A Parameter-Tuned Genetic Algorithm for Economic-Statistical Design of Variable Sampling Interval X-Bar Control Charts for Non-Normal Correlated Samples

Among innovations and improvements that occurred in the past two decades on the techniques and tools used for statistical process control (SPC), adaptive control charts have shown to substantially improve the statistical and/or economical performances. Variable sampling intervals (VSI) control charts are one of the most applied types of the adaptive control charts and have shown to be faster than traditional Shewhart control charts in identifying small changes of concerned quality characteristics. While in the designing procedure of the VSI control charts the data or measurements are assumed independent normal observations, in real situations the validity of these assumptions is under question in many processes. This article develops an economic-statistical design of a VSI X-bar control chart under non-normality and correlation. Since the proposed design consists of a complex nonlinear cost model that cannot be solved using a classical optimization method, a genetic algorithm (GA) is employed to solve it. Moreover, to improve the performances, response surface methodology (RSM) is employed to calibrate GA parameters. The solution procedure, efficiency, and sensitivity analysis of the proposed design are demonstrated through a numerical illustration at the end.     

Monitoring and diagnosing dependent process steps using VSI control charts

The paper proposes the variables sampling interval (VSI) scheme to monitor the means and the variances in two dependent process steps. The performance of the considered VSI control charts is measured by the adjusted average time to signal derived by a Markov chain approach. An example of the process control for the metallic film thickness of the computer connectors system shows the application and performance of the proposed VSI control charts in detecting shifts. Furthermore, the performance of the VSI control charts and the fixed sampling interval control charts are compared via the numerical analysis results. These demonstrate that the former is much faster in detecting shifts. Whenever quality engineers cannot specify the values of variable sampling intervals, the optimal VSI control charts are recommended. Furthermore, the impacts of misusing Shewhart charts to monitoring the process mean and variance in the second process step are also investigated.     

Economic-Statistical Design of EWMA Control Charts Based on Taguchi's Loss Function

This paper proposes an economic-statistical design of the EWMA chart with time-varying control limits in which the Taguchi's quadratic loss function is incorporated into the economic-statistical design based on Lorenzen and Vance's economical model. A nonlinear programming with statistical performance constraints is developed and solved to minimize the expected total quality cost per unit time. This model, which is divided into three parts, depends on whether production continues during the period when the assignable cause is being searched for and/or repaired. Through a computational procedure, the optimal decision variables, including the sample size, the sampling interval, the control limit width, and the smoothing constant, can be solved for by each model. It is showed that the optimal economic-statistical design solution can be found from the set of optimal solutions obtained from the statistical design, and both the optimal sample size and sampling interval always decrease as the magnitude of shift increases.     

Economic-statistical design of X ¥ charts for non-normal data by considering quality loss

When the X ¥ control chart is used to monitor a process, three parameters should be determined: the sample size, the sampling interval between successive samples, and the control limits of the chart. Duncan presented a cost model to determine the three parameters for an X ¥ chart. Alexander et al. combined Duncan's cost model with the Taguchi loss function to present a loss model for determining the three parameters. In this paper, the Burr distribution is employed to conduct the economic-statistical design of X ¥ charts for non-normal data. Alexander's loss model is used as the objective function, and the cumulative function of the Burr distribution is applied to derive the statistical constraints of the design. An example is presented to illustrate the solution procedure. From the results of the sensitivity analyses, we find that small values of the skewness coefficient have no significant effect on the optimal design; however, a larger value of skewness coefficient leads to a slightly larger sample size and sampling interval, as well as wider control limits. Meanwhile, an increase on the kurtosis coefficient results in an increase on the sample size and wider control limits.     

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.     

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.     

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 designs of VSI Bayesian control chart using Monte Carlo method and ABC algorithm

The usual practice in using a Bayesian control chart to monitor a process is done by taking samples from the process with fixed sampling intervals. Recent studies on traditional control charts have shown that variable sampling interval (VSI) scheme compared to classical scheme (fixed ratio sampling, FRS) helps practitioners to detect process shifts more quickly. In this paper, the effectiveness of VSI scheme on performance of Bayesian control chart has been studied, based on economic (ED) and economic–statistical designs (ESD). Monte Carlo method and artificial bee colony algorithm have been utilized to obtain optimal design parameters of Bayesian control chart (sample size, sampling intervals, warning limit and control limit) since the statistic of this approach does not have any specified distribution. Finally, VSI Bayesian control chart has been compared to FRS Bayesian and VSI X-bar approaches based on ED and ESD, separately. According to the results, it has been found that the performance of VSI Bayesian scheme is better than FRS Bayesian and VSI X-bar approaches.     

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.     

An Extension of Economic Design of x-Bar Control Charts for Non Normally Distributed Data Under Weibull Shock Models

Three parameters—sample size, sampling intervals, and the control limits—must be determined when the x bar chart to monitor a manufacturing process. The constant sampling intervals were widely employed because of its administrative simplicity. However, the variable sampling interval (VSI) has recently been shown to give substantially faster detection of most process shifts than fixed-sampling-interval (FSI) for x-bar charts. In addition, these measurements in the subgroup are assumed to be normally distributed. That assumption may not be tenable. This investigation compares the economic design of x-bar control charts for non normal data under Weibull shock models with various sampling avenues.     

Shewhart control charts for the scale parameter of a Weibull control variable with fixed and variable sampling intervals

In this paper, we are concerned with pure statistical Shewhart control charts for the scale parameter of the three-parameter Weibull control variable, where, and are the location, the scale and the shape parameters, respectively, with fixed (FSI) and variable (VSI) sampling intervals. The parameters and are assumed to be known. We consider two-sided, and lower and upper one-sided Shewhart control charts and their FSI and VSI versions . They jointly control the mean and the variance of the Weibull control variable X. The pivotal statistic of those control charts is the maximum-likelihood estimator of for the Nth random sample XN=(X1N,X2N,...,XnN) of the Weibull control variable X. The design and performance of these control charts are studied. Two criteria, i.e. 'comparability criterion' (or 'matched criterion') under control and 'primordial criterion', are imposed on their design. The performance of these control charts is measured using the function average time to signal. For the VSI versions, the constant which defines the partition of the 'continuation region' is obtained through the 'comparability criterion' under control. The monotonic behaviour of the function average time to signal in terms of the parameters (magnitude of the shift suff ered by the target value 0), and is studied. We show that the function average time to signal of all the control charts studied in this paper does not depend on the value of the parameter or on 0, and, under control, does not depend on the parameter, when Delta (the probability of a false alarm) and n (sample size) are fixed. All control charts satisfy the 'primordial criterion' and, for fixed, on average, they all (except the two-sided VSI, for which we were not able to ascertain proof) are quicker in detecting the shift as increases. We conjecture - and we are not contradicted by the numerical example considered - that the same is true for the two-sided VSI control chart. We prove that, under the average time to signal criterion, the VSI versions are always preferable to their FSI versions. In the case of one-sided control charts, under the 'comparability criterion', the VSI version is always preferable to the FSI version, and this advantage increases with and the extent of the shift. Our one-sided control charts perform better and have more powerful statistical properties than does our two-sided control chart. The numerical example where n=5,0=1,=0.5, 1.0, 2.0, and Delta=1/370.4 is presented for the two-sided, and the lower and upper one-sided control charts. These numerical results are presented in tables and in figures. The joint influence of the parameters and in the function average time to signal is illustrated.     

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.     

Adaptive Hotelling's T 2 Control Charts with Run Rules

This study investigates the statistical properties of the adaptive Hotelling's T ² charts with run rules in which the sample size and sampling interval are allowed to vary according on the current and past sampling points. The adaptive charts include variable sample size (VSS), variable sampling interval (VSI), and variable sample size and sampling interval (VSSI) charts. The adaptive Hotelling's T ² charts with run rules are compared with the fixed sampling rate Hotelling's T ² chart with run rules. The numerical results show that the VSS, VSI, and VSSI features improve the performance of the Hotelling's T ² chart with run rules.     

Optimal Variable Sample Size and Sampling Interval MSE Chart Based on Improved Square Root Transformation

In the field of statistical process control (SPC), control charts for attributes are widely used to detect the out-of-control condition by checking the number of nondefective units or nondefective in a sample. In this article, we use the average time to signal (ATS) and the average number of observations to signal (ANOS) to evaluate the performance of the optimal variable sample size and sampling interval (VSSI) improved square root transformation (ISRT) mean square error (MSE) (VSSI_ ISRT_ MSE) control chart for attribute data. In addition, this control chart will be used to monitor: (1) the difference between the process mean and the target value, and (2) the process variance shifts. We found that the optimal VSSI_ ISRT_ MSE chart performs better than the specific VSSI, the optimal variable sampling interval (VSI), and the fixed parameters (FP) ISRT_MSE charts. An example is given to illustrate this new proposed approach.     

An extension of Banerjee and Rahim model in economic and economic statistical designs for multivariate quality characteristics under Burr XII distribution

The design parameters of the economic and economic statistical designs of control charts depend on the distribution of process failure mechanism or shock model. So far, only a small number of failure distributions, such as exponential, gamma, and Weibull with fixed or increasing hazard rates, have been used as a shock model in the economic and economic statistical designs of the Hotelling T² control charts. Due to both theoretical and practical aspects, the lifetime of the process under study may not follow a distribution with fixed or increasing hazard rate. A proper alternative for this situation may be the Burr distribution, in which the hazard rate can be fixed, increasing, decreasing, single mode, or even U-shaped. In this research article, economic and economic statistical designs of the Hotelling T² control charts under the Burr XII shock models under two uniform and non uniform sampling schemes were proposed, constructed, and compared. The obtained design models were implemented by a numerical example, and a sensitivity analysis was conducted to evaluate the effect of changing parameters of shock model distribution on the optimum values of the proposed design models. The results showed that first the proposed designs under non uniform sampling scheme perform better and second the optimum values of the designs are not significantly sensitive to changing of the Burr XII distribution parameters. We showed that the obtained design models are also true for the beta Burr XII shock model.     

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.     

Improved switching rules in control procedures using variable sampling intervals

Some properties of control procedures with variable sampling intervals (VSI) have been investigated in recent years by Amin, Renolds et al, and others. Such procedures have been shown to be more efficient when compared to the corresponding fixed sampling interval (FSI) charts with respect to the Average Time to Signal (ATS) when the Average Run Length (ARL) values for both types of procedures are held equal. Frequent switching between the different sampling intervals can be a complicating factor in the application of control charts with variable sampling intervals (VSI). This problem is being addressed in this article, and improved switching rules are presented and evaluated for Shewhart, CUSUM, and EWMA control procedures. The proposed rules considerably reduce the average number of switches between the sampling intervals and also improve the ATS properties of the control procedures when compared to the conventional variable sampling interval procedures     

Weighted adaptive multivariate CUSUM charts with variable sampling intervals

The adaptive multivariate CUSUM (AMCUSUM) chart has received considerable attention because of its superior sensitivity against a range of mean shift sizes than that of the conventional non-adaptive multivariate CUSUM (MCUSUM) chart. Recently, weighted AMCUSUM (WAMCUSUM) charts with a fixed sampling interval (FSI) have been proposed, called the WAMCUSUM-FSI charts, which provide more sensitivity than the AMCUSUM-FSI charts. In this paper, we extend this work and propose WAMCUSUM charts with variable sampling interval (VSI), named the WAMCUSUM-VSI charts, for efficiently monitoring the mean of a multivariate normally distributed process. The Monte Carlo simulation method is used to compute the average time to signal (ATS) and the adjusted ATS (AATS) profiles of the existing and proposed charts. It is found that the WAMCUSUM-VSI charts perform substantially and nearly uniformly better than the WAMCUSUM-FSI charts in terms of the ATS and AATS performance criterion. An example is given to explain the implementation of the WAMCUSUM charts with fixed and VSIs.     

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.