Generally weighted moving average control charts with fast initial response features

The generally weighted moving average (GWMA) control chart is an extension model of exponentially weighted moving average (EWMA) control chart. Recently, some approaches have been proposed to modify EWMA charts with fast initial response (FIR) features. We introduce these approaches in GWMA-type charts. Via simulation, various control schemes are designed and then their average run lengths are computed and compared. Based on the overall performance, it is showed that the DGWMA chart is the best choice especially when the shift is moderate, and the GWMA charts provided with additional FIR feature have a good performance only in detecting large shifts during the initial stage.     

Applying fast initial response features on GWMA control charts for monitoring autocorrelation data

ABSTRACT

A generally weighted moving average (GWMA) control chart with fast initial response (FIR) features is addressed to monitor an autoregressive process mean shift. Numerical simulations based on average run length (ARL) show that the GWMA control chart with additional FIR feature requires less time to detect small or moderate shifts than GWMA control chart at low level of autocorrelation; whereas these two control charts perform similarly at high level of autocorrelation. Regardless of any level of autocorrelation, GWMA control charts provided with additional FIR feature have a good performance in detecting large shifts during the initial stage.     

The Run Sum R Chart with Fast Initial Response

A fast initial response (FIR) feature for the run sum R chart is proposed and its ARL performance estimated by a Markov chain representation. It is shown that this chart is more sensitive than several R charts with runs rules proposed by different authors. We conclude that the run sum R chart is simple to use and a very effective tool for monitoring increases and decreases in process dispersion.     

Performance of the zone control chart

Average run lengths of the zone control chart are presented, The performance of this chart is compared with that of several Shewhart charts with and without runs rules, It is shown that the standard zone control chart has performance similar to some even simpler charts and a much higher false alarm rate than the Shewhart chart with all of the common runs rules. It is also shown that a slightly modified zone control chart outperforms the Shewhart chart with the common runs rules.     

The Continuous Run Sum Chart

The run sum chart is an effective two-sided chart that can be used to monitor for process changes. It is known that it is more sensible than the Shewhart chart with runs rules and its performance improves as the number of regions increases. However, as the number of regions increses the resulting chart has more parameters to be defined and its design becomes more involved. In this article, we introduce a one-parameter run sum chart. This chart accumulates scores equal to the subgroup means and signals when the cummulative sum exceeds a limit value. A fast initial response feature is proposed and its run length distribution function is found by a set of recursive relations. We compare this chart with other charts suggested in the literature and find it competitive with the CUSUM, the FIR CUSUM, and the combined Shewhart FIR CUSUM schemes.     

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.     

Transition probabilities and ARL performance of Six Sigma zone control charts

In this article, Six Sigma zone control charts (SSZCCs) are proposed for world class organizations. The transition probabilities are obtained using the Markov chain approach. The Average Run Length (ARL) values are then presented. The ARL performance of the proposed SSZCCs and the standard Six Sigma control chart (SSCC) without zones or run rules is studied. The ARL performance of these charts is then compared with those of the other standard zone control charts (ZCCs), the modified ZCC and the traditional Shewhart control chart (SCC) with common run rules. As expected, it is shown that the proposed SSZCC outperforms the standard SSCC without zones or run rules for process shifts of any magnitude. When compared to the other standard ZCCs and the Shewhart chart with common run rules, it is observed that the proposed SSZCCs have much higher false alarm rates for smaller shifts and hence they prevent unwanted process disturbances. The application of the proposed SSZCC is illustrated using a real time example.     

Poisson GWMA Control Chart

A generally weighted moving average (GWMA) control chart for monitoring Poisson observations is introduced. Using simulation, its average run lengths and standard deviations of run lengths are compared with those of other control charts for Poisson data. It is shown that the Poisson GWMA chart outperforms other control charts, especially when the process shift is small.     

A CUSUM control chart for monitoring the variance when parameters are estimated

CUSUM control chart has been widely used for monitoring the process variance. It is usually used assuming that the nominal process variance is known. However, several researchers have shown that the ability of control charts to signal when a process is out of control is seriously affected unless process parameters are estimated from a large in-control Phase I data set. In this paper we derive the run length properties of a CUSUM chart for monitoring dispersion with estimated process variance and we evaluate the performance of this chart by comparing it with the same chart but with assumed known process parameters.     

Multivariate Synthetic |S| Control Chart with Variable Sampling Interval

A variable sampling interval (VSI) feature is introduced to the multivariate synthetic generalized sample variance |S| control chart. This multivariate synthetic control chart is a combination of the |S| sub-chart and the conforming run length sub-chart. The VSI feature enhances the performance of the multivariate synthetic control chart. The comparative results show that the VSI multivariate synthetic control chart performs better than other types of multivariate control charts for detecting shifts in the covariance matrix of a multivariate normally distributed process. An example is given to illustrate the operation of the VSI multivariate synthetic chart.     

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.     

Statistical quality control based on ranked set sampling

Different quality control charts for the sample mean are developed using ranked set sampling (RSS), and two of its modifications, namely median ranked set sampling (MRSS) and extreme ranked set sampling (ERSS). These new charts are compared to the usual control charts based on simple random sampling (SRS) data. The charts based on RSS or one of its modifications are shown to have smaller average run length (ARL) than the classical chart when there is a sustained shift in the process mean. The MRSS and ERSS methods are compared with RSS and SRS data, it turns out that MRSS dominates all other methods in terms of the out-of-control ARL performance. Real data are collected using the RSS, MRSS, and ERSS in cases of perfect and imperfect ranking. These data sets are used to construct the corresponding control charts. These charts are compared to usual SRS chart. Throughout this study we are assuming that the underlying distribution is normal. A check of the normality for our example data set indicated that the normality assumption is reasonable.     

On designing new optimal synthetic Tukey’s control charts

Tukey’s control chart is generally used for monitoring the processes where the measurement process physically damages the product. It is based on single observation and robust to outliers. In this paper, two optimal synthetic Tukey’s control charts are proposed by integrating the conforming run length chart with the Tukey’s control chart and its modification. The performance comparison of the proposed charts with the existing Tukey’s control charts is made by using out-of-control average run length and extra quadratic loss as performance metrics. The proposed charts offer better protection against the process shifts as compare to the existing Tukey’s control charts when the underlying process distribution is symmetric or asymmetric. Simulation studies also establish the supremacy of the proposed control charts over the existing Tukey’s control charts. In the end, an illustrative example based on a real data set of the combined cycle power plant is provided for practical implementation.     

Comparison of different control charts for a Weibull process with type-I censoring

Some control charts have been proposed to monitor the mean of a Weibull process with type-I censoring. One type of control charts is to monitor changes in the scale parameter because it indicates changes in the mean. With this approach, we compare different control charts such as Shewhart-type and exponentially weighted moving average (EWMA) charts based on conditional expected value (CEV) and cumulative sum (CUSUM) chart based on likelihood-ratio. A simulation approach is employed to compute control limits and average run lengths. The results show that the CUSUM chart has the best performance. However, the EWMA-CEV chart is recommendable for practitioners with its competitive performance and ease of use advantage. An illustrative example is also provided.     

One-sided synthetic control charts for monitoring the multivariate coefficient of variation

Shewhart's type control charts for monitoring the Multivariate Coefficient of Variation (MCV) have recently been proposed in order to monitor the relative variability compared with the mean. These approaches are known to be rather slow in the detection of small or moderate process shifts. In this paper, in order to improve the detection efficiency, two one-sided Synthetic charts for the MCV are proposed. A Markov chain method is used to evaluate the statistical performance of the proposed charts. Furthermore, computational experiments reveal that the proposed control charts outperform the Shewhart MCV control chart in terms of the average run length to detect an out-of-control state. Finally, the implementation of the proposed chart is illustrated with an example using steel sleeves data.     

Short run spc based upon the second order dynamic linear model for trend detection

Recently, several new applications of control chart procedures for short production runs have been introduced. Bothe (1989) and Burr (1989) proposed the use of control chart statistics which are obtained by scaling the quality characteristic by target values or process estimates of a location and scale parameter. The performance of these control charts can be significantly affected by the use of incorrect scaling parameters, resulting in either an excessive "false alarm rate," or insensitivity to the detection of moderate shifts in the process. To correct for these deficiencies, Quesenberry (1990, 1991) has developed the Q-Chart which is formed from running process estimates of the sample mean and variance. For the case where both the process mean and variance are unknown, the Q-chaxt statistic is formed from the standard inverse Z-transformation of a t-statistic. Q-charts do not perform correctly, however, in the presence of special cause disturbances at process startup. This has recently been supported by results published by Del Castillo and Montgomery (1992), who recommend the use of an alternative control chart procedure which is based upon a first-order adaptive Kalman filter model Consistent with the recommendations by Castillo and Montgomery, we propose an alternative short run control chart procedure which is based upon the second order dynamic linear model (DLM). The control chart is shown to be useful for the early detection of unwanted process trends. Model and control chart parameters are updated sequentially in a Bayesian estimation framework, providing the greatest degree of flexibility in the level of prior information which is incorporated into the model. The result is a weighted moving average control chart statistic which can be used to provide running estimates of process capability. The average run length performance of the control chart is compared to the optimal performance of the exponentially weighted moving average (EWMA) chart, as reported by Gan (1991). Using a simulation approach, the second order DLM control chart is shown to provide better overall performance than the EWMA for short production run applications     

On increasing the sensitivity of mixed EWMA–CUSUM control charts for location parameter

Control chart is an important statistical technique that is used to monitor the quality of a process. Shewhart control charts are used to detect larger disturbances in the process parameters, whereas cumulative sum (CUSUM) and exponential weighted moving average (EWMA) are meant for smaller and moderate changes. In this study, we enhanced mixed EWMA–CUSUM control charts with varying fast initial response (FIR) features and also with a runs rule of two out of three successive points that fall above the upper control limit. We investigate their run-length properties. The proposed control charting schemes are compared with the existing counterparts including classical CUSUM, classical EWMA, FIR CUSUM, FIR EWMA, mixed EWMA–CUSUM, 2/3 modified EWMA, and 2/3 CUSUM control charting schemes. A case study is presented for practical considerations using a real data set.     

A new double sampling control chart for monitoring process mean using auxiliary information

Statistical quality control charts have been widely accepted as a potentially powerful process monitoring tool because of their excellent speed in tracking shifts in the underlying process parameter(s). In recent studies, auxiliary-information-based (AIB) control charts have shown superior run length performances than those constructed without using it. In this paper, a new double sampling (DS) control chart is constructed whose plotting-statistics requires information on the study variable and on any correlated auxiliary variable for efficiently monitoring the process mean, namely AIB DS chart. The AIB DS chart also encompasses the classical DS chart. We discuss in detail the construction, optimal design, run length profiles, and the performance evaluations of the proposed chart. It turns out that the AIB DS chart performs uniformly better than the DS chart when detecting different kinds of shifts in the process mean. It is also more sensitive than the classical synthetic and AIB synthetic charts when detecting a particular shift in the process mean. Moreover, with some realistic beliefs, the proposed chart outperforms the exponentially weighted moving average chart. An illustrative example is also presented to explain the working and implementation of the proposed chart.     

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.