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.     

The Variable Sampling Interval (VSI) in an Analysis of Taguchi's On-line Quality Monitoring Procedure for Variables

The procedure of on-line process control for variables proposed by Taguchi consists of inspecting the mth item (a single item) of every m items produced and deciding, at each inspection, whether the mean value is increased or not. If the value of the monitored statistic is outside of the control limits, one decides the process is out-of-control and the production is stopped for adjustment; otherwise, it continues. In this article, a variable sampling interval (with a longer L and a shorter m ≤ L) chart with two set of limits is used. These limits are the warning (±W) and the control (±C), where W ≤ C. The process is stopped for adjustment when an observation falls outside of the control limits or a sequence of h observations falls between the warning limits and the control limits. The longer sample interval is used after an adjustment or when an observation falls inside the warning limits; otherwise, the short sampling interval is used. The properties of an ergodic Markov chain are used to evaluate the time (in units) that the process remains in-control and out-of-control, with the aim of building an economic–statistical model. The parameters (the sampling intervals m and L, the control limits W and C and the length of run h) are optimized by minimizing the cost function with constraints on the average run lengths (ARLs) and the conformity fraction. The performance of the current proposal is more economical than the decision taken based on a sequence of length h = 1, L = m, and W = C, which is the model employed in earlier studies. A numerical example illustrates the proposed procedure.     

A new economic scheme for CCC charts with run rules based on average number of inspected items

New statistical techniques and procedures have been developed to control high-yield processes along with looking for process improvement opportunities and minimizing production cost. Cumulative count of conforming control chart is generally a technique for high-quality processes, when nonconforming items are rarely produced. The objective of this study is to design control chart based on cumulative count of conforming items and run rules that develops an economic model based on the average number of inspected items to design m-of-m CCC chart in order to facilitate minimum average cost per item produced. The optimal design parameters for different values of nonconforming fraction and different cost parameters in each scenario are determined. Finally, to analyze the behavior of optimal economic solutions, sensitivity analysis of the model parameters is performed.     

A New Acceptance Sampling Policy Based on Number of Successive Conforming Items

In an acceptance-sampling plan, where items of an incoming batch of products are inspected one by one, if the number of conforming items between successive non conforming items falls below a lower control threshold, the batch is rejected. If it falls above an upper control threshold, the batch is accepted, and if it lies within the thresholds then the process of inspecting the items continues. The purpose of this article is to develop an optimization model to determine the optimum values of the thresholds such that constraints on the probability of Type I and Type II errors are satisfied. This article starts by developing a Markovian model to derive the expected total cost of the inspection problem containing the costs of acceptance, rejection, and inspection. Then, the optimum values of the thresholds are selected in order to minimize the expected cost. To demonstrate the application of the proposed methodology, perform sensitivity analysis, and compare the performance of the proposed procedure to the one of another method, a numerical example is given at the end and the results are reported.     

An investigation of the effects of inspection errors on the run-length control charts

For continuous inspection schemes in an automated manufacturing environment, a useful alternative to the traditional p or np chart is the Run-Length control chart, which is based on plotting the run lengths (the number of conforming items) between successive nonconforming items. However, its establishment relies on the error-free inspection assumption, which can seldom be met in practice. In this paper, the effects of inspection errors on the Run-Length chart are investigated based on that these errors are assumed known. The actual false alarm probability and the average number inspected (ANI) in the presence of inspection errors are studied. This paper also presents the adjusted control limits for the Run-Length chart, which can provide much closer ANI curves to the ones obtained under error-free inspection.     

An optimization model for economic design of sampling plans based on conforming run length considering outgoing quality

In this article, a new economical acceptance sampling model is proposed based on Taguchi loss function. The objective function of the model consists of inspection cost, scrap cost, and Taguchi loss function including producer loss and consumer loss. The expected total cost includes the loss for an inspected item plus the loss for an accepted item which has not been inspected. Decision-making is based on conforming run length. It is assumed that the quality characteristics follow normal distribution. A numerical example is solved for illustrating application of this model. Sensitivity analysis is proposed for illustrating the effect of some important parameters on the objective function. Finally, we compared the results of the proposed method with classical Dodge–Romig sampling plans tables based on average outgoing quality limit. The results confirmed the superiority of proposed model.     

Economic design of quick switching sampling system for resubmitted lots

This paper proposes a quick switching sampling system for the inspection of attributes quality characteristics for resubmitted lots. The optimal parameters for both fraction non conforming items and fraction non conformities of the proposed sampling system are determined using an optimization procedure so that producer’s risk and consumer’s risk are simultaneously satisfied. Tables are also constructed for the selection of parameters for specified AQL and LQL. The advantage of the proposed plan over the existing plan is discussed and illustrate. An economic design of the proposed sampling system is also discussed and shown that the proposed sampling system has minimum total cost and average total inspection compared to other existing sampling plans.     

A new policy for designing acceptance sampling plan based on Bayesian inference in the presence of inspection errors

The purpose of this article is to present a new policy for designing an acceptance sampling plan based on the minimum proportion of the lot that should be inspected in the presence of inspection errors. It is assumed that inspection is not perfect and every defective item cannot be detected with complete certainty. The Bayesian method is used for obtaining the probability distribution function of the number of defective items in the lot. To design this model, two constraints of producer risk and consumer risk are considered during the inspection process by using two specified points on operating characteristic curve. In order to illustrate the application of the proposed model, an example is presented. In addition, a sensitivity analysis is performed to analyze the model performance under different scenarios of process parameters and the results are elaborated. Finally, the efficiency of the proposed model is compared with the sampling method of Spencer and Kevan de Lopez (2017) at the same conditions.     

Dodge-Romig AOQL single sampling plans for inspection by variables

Acceptance sampling plans for inspection by variables, which minimize the mean inspection cost per lot of process average quality (assuming that the remainder of rejected lots is inspected), are derived under the condition that the maximum value of the mean fraction defective after sampling inspection, replacing all defective items found by good ones, shall be equal top _L . These plans are tabulated for chosen values of the given parameters, and compared with the Dodge-Romig AOQL attribute sampling plans. From the comparison it follows that under the same protection of consumer the AOQL plans for inspection by variables are in some situations more economical than the corresponding Dodge-Romig plans.     

Bayes and Empirical Bayes Two-Stage Procedures for Sampling Inspection

A batch of M items is inspected for defectives. Suppose there are d defective items in the batch. Let d ₀ be a given standard used to evaluate the quality of the population where 0 < d ₀ < M. The problem of testing H ₀: d < d ₀ versus H ₁: d ≥ d ₀ is considered. It is assumed that past observations are available when the current testing problem is considered. Accordingly, the empirical Bayes approach is employed. By using information obtained from the past data, an empirical Bayes two-stage testing procedure is developed. The associated asymptotic optimality is investigated. It is proved that the rate of convergence of the empirical Bayes two-stage testing procedure is of order O (exp(? c? n)), for some constant c? > 0, where n is the number of past observations at hand.     

Asymptotic Distribution for Symmetric Spacing Statistics

A new procedure for testing the H ₀: μ₁ = ··· = μ _k against the alternative H _u :μ₁ ≥ ··· ≥μ _r  ≤ ··· ≤ μ _k with at least one strict inequality, where μ _i is the location parameter of the ith two-parameter exponential distribution, i = 1,…, k, is proposed. Exact critical constants are computed using a recursive integration algorithm. Tables containing these critical constants are provided to facilitate the implementation of the proposed test procedure. Simultaneous confidence intervals for certain contrasts of the location parameters are derived by inverting the proposed test statistic. In comparison to existing tests, it is shown, by a simulation study, that the new test statistic is more powerful in detecting U-shaped alternatives when the samples are derived from exponential distributions. As an extension, the use of the critical constants for comparing Pareto distribution parameters is discussed.     

Study of a Markov model for a high-quality dependent process

For high-quality processes, non-conforming items are seldom observed and the traditional p (or np) charts are not suitable for monitoring the state of the process. A type of chart based on the count of cumulative conforming items has recently been introduced and it is especially useful for automatically collected one-at-a-time data. However, in such a case, it is common that the process characteristics become dependent as items produced one after another are inspected. In this paper, we study the problem of process monitoring when the process is of high quality and measurement values possess a certain serial dependence. The problem of assuming independence is examined and a Markov model for this type of process is studied, upon which suitable control procedures can be developed.     

A note on some modified Pulak and Al-Sultan's model

Pulak and Al-Sultan presented a rectifying inspection plan applying in the determination of optimum process mean. However, they did not point out whether the non-conforming items in the sample of accepted lot are replaced or eliminated from the lot and neglected the quality loss within specification limits. In this paper, we further propose the modified Pulak and Al-Sultan model with quadratic quality loss function. There are four cases considered in the modified model: (1) the non-conforming items in the sample of accepted lot are neither replaced nor eliminated from the lot; (2) the non-conforming items in the sample of accepted lot are not replaced but are eliminated from the lot; (3) the non-conforming items in the sample of accepted lot are replaced by conforming ones; (4) the non-conforming items in the sample of accepted lot are replaced by non-inspected items. The numerical results and sensitivity analysis of parameters show that their solutions are slightly different.     

Inferences in dichotomous classifications with misclassifications based on sequential repetitive classifications

To create inferences in dichotomous classifications with misclassifications and possibly perform repeated classifications, the maximum likelihood method is commonly used, mainly because of its efficiency in obtaining parameter estimators of a mixture of two binomial distributions. One simpler alternative that is operationally easier is to consider the simple majority method. In this method, each of n items are classified r times as conforming or non-conforming. The final classification of the item is determined by the most frequent class. This method yielded lower mean squared errors than the maximum likelihood and the moments estimators and is asymptotically efficient. In this paper, we introduce a new approach in which the realization of all r repeated classifications of each item may not be needed. Each of n items is sequentially classified as conforming or nonconforming, and the process ceases when the frequency of conforming or non-conforming classification reaches the integer a. We show that, by a Monte Carlo simulation, the last procedure presents a lower mean squared error than the simple majority results for a similar number of r repeated classifications.     

Lot Sampling Distributions for Bounded Number of Nonconformities

Attributes sampling is an important inspection tool in areas like product quality control, service quality control or auditing. The classical item quality scheme of attributes sampling distinguishes between conforming and nonconforming items, and measures lot quality by the lot fraction nonconforming. A more refined quality scheme rates item quality by the number of nonconformities occurring on the item, e.g., the number of defective components in a composite product or the number of erroneous entries in an accounting record, where lot quality is measured by the average number of nonconformities occurring on items in the lot. Statistical models of sampling for nonconformities rest on the idealizing assumption that the number of nonconformities on an item is unbounded. In most real cases, however, the number of nonconformities on an item has an upper bound, e.g., the number of product components or the number of entries in an accounting record. The present study develops two statistical models of sampling lots for nonconformities in the presence of an upper bound a for the number of nonconformities on each single item. For both models, the statistical properties of the sample statistics and the operating characteristics of single sampling plans are investigated. A broad numerical study compares single sampling plans with prescribed statistical properties under the bounded and unbounded quality schemes. In a large number of cases, the sample sizes for the realistic bounded models are smaller than the sample sizes for the idealizing unbounded model.     

The Likelihood Ratio Test with the Box–Cox Transformation for the Normal Mixture Problem: Power and Sample Size Study

Abstract

Through simulation and regression, we study the alternative distribution of the likelihood ratio test in which the null hypothesis postulates that the data are from a normal distribution after a restricted Box–Cox transformation and the alternative hypothesis postulates that they are from a mixture of two normals after a restricted (possibly different) Box–Cox transformation. The number of observations in the sample is called N. The standardized distance between components (after transformation) is D = (μ₂ ? μ₁)/σ, where μ₁ and μ₂ are the component means and σ² is their common variance. One component contains the fraction π of observed, and the other 1 ? π. The simulation results demonstrate a dependence of power on the mixing proportion, with power decreasing as the mixing proportion differs from 0.5. The alternative distribution appears to be a non-central chi-squared with approximately 2.48 + 10N ^?0.75 degrees of freedom and non-centrality parameter 0.174N(D ? 1.4)² × [π(1 ? π)]. At least 900 observations are needed to have power 95% for a 5% test when D = 2. For fixed values of D, power, and significance level, substantially more observations are necessary when π ≥ 0.90 or π ≤ 0.10. We give the estimated powers for the alternatives studied and a table of sample sizes needed for 50%, 80%, 90%, and 95% power.     

Dorfman-sterrett screening (group testing) schemes and the effects of faulty inspection

The Dorfman screening procedure is based on first testing a group of items as a whole, proceeding to individual testing only if the group-test indicates existence of at least one nonconforming item. A modification suggested by Sterrett allows for reintroduct-ion of group testing of all items, not yet tested individually, when an item is classified as nonconforming by an individual test. Effects of faulty test inspection on the properties of the modified procedures are studied.     

Bounds for Expectations of Differences of Generalized Order Statistics Based on General and Life Distributions

Let X _? ^(r), r ≥ 1, denote generalized order statistics based on an arbitrary distribution function F with finite pth absolute moment for some 1 ≤ p ≤ ∞. We present sharp upper bounds on E(X _? ^(s) ? X _? ^(r)), 1 ≤ r < s, for F being either general or life distribution. The bounds are expressed in various scale units generated by pth central absolute or raw moments of F, respectively. The distributions achieving the bounds are specified.     

Dependence Structure of Spacings of Order Statistics

Let X_1:n ≤ X_2:n ≤···≤ X_n:n denote the order statistics of a sample of n independent random variables X₁, X₂,…, X_n, all identically distributed as some X. It is shown that if X has a log-convex [log-concave] density function, then the general spacing vector (X_k1:n, X_k2:n ? X_k1:n,…, X_kr:n ? X_kr?1:n) is MTP₂ [S-MRR₂] whenever 1 ≤ k₁ < k₂ <···< k_r ≤ n and 1 ≤ r ≤ n. Multivariate likelihood ratio ordering of such general spacing vectors corresponding to two random samples is also considered. These extend some of the results in the literature for usual spacing vectors.     

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.