Cumulative sum (cusum) control schemes

Cumulative Sum (CUSUM) quality control schemes are becoming widely used i n industry because they are powerful, versatile, and easy to use. They cumulate recent process data to quickly detect out-of-control situations. They also serve as a powerful diagnostic tool. There are now more than 10,000 CUSUM control schemes in use daily in Du Pont. This paper describes design and implementation procedures for CUSUM control schemes with emphasison properties that are recorded as counts. The paper will describe recent developments which make CUSUM procedures more useful and more powerful.

The recent developments described are: Fast Initial Response (FIR) CUSUM which gives extra sensitivity to out-of-control situations at start up or after a(possiblyin effective)control action.

A Combined She whart-CUSUM which combines the key features

of CUSUM schemes and She whart Schemes by adding She whart Control Limits to a CUSUM scheme.

ROBUST CUSUM schemes which are no tunduly influenced by a few outliers or fliers occurring in the stream of data.

The philosophy of continual improvement of aprocessisvery compatible with CUSUM procedures.As CUSUM procedures give much more responsive control,a CUSUM signal does notmean that the process is producing bad product.Rather it means that action should be taken sothat the process does not produce bad product.     

A cusum test in the linear regression model with serially correlated disturbances

This paper considers a modified CUSUM test, suggested by Dufour (1982) for parameter instability and structural change with an unknown change point in a linear model with serially correlated disturbances, in which a preliminary estimate of the autoregressive coefficient for the error process is obtained, and used to transform the data. Then the standard CUSUM statistic is calculated on the transformed data. This paper derives the asymptotic distribution of the modified CUSUM test. We show that the modified CUSUM test retains its asymptotic significance level, i.e., the modified CUSUM test has the same asymptotic distribution as the CUSUM test with serially uncorrelated errors.     

EVVMA and cusum control charts in the presence of correlation

The statistical properties of control charts are usually evaluated under the assumption that the observations from the process are independent. For many processes however, observations which are closely spaced in time will be correlated. This paper considers EWMA and CUSUM control charts for the process mean when the observations are from an AR(1) process with additional random error. This simple model may be a reasonable model for many processes encountered in practice. The ARL and steady state ARL of the EWMA and CUSUM charts are evaluated numerically using an integral equation approach and a Markov chain approach. The numerical results show that correlation can have a significant effect on the properties of these charts. Tables are given to aid in the design of these charts when the observations follow the assumed model.     

Average run lengths for cusum control charts applied to residuals

A common approach to building control charts for autocorrelated data is to apply classical SPC to the residuals from a time series model of the process. However, Shewhart charts and even CUSUM charts are less sensitive to small shifts in the process mean when applied to residuals than when applied to independent data. Using an approximate analytical model, we show that the average run length of a CUSUM chart for residuals can be reduced substantially by modifying traditional chart design guidelines to account for the degree of autocorrelation in the data.     

Cumulative sum schemes for surgical performance monitoring

Summary.  The standard cumulative sum (CUSUM), risk-adjusted CUSUM and Shiryayev–Roberts schemes for monitoring surgical performance are compared. We find that both CUSUM schemes are comparable in run length performance except when there is a high heterogeneity of surgical risks, in which case the risk-adjusted CUSUM scheme is more sensitive in detecting a shift in surgical performance. The Shiryayev–Roberts scheme is found to be less sensitive compared with the CUSUM schemes in detecting a deterioration in surgical performance. Using the Markov chain method, the exact average run length of a standard CUSUM scheme can be computed whereas the average run length of a risk-adjusted CUSUM scheme is approximated. For a risk-adjusted CUSUM scheme, the accuracy of the average run length depends on the fineness of the discretization of CUSUM values, which relies on the chart limit, shift to be detected optimally and in-control surgical risk distribution. A sensitivity analysis shows that the risk-adjusted CUSUM and Shiryayev–Roberts schemes still perform moderately well in detecting a deterioration and an improvement in surgical performances respectively even though there is a misspecification of the in-control surgical risk distribution. In general, the run length performance of the Shiryayev–Roberts scheme is comparatively less sensitive to a misspecification of the in-control surgical risk distribution.     

CUSUM Chart with Transformed Exponential Data

Time Between Events (TBE) charts were proposed to monitor the time between events occur based on exponential distribution, and have been shown to be more effective than monitoring the fraction non conforming directly. In this article, we consider monitoring the TBE data with CUSUM scheme by transformation. The idea behind it is to transform the TBE data to normal, and then apply the CUSUM scheme for the approximate normal data. Several simple transformation methods are examined. The calculation of Average Run Length (ARL) with Markov chain approach is described. Comparative studies on the ARL performance show that the transformed CUSUM is superior to the X-MR (Moving Range) chart with transformation, the Cumulative Quantity Control (CQC) chart, and have comparable performance with exponential CUSUM charts. The design procedures of optimal CUSUM chart are also presented. This study provides another possible alternative for monitoring TBE data with easy design procedures and relatively good performance.     

Simulating the average run length for cusum schemes using variance reduction techniques

Some variance reduction techniques utilizing the total hazard are developed to estimate the average run lengths of the cumulative sum charts through simulation when the process follows a general probability distribution. Particularly, we propose the hazard estimator and the cycle estimator. Simulation results are shown for the exponential case and these estimators are compared with the raw simulation estimator. Applicability to multivariate CUSUM schemes is briefly discussed in the conclusion.     

A minimum cost exponential cusum test

A minimum cost CUSUM test for an event rate increase when inter-event times are exponentially distributed is presented. Optimal values of the test decision parameters, h and k, are developed from a renewal reward model of the event cycle by combining a non-linear optimization technique with an exact method for determining exponential average run lengths. Test robustness for event cycle parameter estimates and departures from the assumption of exponentially distributed inter-event times are discussed in the context of an injury monitoring scenario. Robustness to positively serially correlated observations emanating from EAR(1) and EMA(1) processes is also examined.     

CUSUM control schemes for Gaussian processes

A CUSUM control scheme for detecting a change point in a Gaussian process is derived. An upper and a lower bound for the distribution of the run length and for its moments is given. In a Monte Carlo study the average run length (ARL) of this chart is compared with the ARL of two other CUSUM procedures which are based on approximations to the sequential probability ratio, and, moreover, with EWMA schemes for autocorrelated data. Results on the optimal choice of the reference value are presented. Furthermore it is investigated how these charts behave if the model parameters are estimated.     

The random intrinsic fast initial response of one-sided CUSUM charts

This article analyses the performance of a one-sided cumulative sum (CUSUM) chart that is initialized using a random starting point following the natural or intrinsic probability distribution of the CUSUM statistic. By definition, this probability distribution remains stable as the chart is used. The probability that the chart starts at zero according to this intrinsic distribution is always smaller than one, which confers on the chart a fast initial response feature. The article provides a fast and accurate algorithm to compute the in-control and out-of-control average run lengths and run-length probability distributions for one-sided CUSUM charts initialized using this random intrinsic fast initial response (RIFIR) scheme. The algorithm also computes the intrinsic distribution of the CUSUM statistic and random samples extracted from this distribution. Most importantly, no matter how the chart was initialized, if no level shifts and no alarms have occurred before time τ?>?0, the distribution of the run length remaining after τ is provided by this algorithm very accurately, provided that τ is not too small.     

Data-analytic aspects of the Shiryayev-Roberts control chart: surveillance of a non-homogeneous Poisson process

The Shiryayev-Roberts control chart has been proposed as a powerful competitor of the Shewhart control chart and the CUSUM procedure, on theoretical grounds. We demonstrate here the application of a Shiryayev-Roberts control chart to a non-homogeneous Poisson process. We show that, from a data-analytic point of view, the Shiryayev-Roberts surveillance scheme has several advantages over classical CUSUM charts. A case study of power failure times in a computer centre is used to illustrate our main points.     

Parameter Change Test for Poisson Autoregressive Models

In this paper, we consider the problem of testing for a parameter change in Poisson autoregressive models. We suggest two types of cumulative sum (CUSUM) tests, namely, those based on estimates and residuals. We first demonstrate that the conditional maximum likelihood estimator (CMLE) is strongly consistent and asymptotically normal and then construct the CMLE‐based CUSUM test. It is shown that under regularity conditions, its limiting null distribution is a function of independent Brownian bridges. Next, we construct the residual‐based CUSUM test and derive its limiting null distribution. Simulation results are provided for illustration. A real‐data analysis is performed on data for polio incidence and campylobacteriosis infections.     

Dual Nonparametric CUSUM Control Chart Based on Ranks

In this article, we provide a sequential rank-based dual nonparametric CUSUM (DNC) control chart for detecting arbitrary magnitude of shifts in the location parameter. It is a self-starting scheme and thus can be used to monitor processes at the start-up stages. Moreover, we do not require any prior knowledge of the underlying distribution. A simulation study demonstrates that the proposed control chart not only performs robustly for different distributions, but also is efficient in detecting various magnitudes of shifts. An illustrative example is given to introduce the implementation of our proposed DNC control chart. It is easy to construct and fast to compute.     

Comments on zacks' recent paper on one-sided cusum procedures

The goal of this paper is to propose approximations for the cdf and the inverse cdf of the normal sample median. The presented methodology, which seems to not have been investigated before, suggests to fit the normal sample median distribution with a symmetrical Johnson S_U: distribution having ap-proximatively the same second and fourth moments. The results obtained with this approach, compared with the normal approximation, are very impressive, especially for the inverse cdf. One important application of the inverse cdf approximation of the normal sample median is the computation of accurate α‐level median/range control limits for any value of α (and not only for the popular value α = 0.0027). This paper can be also viewed as an homage to Professor N.L. Johnson's works by making a link between two of his major papers.     

Computation of the run-length percentiles of CUSUM control charts under changes in variances

In this paper, the run-length distributions of cumulative sum (CUSUM) charts for monitoring mean changes under normal distributions have been investigated thoroughly. However, there are few studies devoted to the analysis of the run-length distributions of CUSUM charts under changes in process variances. Motivated by this, this paper develops a fast and accurate algorithm based on piecewise collocation method for computing the run-length distributions of CUSUM scale charts. It is shown that the proposed method can provide more accurate approximation to the run-length distribution than the conventional Gauss-type quadrature-based methods applied to the CUSUM location charts. Some computational aspects for facilitating computation load are discussed, including the alternative formulation based on matrix decomposition and the geometric approximation to the distribution of large run lengths.     

Distribution-Free Exceedance CUSUM Control Charts for Location

Distribution-free (nonparametric) control charts can be useful to the quality practitioner when the underlying distribution is not known. A Phase II nonparametric cumulative sum (CUSUM) chart based on the exceedance statistics, called the exceedance CUSUM chart, is proposed here for detecting a shift in the unknown location parameter of a continuous distribution. The exceedance statistics can be more efficient than rank-based methods when the underlying distribution is heavy-tailed and/or right-skewed, which may be the case in some applications, particularly with certain lifetime data. Moreover, exceedance statistics can save testing time and resources as they can be applied as soon as a certain order statistic of the reference sample is available. Guidelines and recommendations are provided for the chart's design parameters along with an illustrative example. The in- and out-of-control performances of the chart are studied through extensive simulations on the basis of the average run-length (ARL), the standard deviation of run-length (SDRL), the median run-length (MDRL), and some percentiles of run-length. Further, a comparison with a number of existing control charts, including the parametric CUSUM chart and a recent nonparametric CUSUM chart based on the Wilcoxon rank-sum statistic, called the rank-sum CUSUM chart, is made. It is seen that the exceedance CUSUM chart performs well in many cases and thus can be a useful alternative chart in practice. A summary and some concluding remarks are given.     

Comparison of Confidence Intervals on Between Group Variance in Unbalanced Heteroscedastic One-Way Random Models

A computer algorithm for computing the alternative distributions of the Wilcoxon signed rank statistic under shift alternatives is discussed. An explicit error bound is derived for the numeric integration approximation to these distributions.

A nonparametric process control procedure in which the standard CUSUM procedure is applied to the Wilcoxon signed rank statistic is discussed. In order to implement this procedure, the distribution of the Wilcoxon statistic under shift of the underlying distribution from its point of symmetry needs to be computed. The average run length of the nonparametric and parametric CUSUM are compared.     

A HEWMA-CUSUM control chart for the Weibull distribution

The Weibull distribution is one of the most popular distributions for lifetime modeling. However, there has not been much research on control charts for a Weibull distribution. Shewhart control is known to be inefficient to detect a small shift in the process, while exponentially weighted moving average (EWMA) and cumulative sum control chart (CUSUM) charts have the ability to detect small changes in the process. To enhance the performance of a control chart for a Weibull distribution, we introduce a new control chart based on hybrid EWMA and CUSUM statistic, called the HEWMA-CUSUM chart. The performance of the proposed chart is compared with the existing chart in terms of the average run length (ARL). The proposed chart is found to be more sensitive than the existing chart in ARL. A simulation study is provided for illustration purposes. A real data is also applied to the proposed chart for practical use.     

A continuous sampling plan using CUSUMs

A Continuous Sampling Plan, CSP-CUSUM, is proposed based on the use of Cumulative Sums (CUSUMs) for deciding when to switch between the phases of sampling inspection and 100% inspection. The Geometric CUSUM, also termed the Run-length CUSUM, is chosen for this purpose, and two separate CUSUMs are to be operated, one for each inspection phase. The conventional measures of performance for CSPs such as average outgoing quality, average fraction inspected, and average proportion passed under sampling inspection are evaluated for CSP-CUSUM, and comparisons with some standard CSPs are presented. An additional performance-measure, Average Cycle Length, is proposed. A table is provided to aid the choice of parameters for the operation of CSP-CUSUM. It is recommended that a Geometric CUSUM control chart be maintained in parallel with CSP-CUSUM to detect significant upward shifts in the incoming fraction defective.