common to simultaneously monitor several quality characteristics of a process with rapid evolving data-acquisition technology. When the multivariate process distribution is unknown and only a set of in-control data is available, the bootstrap technique can be used to adjust the constant limit of the multivariate cumulative sum (MCUSUM) control chart. To further improve the performance of the control chart, we extend the constant control limit to a sequence of dynamic control limits which are determined by the conditional distribution of the charting statistics given the sprint length. Simulation results show that the novel control chart with dynamic control limits offers a better ARL performance, compared with the traditional MCUSUM control chart. Despite it, the proposed control chart is considerably computer-intensive. This leads to the development of a more flexible control chart which uses a continuous function of the sprint length as the control limit sequences. More importantly, the control chart is easy to implement and can reduce the computational time significantly. A white wine data illustrates that the novel control chart performs quite well in applications.     

On the run length of a Shewhart chart for correlated data

We consider an extension of the classical Shewhart control chart to correlated data which was introduced by Vasilopoulos/Stamboulis (1978). Inequalities for the moments of the run length are given under weak conditions. It is proved analytically that the average run length (ARL) in the in-control state of the correlated process is larger than that in the case of independent variables. The exact ARL is calculated for exchangeable normal variables and autoregressive processes (AR). Moreover, we compare this chart with residual charts. Especially, in the case of an AR(1)—process with positive coefficient, it turns out that the out-of-control ARL of the modified Shewhart chart is smaller than that of the Shewhart chart for the residuals.     

Parameter estimation and design considerations in prospective applications of the � chart

The effects of parameter estimation on the in-control performance of the Shewhart X¯ chart are studied in prospective (phase 2 or stage 2) applications via a thorough examination of the attained false alarm rate (AFAR), the conditional false alarm rate (CFAR), the conditional and the unconditional run-length distributions, some run-length characteristics such as the ARL, the conditional ARL (CARL), some selected percentiles including the median, and cumulative run-length probabilities. The examination involves both numerical evaluations and graphical displays. The effects of parameter estimation need to be accounted for in designing the chart. To this end, as an application of the exact formulations, chart constants are provided for a specified in-control average run-length of 370 and 500 for a number of subgroups and subgroup sizes. These will be useful in the implementation of the X¯ chart in practice.     

Determining Optimal Number of Samples for Constructing Multivariate Control Charts

Normally, an average run length (ARL) is used as a measure for evaluating the detecting performance of a multivariate control chart. This has a direct impact on the false alarm cost in Phase II. In this article, we first conduct a simulation study to calculate both in-control and out-of-control ARLs under various combinations of process shifts and number of samples. Then, a trade-off analysis between sampling inspection and false alarm costs is performed. Both the simulation results and trade-off analysis suggest that the optimal number of samples for constructing a multivariate control chart in Phase I can be determined.     

Reduction of control-chart signal variablity for high-quality processes

The design of a control chart is often based on the statistical measure of average run length (ARL). A longer in-control ARL is ensured by the design, but the variance run length distribution may also be large for such a design. In practical terms, the variability in false alarms and true signals may be large. If the sample size for plotting a point is not constant, then the focus is on the average number inspected as against the ARL. This article considers two well-known attribute control chart procedures for monitoring high quality based on the number inspected, and shows how the variability in false alarms and correct signals can be reduced.