Concurrent Design for Process Quality,Statistical Tolerance,and SPC

The rapid response to the requirements of customers and markets promotes the concurrent engineering (CE) technique in product and process design. The decision making for process quality target, SPC method, sampling plan, and control chart parameter design can be done at the stage of process quality plan based on historical data and process knowledge database. Therefore, it is a reasonable trend to introduce the concepts and achievements on process quality evaluation and process capability analysis, CE, and SPC techniques into process plan and tolerance design. A new systematic method for concurrent design of process quality, statistical tolerance (ST), and control chart is presented based on a NSFC research program. A set of standardized process quality indices (PQIs) for variables is introduced for meeting the measurement and evaluation to process yield, process centering, and quality loss. This index system that has relatively strong compatibility and adaptability is based on raisonne grading by using the series of preferred numbers and arithmetical progression. The expected process quality based on this system can be assured by a standardized interface between PQIs and SPC, that is, quality-oriented statistical tolerance zone. A quality-oriented ST and SPC approach that quantitatively specifies what a desired process is and how to assure it will realize the optimal control for a process toward a predetermined quality target.     

A study of economic design of control charts for cumulative count of conforming items

In this paper the economic design of Cumulative Count of Conforming (CCC) control charts to maintain the current control of fraction nonconforming of a process is studied. CCC chart is an attribute chart for monitoring high quality processes by plotting the cumulative count of conforming items between two nonconforming ones on a suitable chart. A process model is proposed to obtain an appropriate loss function. An alogorithm to search for the optimal setting of the sampling and control parameters is derived. Numerical illustrations of the method and some properties of the optimal economic design are provided.     

Economic design of non parametric sign control chart

An economic design of sign chart to control the median is proposed. Since the sign chart is distribution free, it can easily be applied to any process without prior knowledge of process quality distribution. The effect on loss cost observed for different shifts in location shows that the sign chart performs better for large shifts. The economic statistical performance study reveals that statistical performance of sign chart can be improved sufficiently for moderate shifts in the process. Sensitivity study shows that design is more sensitive for change in values of penalty loss cost and time required for search and repair of an assignable cause.     

Robust design of adaptive control charts for manual manufacturing/inspection workstations

Often the manufacturing and the inspection workstations in a manufacturing process can coincide: thus, in these workstations the statistical process control (SPC) procedure of collecting sample statistics related to a critical-to-quality parameter is a task required to be done by the same worker who has to complete the working operations on a part. The aim of this study is to design a local SPC inspection procedure implementing an adaptive Shewhart control chart locally managed by the worker within the manufacturing workstation: the economic design of the inspection procedure is constrained by the expected number of false alarms issued and is restricted to those designs feasible with respect to the available shared labour resource. Furthermore, a robust approach that models the shift of the controlled parameter mean as a random variable is taken into account. The numerical analysis allows the most influencing environmental process factors to be captured and commented upon. The obtained results show that a few process operating parameters drive the choice of performing a robust optimization and the selection of the optimal SPC adaptive procedure.     

One-cluster sampling designs for an autocorrelated population

The variance of the sampling distribution of the sample mean is derived for two sampling designs in which a single cluster is randomly drawn from an autocorrelated population. The derivations are motivated by potential applications to statistical quality control, where a "one-cluster" sampling design may often be used because of ease of implementation, and where it is likely that process output is autocorrelated Scenarios in statistical process control for which either non-overlapping or overlapping clusters are appropriate are described The sampling design variance under non-overlapping clusters is related to the sampling design variance under overlapping clusters through the use of a circular population.     

Difference variance dispersion graphs for comparing response surface designs with applications in food technology

Variance dispersion graphs have become a popular tool in aiding the choice of a response surface design. Often differences in response from some particular point, such as the expected position of the optimum or standard operating conditions, are more important than the response itself. We describe two examples from food technology. In the first, an experiment was conducted to find the levels of three factors which optimized the yield of valuable products enzymatically synthesized from sugars and to discover how the yield changed as the levels of the factors were changed from the optimum. In the second example, an experiment was conducted on a mixing process for pastry dough to discover how three factors affected a number of properties of the pastry, with a view to using these factors to control the process. We introduce the difference variance dispersion graph (DVDG) to help in the choice of a design in these circumstances. The DVDG for blocked designs is developed and the examples are used to show how the DVDG can be used in practice. In both examples a design was chosen by using the DVDG, as well as other properties, and the experiments were conducted and produced results that were useful to the experimenters. In both cases the conclusions were drawn partly by comparing responses at different points on the response surface.     

On-line monitoring data quality of high-dimensional data streams

ABSTRACT

In recent years, effective monitoring of data quality has increasingly attracted attention of researchers in the area of statistical process control. Among the relevant research on this topic, none used multivariate methods to control the multidimensional data quality process, but instead relied on multiple univariate control charts. Based on a novel one-sided multivariate exponentially weighted moving average (MEWMA) chart, we propose a conditional false discovery rate-adjusted scheme to on-line monitor the data quality of high-dimensional data streams. With thousands of input data streams, the average run length loses its usefulness because one will likely have out-of-control signals at each time period. Hence, we first control the percentage of signals that are false alarms. Then, we compare the power of the proposed MEWMA scheme with that of two alternative methods. Compared with two competitors, numerical results show that the proposed MEWMA scheme has higher average power.     

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.     

Making control charts more effective by time series analysis: three illustrative applications

Control charts contribute to the monitoring and improvement of process quality by helping to separate out special cause variation from common cause variation. By common cause variation we mean the usual variation in an in-control process. Special causes can be thought of as disturbances, possibly transitory, impacting a process that is in a state of statistical control. However, there is no clear place in this scheme of special causes and common causes for systematic non-iid variation, such as trend, seasonal, autoregression variation, and intervention effects from efforts to improve the proess. When systematic non-iid variation is present, time series modeling and fitting can fill in this picture. In the time series framework, observations influenced by special causes can be treated as outliers from the currently-entertained time-series model and can be detected by outlier detection methods. We discuss three data sets that illustrate how this can be done in order to make control charts more effective. We show also how a standard control-chart supplement called "pattern analysis" can be useful in time-series work.     

Variable repetitive group sampling plans with process loss consideration

Traditionally, most acceptance sampling plans considering the fraction defective do not distinguish among the products that fall within the specification limits. However, products that fall within the specification limits may not be good if their mean is far away from the target. So, developing an acceptance sampling plan with process loss consideration is essential. In this paper, a variable repetitive group sampling plan is proposed to deal with process loss. The design parameters of the proposed plan are tabulated for various combinations of acceptance quality levels. The proposed methodology can be used to determine whether the products meet the desired levels of protection for both producers and consumers.     

A rational sequential probability ratio test control chart for monitoring process shifts in mean and variance

The sequential probability ratio test (SPRT) chart is a very effective tool for monitoring manufacturing processes. This paper proposes a rational SPRT chart to monitor both process mean and variance. This SPRT chart determines the sampling interval d based on the rational subgroup concept according to the process conditions and administrative considerations. Since the rational subgrouping is widely adopted in the design and implementation of control charts, the studies of the rational SPRT have a practical significance. The rational SPRT chart is designed optimally in order to minimize the index average extra quadratic loss for the best overall performance. A systematic performance study has also been conducted. From an overall viewpoint, the rational SPRT chart is more effective than the cumulative sum chart by more than 63%. Furthermore, this article provides a design table, which contains the optimal values of the parameters of the rational SPRT charts for different specifications. This will greatly facilitate the potential users to select an appropriate SPRT chart for their applications. The users can also justify the application of the rational SPRT chart according to the achievable enhancement in detection effectiveness.     

On-Line Process Control using Attributes with Misclassification Errors: An Economical Design for Short-Run Production

On-line process control consists of inspecting a single item for every m (integer and m ≥ 2) produced items. Based on the results of the inspection, it is decided whether the process is in-control (the fraction of conforming items is p ₁; State I) or out-of-control (the fraction of conforming items is p ₂ < p ₁; State II). If the inspected item is non conforming, it is determined that the process is out-of-control, and the production process is stopped for an adjustment; otherwise, production continues. As most designs of on-line process control assume a long-run production, this study can be viewed as an extension because it is concerned with short-run production and the decision regarding the process is subject to misclassification errors. The probabilistic model of the control system employs properties of an ergodic Markov chain to obtain the expression of the average cost of the system per unit produced, which can be minimised as a function of the sampling interval, m. The procedure is illustrated by a numerical example.     

A new generation of process capability indices based on fuzzy measurements

Process capability indices (PCIs) provide numerical measures on whether a process conforms to the defined manufacturing capability prerequisite. These have been successfully applied by companies to compete with and to lead high-profit markets by evaluating the quality and productivity performance. The PCI C_p compares the output of a process to the specification limits (SLs) by forming the ratio of the width between the process SLs with the width of the natural tolerance limits which is measured by six process standard deviation units. As another common PCI, C_pm incorporates two variation components which are variation to the process mean and deviation of the process mean from the target. A meaningful generalized version of above PCIs is introduced in this paper which is able to handle in a fuzzy environment. These generalized PCIs are able to measure the capability of a fuzzy-valued process in producing products on the basis of a fuzzy quality. Fast computing formulas for the generalized PCIs are computed for normal and symmetric triangular fuzzy observations, where the fuzzy quality is defined by linear and exponential fuzzy SLs. A practical example is presented to show the performance of proposed indices.     

SPC Study of a Brewing Process

The process of brewing is a complex one, in which several biological and chemical reactions occur that involve many variables and their interactions. This pilot study is an attempt to understand and to control the chemical and biological nature of the process of 'beer cooking'. Through data collection and analysis the measurement system was initially evaluated and improved to allow the assessment of the stability of the analysed response variable: wort's F (F is a fictitious name for this variable due to confidentiality). Next, a deeper analysis was carried out to characterize, improve and control the behaviour of this factor by means of confidence intervals and several regression analyses. The way to control F is by adding a certain amount of element X according to a previously empirically developed table. After the analyses, this table was questioned and a new one was developed. This study is the outcome of the willingness of a group of people in this company to incorporate into its traditional and, at some stages, artisan way of producing beer, the utilization of statistical techniques for analysing and improving its processes and products.     

An integrated model for economic design of chi-square control chart and maintenance planning

Considered process in this article is a two-stage dependent process. Each item in this process has two quality characteristics as x and y while x and y are related to the stage 1 and 2, respectively. Each stage has two operational states as the in-control state and out-of-control state and transition time from the in-control state to the out-of-control state follows a general continues distribution function. The process is monitored using a chi-square control chart. An integrated model that coordinates the decisions related to the economic design of the used control chart and maintenance planning is presented. For the evaluation of the integrated model performance, a stand-alone maintenance model is also presented, and the performance of these two models is compared with each other.     

Interval robust design under contaminated and non normal data

Abstract

Robust parameter design (RPD) is an effective tool, which involves experimental design and strategic modeling to determine the optimal operating conditions of a system. The usual assumptions of RPD are that normally distributed experimental data and no contamination due to outliers. And generally the parameter uncertainties in response models are neglected. However, using normal theory modeling methods for a skewed data and ignoring parameter uncertainties can create a chain of degradation in optimization and production phases such that misleading fit, poor estimated optimal operating conditions, and poor quality products. This article presents a new approach based on confidence interval (CI) response modeling for the process mean. The proposed interval robust design makes the system median unbiased for the mean and uses midpoint of the interval as a measure of location performance response. As an alternative robust estimator for the process variance response modeling, using biweight midvariance is proposed which is both resistant and robust of efficiency where normality is not met. The results further show that the proposed interval robust design gives a robust solution to the skewed structure of the data and to contaminated data. The procedure and its advantages are illustrated using two experimental design studies.     

A new synthetic control chart for monitoring process mean using auxiliary information

ABSTRACT

Quality control charts have been widely recognized as a potentially powerful statistical process monitoring tool in statistical process control because of their superior ability in detecting shifts in the process parameters. Recently, auxiliary-information-based control charts have been proposed and shown to have excellent speed in detecting process shifts than those based without it. In this paper, we design a new synthetic control chart that is based on a statistic that utilizes information from both the study and auxiliary variables. The proposed synthetic chart encompasses the classical synthetic chart. The construction, optimal design, run length profiles, and the performance evaluation of the new chart are discussed in detail. It turns out that the proposed synthetic chart performs uniformly better than the classical synthetic chart when detecting different kinds of shifts in the process mean under both zero-state and steady-state run length performances. Moreover, with reasonable assumptions, the proposed chart also surpasses the exponentially weighted moving average control chart. An application with a simulated data set is also presented to explain the implementation of the proposed control chart.     

Developing and designing of an efficient variables sampling system based on the process capability index

Process capability indices (PCIs) are extensively used in the manufacturing industries in order to confirm whether the manufactured products meet their specifications or not. PCIs can be used to judge the process precision, process accuracy, and the process performance. So developing of sampling plans based on PCIs is inevitable and those plans will be very much useful for maintaining and improving the product quality in the manufacturing industries. In view of this, we propose a variables sampling system based on the process capability index C_pmk, which takes into account of process yield and process loss, when the quality characteristic under study will have double specification limits. The proposed sampling system will be effective in compliance testing. The advantages of this system over the existing sampling plans are also discussed. In order to determine the optimal parameters, tables are also constructed by formulating the problem as a nonlinear programming in which the average sample number is minimized by satisfying the producer and consumer risks.     

Designing of variables quick switching sampling system by considering process loss functions

This paper proposes a variables quick switching system where the quality characteristic of interest follows a normal distribution and the quality characteristic is evaluated through a process loss function. Most of the variables sampling plans available in the literature focus only on the fraction non-conforming and those plans do not distinguish between the products that fall within the specification limits. The products that fall within specification limits may not be good if their mean is too away from the target value. So developing a sampling plan by considering process loss is inevitable in these situations. Based on this idea, we develop a variables quick switching system based on the process loss function for the application of the processes requiring low process loss. Tables are also constructed for the selection of parameters of variables quick switching system for given acceptable quality level and limiting quality level. The results are explained with examples.