Acceptance control charts for non-normal data

Control charts are one of the most important methods in industrial process control. The acceptance control chart is generally applied in situations when an X¯ chart is used to control the fraction of conforming units produced by the process and where 6-sigma spread of the process is smaller than the spread in the specification limits. Traditionally, when designing control charts, one usually assumes that the data or measurements are normally distributed. However, this assumption may not be true in some processes. In this paper, we use the Burr distribution, which is employed to represent various non-normal distributions, to determine the appropriate control limits or sample size for the acceptance control chart under non-normality. Some numerical examples are given for illustration. From the presented examples, ignoring the effect of non-normality in the data leads to a higher type I or type II error probability.     

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 control chart using an auxiliary variable and repetitive sampling for monitoring process mean

In this paper, a new control chart is proposed by using an auxiliary variable and repetitive sampling in order to enhance the performance of detecting a shift in process mean. The product-difference type estimator of the mean is plotted on the proposed control chart, which utilizes the information of an auxiliary variable correlated with the main quality variable. The proposed control chart is based on the outer and inner control limits so that repetitive sampling is allowed when the plotted statistic falls between the two limits. The average run length (ARL) of the proposed control chart is evaluated using the Monte Carlo simulation. The proposed control chart is compared with the Riaz M control chart and the results show the outperformance of the proposed control chart in terms of the ARL.     

Attribute Control Chart for Multivariate Poisson Distribution

In this study, a control chart is constructed to monitor multivariate Poisson count data, called the MP chart. The control limits of the MP chart are developed by an exact probability method based on the sum of defects or non conformities for each quality characteristic. Numerical examples are used to illustrate the MP chart. The MP chart is evaluated by the average run length (ARL) in simulation. The result indicates that the MP chart is more appropriate than the Shewhart-type control chart when the correlation between variables exists.     

Control Chart for Monitoring Autocorrelated Process with Multiple Exogenous Inputs

We propose to use AR-Sieve Bootstrap in the construction of a control chart of an autocorrelated process influenced by multiple exogenous inputs. The control charts are compared with Exponentially Weighted Moving Average (EWMA) control chart through a simulation study. AR-Sieve bootstrap control limits are narrower than EWMA control limits. While the proposed method yields a higher rate of false alarms, it is quick in detecting even minimal structural changes.     

A single-featured EWMA-X control chart for detecting shifts in process mean and standard deviation

The combined EWMA-X chart is a commonly used tool for monitoring both large and small process shifts. However, this chart requires calculating and monitoring two statistics along with two sets of control limits. Thus, this study develops a single-featured EWMA-X (called SFEWMA-X) control chart which has the ability to simultaneously monitor both large and small process shifts using only one set of statistic and control limits. The proposed SFEWMA-X chart is further extended to monitoring the shifts in process standard deviation. A set of simulated data are used to demonstrate the proposed chart's superior performance in terms of average run length compared with that of the traditional charts. The experimental examples also show that the SFEWMA-X chart is neater and easier to visually interpret than the original EWMA-X chart.     

On Statistical Design of the Cumulative Quantity Control Chart for Monitoring High Yield Processes

When dealing with high-yield processes, the cumulative quantity control chart (CQC chart) has been shown to be more suitable than the traditional c chart and u chart. However, the CQC chart shows an ARL-biased performance. In this article, we propose a design procedure to derive modified control limits for the CQC chart and the CQC chart with runs rules that can produce ARL-unbiased performance and maintain the predetermined false alarm rate. After extensive numerical work we have found that the proposed ARL-unbiased CQC chart is more sensitive than the conventional CQC chart in detecting process deteriorations.     

Control Charts for the Mean and Variance based on Changepoint Methodology

This article develops a control chart for the mean and variance of a normal distribution based on changepoint methodology. A Bayesian approach is used to incorporate parameter uncertainty. The resulting control chart plots the probabilities of “no change” as samples become available at the monitoring stage. Average run length considerations are used to set the control limits. Simulations are used to compare the proposed chart with a more traditional Shewhart-type combined control chart for the mean and variance.     

New V control chart for the Maxwell distribution

Control charts have been popularly used as a user-friendly yet technically sophisticated tool to monitor whether a process is in statistical control or not. These charts are basically constructed under the normality assumption. But in many practical situations in real life this normality assumption may be violated. One such non-normal situation is to monitor the process variability from a skewed parent distribution where we propose the use of a Maxwell control chart. We introduce a pivotal quantity for the scale parameter of the Maxwell distribution which follows a gamma distribution. Probability limits and L-sigma limits are studied along with performance measure based on average run length and power curve. To avoid the complexity of future calculations for practitioners, factors for constructing control chart for monitoring the Maxwell parameter are given for different sample sizes and for different false alarm rate. We also provide simulated data to illustrate the Maxwell control chart. Finally, a real life example has been given to show the importance of such a control chart.     

Shewhart-Karten mit und ohne Warngrenzen

Shewhart control charts with and without warning limits are the most frequently used statistical method to control a production process. This paper investigates the possibilities to improve the performance of a given control chart without warning limits by using an appropriate chart with warning limits.     

Exponentially weighted moving average control charts for three-level products

In this paper, exponentially weighted moving average (EWMA) control charts for multinomial data are developed with a three-level classification scheme. The lower and upper control limits of the proposed EWMA control chart are evaluated using Markov chain approximation. Compared with the three-level Shewhart control chart, numerical results indicate that the proposed EWMA control chart is relatively sensitive to small shifts in a three-level multinomial process. A figure and a table are provided for practitioners to select the value of chart limit coefficient that gives the desired in-control average run length.     

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.     

Fast Initial Response Features for Poisson GWMA Control Charts

The Poisson GWMA (PGWMA) control chart is an extension model of Poisson EWMA chart. It is substantially sensitive to small process shifts for monitoring Poisson observations. Recently, some approaches have been proposed to modify EWMA charts with fast initial response (FIR) features. In this article, we employ these approaches in PGWMA charts and introduce a novel chart called Poisson double GWMA (PDGWMA) chart for comparison. Using simulation, various control schemes are designed and their average run lengths (ARLs) are computer and compared. It is shown that the PDGWMA chart is the first choice in detecting small shifts especially when the shifts are downward, and the PGWMA chart with adjusted time-varying control limits performs excellently in detecting great process shifts during the initial stage.     

An optimal control chart for finite matrix sequences at some unknown change point

We present a new measure for evaluating the performance of control charts to detect abrupt changes of finite matrix sequences. The objective is to minimize the probability that the control chart fails to raise the alarm at unknown change point time for a given in-control average run length. We construct and prove the optimal control chart with dynamic control limits in different pre- and post-change distributions. We validate the optimality of the proposed chart by conducting exhaustive experiments on both simulation study and real-world data.     

Using the predictive distribution to determine control limits for the Bayesian MEWMA chart

Bayesian control charts have been proposed for monitoring multivariate processes with the multivariate exponentially weighted moving average (MEWMA) statistic. It has been suggested that we use limits based on the predictive distribution of the MEWMA statistic. This analysis, however is based on the erroneous result that the average run length (ARL) is a function of the exceedance probability, that is, the probability that the first point exceeds the control limit. We show how this result can be corrected and we discuss how the Bayesian MEWMA chart with limits based on the predictive distribution compares with other multivariate control chart procedures.     

Control Charts for the Variance and Coefficient of Variation Based on Their Predictive Distribution

This article develops a control chart for the variance of a normal distribution and, equivalently, the coefficient of variation of a log-normal distribution. A Bayesian approach is used to incorporate parameter uncertainty, and the control limits are obtained from the predictive distribution for the variance. We evaluate this control chart by examining its performance for various values of the process variance.     

Effects of autocorrelation on control chart performance

In this article, we study the capability of the standard control chart for individual observations with fixed control limits to identify special causes reflected as isolated extreme points in the presence of autocorrelation. We consider both the application of standard Shewhart limits and moving-range limits and derive the risks of false positive and false negative when the control chart observations follow a general ARMA(p,q) process.     

A EWMA control chart based on an auxiliary variable and repetitive sampling for monitoring process location

ABSTRACT

This article develops an exponentially weighted moving average (EWMA) control chart using an auxiliary variable and repetitive sampling for efficient detection of small to moderate shifts in location. A EWMA statistic of a product estimator of the average (which utilities the information of auxiliary variables as well as repetitive sampling) is plotted on the proposed chart. The control chart coefficients of the proposed EWMA chart are determined for two strategic limits known as outer and inner control limits for the target in-control average run length. The performance of the proposed EWMA chart is studied using average run length when a shift occurs in the process average. The efficiency of the developed chart is compared with the competitive existing control charts. The results of the study revealed that proposed EWMA chart is more efficient than others to detect small changes in process mean.     

Bayesian X̄ control limits for exponentially distributed measurements

This article deals with the construction of an X? control chart using the Bayesian perspective. We obtain new control limits for the X? chart for exponentially distributed data-generating processes through the sequential use of Bayes’ theorem and credible intervals. Construction of the control chart is illustrated using a simulated data example. The performance of the proposed, standard, tolerance interval, exponential cumulative sum (CUSUM) and exponential exponentially weighted moving average (EWMA) control limits are examined and compared via a Monte Carlo simulation study. The proposed Bayesian control limits are found to perform better than standard, tolerance interval, exponential EWMA and exponential CUSUM control limits for exponentially distributed processes.