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.     

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.     

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.     

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.     

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.     

Run rules based phase II c and np charts when process parameters are unknown

Abstract

The performance of attributes control charts is usually evaluated under the assumption of known process parameters (i.e., the nominal proportion of non conforming units or the nominal average number of nonconformities). However, in practice, these process parameters are rarely known and have to be estimated from an in-control Phase I data set. The major contributions of this paper are (a) the derivation of the run length properties of the Run Rules Phase II c and np charts with estimated parameters, particularly focusing on the ARL, SDRL, and 0.05, 0.5, and 0.95 quantiles of the run length distribution; (b) the investigation of the number m of Phase I samples that is needed by these charts in order to obtain similar in-control ARLs to the known parameters case; and (c) the proposition of new specific chart parameters that allow these charts to have approximately the same in-control ARLs as the ones obtained in the known parameters case.     

Some Comments Regarding the Synthetic Chart

The steady-state average run length (ARL) is a function of the in-control probabilities of being in each nonabsorbing state. Davis and Woodall (2002) tabulated values that are significantly smaller than the steady-state ARLs, because they used the out-of-control probabilities. The synthetic chart signals when a second sample point falls beyond the control limits, no matter whether one of them falls above the centerline and the other falls below it. The side-sensitive version of the synthetic chart does not signal when the points beyond the control limits are on opposite sides. With this rule, the chart detects mean changes more quickly.     

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.     

An overview of risk-adjusted charts

Summary.  The paper provides an overview of risk-adjusted charts, with examples based on two data sets: the first consisting of outcomes following cardiac surgery and patient factors contributing to the Parsonnet score; the second being age–sex-adjusted death-rates per year under a single general practitioner. Charts presented include the cumulative sum (CUSUM), resetting sequential probability ratio test, the sets method and Shewhart chart. Comparisons between the charts are made. Estimation of the process parameter and two-sided charts are also discussed. The CUSUM is found to be the least efficient, under the average run length (ARL) criterion, of the resetting sequential probability ratio test class of charts, but the ARL criterion is thought not to be sensible for comparisons within that class. An empirical comparison of the sets method and CUSUM, for binary data, shows that the sets method is more efficient when the in-control ARL is small and more efficient for a slightly larger range of in-control ARLs when the change in parameter being tested for is larger. The Shewart p -chart is found to be less efficient than the CUSUM even when the change in parameter being tested for is large.     

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 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.     

A class of distribution-free control charts

Summary.  A class of Shewhart-type distribution-free control charts is considered. A key advantage of these charts is that the in-control run length distribution is the same for all continuous process distributions. Exact expressions for the run length distribution and the average run length (ARL) are derived and properties of the charts are studied via evaluations of the run length distribution probabilities and the ARL. Tables are provided for implementation for some typical ARL values and false alarm rates. The charts proposed are preferable from a robustness point of view, have attractive ARL properties and would be particularly useful in situations where one uses a classical Shewhart   X -chart. A numerical illustration is given.     

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.     

ARL-unbiased control charts for the monitoring of exponentially distributed characteristics based on type-II censored samples

In this paper, the problem of monitoring process data that can be modelled by exponential distribution is considered when observations are from type-II censoring. Such data are common in many practical inspection environment. An average run length unbiased (ARL-unbiased) control scheme is developed when the in-control scale parameter is known. The performance of the proposed control charts are investigated in terms of the ARL and standard deviation of the run length. The effects of parameter estimation on the proposed control charts are also evaluated. Then, we consider the design of the ARL-unbiased control charts when the in-control scale parameter is estimated. Finally, an example is used to illustrate the implementation of the proposed control charts.     

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.     

The Effects of Sample Sizes in Phases I and II on p Control Chart Performance

Control charts designed for the properties of non conformities, also called p control charts, are powerful tools used for monitoring a performance of the fraction of non conforming units. Constructing a p chart is often based on the assumption that the in-control proportion of non conforming items (p ₀) is known. In practice, the value of p ₀ is rarely known and is frequently replaced by an estimate from an in-control reference sample in Phase I. This article investigates the effects of sample sizes in both Phase I and Phase II on the performance of p control charts. The conditional and marginal run length distributions are derived and the corresponding numerical studies are conducted. Moreover, the minimal sample sizes required in Phases I and II to ensure adequate statistical performance are proposed when p ₀ = 0.1 and 0.005.     

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 performance of multivariate CUSUM control charts with estimated parameters

In this paper, we study the effect of estimating the vector of means and the variance–covariance matrix on the performance of two of the most widely used multivariate cumulative sum (CUSUM) control charts, the MCUSUM chart proposed by Crosier [Multivariate generalizations of cumulative sum quality-control schemes, Technometrics 30 (1988), pp. 291–303] and the MC1 chart proposed by Pignatiello and Runger [Comparisons of multivariate CUSUM charts, J. Qual. Technol. 22 (1990), pp. 173–186]. Using simulation, we investigate and compare the in-control and out-of-control performances of the competing charts in terms of the average run length measure. The in-control and out-of-control performances of the competing charts deteriorate significantly if the 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. We recommend the use of the MC1 chart over that of the MCUSUM chart if the parameters are estimated from a small number of Phase I samples.     

CUSUM control schemes for Gaussian processes

A CUSUM control scheme for detecting a change point in a Gaussian process is derived. An upper and a lower bound for the distribution of the run length and for its moments is given. In a Monte Carlo study the average run length (ARL) of this chart is compared with the ARL of two other CUSUM procedures which are based on approximations to the sequential probability ratio, and, moreover, with EWMA schemes for autocorrelated data. Results on the optimal choice of the reference value are presented. Furthermore it is investigated how these charts behave if the model parameters are estimated.