On the Monitoring of Autocorrelated Linear Profiles

Control charts are commonly used to monitor quality of a process or product characterized by a quality characteristic or a vector of quality characteristics. However, in many practical situations the quality of a process or product can be characterized by a function or profile. Here we consider a linear function and investigate the violation of common independence assumption implicitly considered in most control charting applications. We specifically consider the case when profiles are not independent from each other over time. In this article, the effect of autocorrelation between profiles is investigated using average run length (ARL) criterion. Simulation results indicate significant impact on the ARL values when autocorrelation is overlooked. In addition, three methods based on time series approach are used to eliminate the effect of autocorrelation. Their performances are compared using ARL criterion.     

An integrated model based on statistical process control and maintenance for two-stage dependent processes

The close relationship between quality and maintenance of manufacturing systems has contributed to the development of integrated models which use the concept of statistical process control (SPC) and maintenance. This article demonstrates the integration of the Shewhart individual-residual (Z_X ? Z_e) joint control chart and maintenance for two-stage dependent processes by jointly optimizing their policies to minimize the expected total costs associated with quality, maintenance and inspection. To evaluate the effectiveness of the proposed model, two stand-alone models—a maintenance model and an SPC model—are proposed. Then a numerical example is given to illustrate the application of the proposed integrated model. The results show that the integrated model outperforms the two stand-alone models with regard to the expected cost per unit time. Finally, a sensitivity analysis is conducted to develop insights into time parameters and cost parameters that influence the integration efforts.     

Phase I Monitoring of Polynomial Profiles

In some statistical process control applications, quality of a process or product is characterized by a relationship between two or more variables which is referred to as profile. In many practical situations, a profile can be modeled as a polynomial regression. In this article, three methods are developed for monitoring polynomial profiles in Phase I. Their performance is evaluated using power criterion. Furthermore, a method based on likelihood ratio test is developed to identify the location of shifts. Numerical simulation is used to evaluate the performance of the developed method.     

One-sided EWMA control charts for monitoring Poisson processes with varying sample sizes

ABSTRACT

Recently considerable research has been devoted to monitoring increases of incidence rate of adverse rare events. This paper extends some one-sided upper exponentially weighted moving average (EWMA) control charts from monitoring normal means to monitoring Poisson rate when sample sizes are varying over time. The approximated average run length bounds are derived for these EWMA-type charts and compared with the EWMA chart previously studied. Extensive simulations have been conducted to compare the performance of these EWMA-type charts. An illustrative example is given.     

<Emphasis Type="Italic">R</Emphasis>-charts for the exponential,Laplace and logistic processes

This paper (i) discusses theR-chart with asymmetric probability control limits under the assumption that the distribution of the quality characteristic under study is either exponential, Laplace, or logistic, (ii) examines the effect of the estimated probability limits on the performance of theR-chart, and (iii) obtains the desired probability limits of theR-chart that has a specified false alarm rate when probability limits must be estimated from preliminary samples taken from either the exponential, Laplace, or logistic processes.     

The Performance of Phase II Simple Linear Profile Approaches when Parameters Are Estimated

Previous studies of statistical performance of Phase II simple linear profile approaches were reported only for the case of known profile parameters assumption. The main objective of this article is to evaluate and compare the performance of these approaches when the profile parameters are estimated from an in-control Phase I profile data set. Simulations establish that the performance of these approaches is strongly affected when the parameters are estimated compared to the known parameters case. The in-control performance of the competing approaches significantly deteriorates if estimated parameters are used with control limits intended for known parameters, especially when only a few Phase I samples are used to estimate the parameters. The results show also that some profile monitoring approaches need much larger number of Phase I profiles than other approaches to achieve the expected statistical performance. They also show that the profile monitoring approach proposed by Mahmoud et al. (2010 Mahmoud , M. A. , Morgan , J. P. , Woodall , W. H. ( 2010 ). The monitoring of simple linear regression profiles with two observations per sample . Journal of Applied Statistics 37 : 1249 – 1263 .[Taylor & Francis Online], [Web of Science ®] , [Google Scholar]) has generally better out-of-control run length performance than the competing approaches when the estimated parameters are used in the charts design.     

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.     

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 retrospective X-chart

Quality control chart interpretation is usually based on the assumption that successive observations are independent over time. In this article we show the effect of autocorrelation on the retrospective Shewhart chart for individuals, often referred to as the X-chart, with the control limits based on moving ranges. It is shown that the presence of positive first lag autocorrelation results in an increased number of false alarms from the control chart. Negative first lag autocorrelation can result in unnecessarily wide control limits such that significant shifts in the process mean may go undetected. We use first-order autoregressive and first-order moving average models in our simulation of small samples of autocorrelated data.     

Statistical Monitoring of Nominal Logistic Profiles in Phase II

Statistical analysis of profile monitoring, a relatively new sub-area of statistical process control due to its applications in different industries, have urged researchers and practitioners to contribute to the developments of new monitoring methods. A statistical profile is a relationship between a quality characteristic (a response) and one or more independent variables to characterize quality of a process or a product. In this article, statistical profiles based on nominal responses are studied, where logistic regression is used to model the responses. Three approaches including likelihood ratio test (LRT), multivariate exponentially weighted moving average (MEWMA), and support vector machines (SVM) approaches are proposed to monitor quality of a process or product in Phase II. Performances of the proposed approaches are evaluated and compared using a case study. Moreover, the effect of two important factors on average run length (ARL) performance, number of levels and number of covariates, has been considered. Results indicate that performance of all approaches depends on the number of covariates and levels. As the number of these factors increases, SVM performance improves while performance of the other approaches deteriorates.     

A robust R control chart based on a two-step estimator of the process dispersion

ABSTRACT

Control charts are the frequently used tools for monitoring and controlling the processes. Classical control charts are sensitive to existing contaminated data which may be presented in the data collected from the processes. Thus, these charts are not able to control the processes precisely when the data are contaminated. Robust control charts are those which are less sensitive to contamination. Some robust control charts for monitoring the process variability were proposed in the past which are robust to some sorts of contamination. In this paper a new robust R control chart is proposed which is less sensitive to wide range of contaminations, i.e. general and local contaminations. Simulation studies are performed to compare the performance of the proposed control chart with some classical and robust control charts, using ARL and MSD as criteria for comparisons purposes. The simulation results show a very good performance of the proposed chart when both types of contaminations exist.     

Empirical Non-Parametric Control Charts: Estimation Effects and Corrections

Owing to the extreme quantiles involved, standard control charts are very sensitive to the effects of parameter estimation and non-normality. More general parametric charts have been devised to deal with the latter complication and corrections have been derived to compensate for the estimation step, both under normal and parametric models. The resulting procedures offer a satisfactory solution over a broad range of underlying distributions. However, situations do occur where even such a large model is inadequate and nothing remains but to consider non- parametric charts. In principle, these form ideal solutions, but the problem is that huge sample sizes are required for the estimation step. Otherwise the resulting stochastic error is so large that the chart is very unstable, a disadvantage that seems to outweigh the advantage of avoiding the model error from the parametric case. Here we analyse under what conditions non-parametric charts actually become feasible alternatives for their parametric counterparts. In particular, corrected versions are suggested for which a possible change point is reached at sample sizes that are markedly less huge (but still larger than the customary range). These corrections serve to control the behaviour during in-control (markedly wrong outcomes of the estimates only occur sufficiently rarely). The price for this protection will clearly be some loss of detection power during out-of-control. A change point comes in view as soon as this loss can be made sufficiently small.     

Exceedance probabilities for parametric control charts

Common control charts assume normality and known parameters. Quite often, these assumptions are not valid and large relative errors result in the usual performance characteristics such as the false alarm rate or the average run length. A fully nonparametric approach can form an attractive alternative but requires more Phase I observations than usually available. Sufficiently general parametric families then provide realistic intermediate models. In this article, the performance of charts based on such families is considered. Exceedance probabilities of the resulting stochastic performance characteristics during in-control are studied. Corrections are derived to ensure that such probabilities stay within prescribed bounds. Attention is also devoted to the impact of the corrections for an out-of-control process. Simulations are presented both to illustrate and to demonstrate that the approximations obtained are sufficiently accurate for practical usage.     

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.     

Monitoring of zero-inflated binomial processes with a DEWMA control chart

Control charts are widely used for monitoring quality characteristics of high-yield processes. In such processes where a large number of zero observations exists in count data, the zero-inflated binomial (ZIB) models are more appropriate than the ordinary binomial models. In ZIB models, random shocks occur with probability θ, and upon the occurrence of random shocks, the number of non-conforming items in a sample of size n follows the binomial distribution with proportion p. In the present article, we study in more detail the exponentially weighted moving average control chart based on ZIB distribution (ZIB-EWMA) and we also propose a new control chart based on the double exponentially weighted moving average statistic for monitoring ZIB data (ZIB-DEWMA). The two control charts are studied in detecting upward shifts in θ or p individually, as well as in both parameters simultaneously. Through a simulation study, we compare the performance of the proposed chart with the ZIB-Shewhart, ZIB-EWMA and ZIB-CUSUM charts. Finally, an illustrative example is also presented to display the practical application of the ZIB charts.     

Statistical Monitoring of Autocorrelated Simple Linear Profiles Based on Principal Components Analysis

In this article, a transformation method using the principal component analysis approach is first applied to remove the existing autocorrelation within each profile in Phase I monitoring of autocorrelated simple linear profiles. This easy-to-use approach is independent of the autocorrelation coefficient. Moreover, since it is a model-free method, it can be used for Phase I monitoring procedures. Then, five control schemes are proposed to monitor the parameters of the profile with uncorrelated error terms. The performances of the proposed control charts are evaluated and are compared through simulation experiments based on different values of autocorrelation coefficient as well as different shift scenarios in the parameters of the profile in terms of probability of receiving an out-of-control signal.     

A Markov-chain method for computing the run-length distribution of the self-starting cumulative sum scheme

We propose an analytic method for computing the run-length distribution of the cumulative sum (CUSUM) of Q statistics. The method is based on a model in which the operation of this CUSUM is embedded in a nonstationary, discrete-time Markov chain. The calculations of the method agree closely with those of Monte Carlo simulation, supporting the method's accuracy. Our results facilitate understanding the effectiveness of the CUSUM of Q statistics in detecting process mean shifts.     

On the Run Length of a State-Space Control Chart for Multivariate Autocorrelated Data

The literature on statistical process control (SPC) describes the negative effects of autocorrelation in terms of the increase in false alarms. This has been treated by the individual modeling of each series or the application of VAR models. In the former case, the analysis of the cross correlation structure between the variables is altered. In the latter, if the cross correlation is not strong, the filtering process may modify the weakest relations. In order to improve these aspects, state-space models have been introduced in multivariate statistical process control (MSPC). This article presents a proposal for building a control chart for innovations, estimating its average run length to highlight its advantages over the VAR approach mentioned above.     

Phase II Monitoring of Geometric Profiles

Geometric profiles can be modeled effectively by large and small scale components. In several articles, a regression model with spatial autoregressive error term is combined with control charts to monitor geometric profiles. However, once a signal occurs, control charts would not be able to determine whether the shift is due to the large or small scale component. In this article, a combination of a multivariate and an omnibus control charts is used to monitor the large scale and small scale components to determine whether the shift is due to the large scale or small scale components.     

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.