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.     

EWMA control charts for monitoring correlated counts with finite range

In this work, we develop and study upper and lower one-sided EWMA control charts for monitoring correlated counts with finite range. Often in practice, data of that kind can be adequately described by a first-order binomial or beta-binomial autoregressive model. Especially, when there is evidence that data demonstrate extra-binomial variation, the latter model is preferable than the former. The proposed charts can be used for detecting upward or downward shifts in process mean level. Practical guidelines concerning the statistical design of the proposed charts are given, while the effect of the extra-binomial variation is investigated as well. Comparisons with existing control charting procedures are also provided. Finally, an illustrative real-data example is also given.     

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.     

EWMA and DEWMA repetitive control charts under non-normal processes

In this paper, we present a repetitive sampling method to construct control charts using exponentially weighted moving averages (EWMA) and double exponentially weighted moving averages (DEWMA) to monitor shift in the process. For non-normal processes, t-distribution with various degrees of freedom (i.e. df=4,10,20,40,50) is used as symmetric distribution, gamma distribution with unit scale parameter and various shape parameters (i.e. 0.5,1,2,3,4) is used as positively skewed distribution and Weibull distribution with unit scale parameter and various shape parameters (i.e. 10 and 20) is used as negatively skewed distribution. We use Monte Carlo simulations to check whether the process is out of control. We use average run length as a tool to find the ability of proposed control charts to identify a shift earlier in a process, as compared to other control charts currently used to monitor the same type of process. The proposed control charts are applied to two real datasets.KEYWORDS: Control charts, EWMA statistic, DEWMA statistic, t distribution, gamma distribution, Weibull distribution     

The economic design of multivariate binomial EWMA VSSI control charts

Since multi-attribute control charts have received little attention compared with multivariate variable control charts, this research is concerned with developing a new methodology to employ the multivariate exponentially weighted moving average (MEWMA) charts for m-attribute binomial processes; the attributes being the number of nonconforming items. Moreover, since the variable sample size and sampling interval (VSSI) MEWMA charts detect small process mean shifts faster than the traditional MEWMA, an economic design of the VSSI MEWMA chart is proposed to obtain the optimum design parameters of the chart. The sample size, the sampling interval, and the warning/action limit coefficients are obtained using a genetic algorithm such that the expected total cost per hour is minimized. At the end, a sensitivity analysis has been carried out to investigate the effects of the cost and the model parameters on the solution of the economic design of the VSSI MEWMA chart.     

One-sided EWMA control charts for monitoring Poisson processes with varying sample sizes

ABSTRACT

Recently considerable research has been devoted to monitoring increases of incidence rate of adverse rare events. This paper extends some one-sided upper exponentially weighted moving average (EWMA) control charts from monitoring normal means to monitoring Poisson rate when sample sizes are varying over time. The approximated average run length bounds are derived for these EWMA-type charts and compared with the EWMA chart previously studied. Extensive simulations have been conducted to compare the performance of these EWMA-type charts. An illustrative example is given.     

An economic statistical design of the Poisson EWMA control charts for monitoring nonconformities

An economic statistical model of the exponentially weighted moving average (EWMA) control chart for the average number of nonconformities in the sample is proposed. The statistical and economic performance of proposed design are evaluated using the average run length (ARL) and the hourly expected cost, respectively. A Markov chain approach is applied to derive expressions for ARL. The cost model is established based on the general cost function given in Lorenzen and Vance [The economic design of control charts: a unified approach. Technometrics. 1986;28:3–11]. An example is provided to illustrate the application of the proposed model. A sensitivity analysis is also carried out to investigate the effects of model parameters on the solution of the economic statistical design by using the design of experiments (DOE) technique.     

A gradient approach to efficient design and analysis of multivariate EWMA control charts

Compared to the grid search approach to optimal design of control charts, the gradient-based approach is more computationally efficient as the gradient information indicates the direction to search the optimal design parameters. However, the optimal parameters of multivariate exponentially weighted moving average (MEWMA) control charts are often obtained by using grid search in the existing literature. Note that the average run length (ARL) performance of the MEWMA chart can be calculated based on a Markov chain model, making it feasible to estimate the ARL gradient from it. Motivated by this, this paper develops an ARL gradient-based approach for the optimal design and sensitivity analysis of MEWMA control charts. It is shown that the proposed method is able to provide a fast, accurate, and easy-to-implement algorithm for the design and analysis of MEWMA charts, as compared to the conventional design approach based on grid search.     

Detecting mean increases in Poisson INAR(1) processes with EWMA control charts

Processes of serially dependent Poisson counts are commonly observed in real-world applications and can often be modeled by the first-order integer-valued autoregressive (INAR) model. For detecting positive shifts in the mean of a Poisson INAR(1) process, we propose the one-sided s exponentially weighted moving average (EWMA) control chart, which is based on a new type of rounding operation. The s-EWMA chart allows computing average run length (ARLs) exactly and efficiently with a Markov chain approach. Using an implementation of this procedure for ARL computation, the s-EWMA chart is easily designed, which is demonstrated with a real-data example. Based on an extensive study of ARLs, the out-of-control performance of the chart is analyzed and compared with that of a c chart and a one-sided cumulative sum (CUSUM) chart. We also investigate the robustness of the chart against departures from the assumed Poisson marginal distribution.     

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.     

Double-sampling control charts for attributes

In this article, we propose a double-sampling (DS) np control chart. We assume that the time interval between samples is fixed. The choice of the design parameters of the proposed chart and also comparisons between charts are based on statistical properties, such as the average number of samples until a signal. The optimal design parameters of the proposed control chart are obtained. During the optimization procedure, constraints are imposed on the in-control average sample size and on the in-control average run length. In this way, required statistical properties can be assured. Varying some input parameters, the proposed DS np chart is compared with the single-sampling np chart, variable sample size np chart, CUSUM np and EWMA np charts. The comparisons are carried out considering the optimal design for each chart. For the ranges of parameters considered, the DS scheme is the fastest one for the detection of increases of 100% or more in the fraction non-conforming and, moreover, the DS np chart is easy to operate.     

Loss-based optimal control statistics for control charts

This work proposes a means for interconnecting optimal sample statistics with parameters of the process output distribution irrespective of the specific way in which these parameters change during transition to the out-of-control state (jumps, trends, cycles, etc). The approach, based on minimization of the loss incurred by the two types of decision errors, leads to a unique sample statistic and, therefore, to a single control chart. The optimal sample statistics are obtained as a solution of the developed optional boundary equation. The paper demonstrates that, for particular conditions, this equation leads to the same statistics as are obtained through the Neyman-Pearson fundamental lemma. Application examples of the approach when the process output distribution is Gamma and Weibull are given. A special loss function representing out-of-control state detection as a pattern recognition problem is presented.     

Runs tests for group control charts

When a process consists of several identical streams that are not highly correlated, an alternative to using separate control charts for each stream is to use a group control chart. Rather than plotting sample means from each stream at any time point, one could plot only the largest and/or smallest sample mean from among all the streams. Using the theory of stochastic processes and majorization together with numerical methods, the properties of a test that signals if r consecutive extreme values come from the same stream are examined. Both one and two-sided cases are considered. Average run lengths (ARL's), the least favorable configuration of the stream (population) means, and sample sizes necessary to have specified in-control and out-of-control ARL's are obtained. A test that signals if r-1 out of r consecutive extreme values come from the same stream is also considered     

Parametric control charts

Standard control charts are based on the assumption that the observations are normally distributed. In practice, normality often fails and consequently the false alarm rate is seriously in error. Application of a nonparametric approach is only possible with many Phase I observations. Since nowadays such very large sample sizes are usually not available, there is need for an intermediate approach by considering a larger parametric model containing the normal family as a submodel. In this paper control limits are presented in such a larger parametric model, the so called normal power family. Correction terms are derived, taking into account that the parameters are estimated. Simulation results show that the control limits are accurate, not only in the considered parametric family, but also for common distributions outside the parametric family, thus covering a broad class of distributions.     

Exceedance probabilities for parametric control charts

Common control charts assume normality and known parameters. Quite often, these assumptions are not valid and large relative errors result in the usual performance characteristics such as the false alarm rate or the average run length. A fully nonparametric approach can form an attractive alternative but requires more Phase I observations than usually available. Sufficiently general parametric families then provide realistic intermediate models. In this article, the performance of charts based on such families is considered. Exceedance probabilities of the resulting stochastic performance characteristics during in-control are studied. Corrections are derived to ensure that such probabilities stay within prescribed bounds. Attention is also devoted to the impact of the corrections for an out-of-control process. Simulations are presented both to illustrate and to demonstrate that the approximations obtained are sufficiently accurate for practical usage.     

EWMA charts: ARL considerations in case of changes in location and scale

Widely spread tools within the area of Statistical Process Control are control charts of various designs. Control chart applications are used to keep process parameters (e.g., mean \(\mu \) , standard deviation \(\sigma \) or percent defective \(p\) ) under surveillance so that a certain level of process quality can be assured. Well-established schemes such as exponentially weighted moving average charts (EWMA), cumulative sum charts or the classical Shewhart charts are frequently treated in theory and practice. Since Shewhart introduced a \(p\) chart (for attribute data), the question of controlling the percent defective was rarely a subject of an analysis, while several extensions were made using more advanced schemes (e.g., EWMA) to monitor effects on parameter deteriorations. Here, performance comparisons between a newly designed EWMA \(p\) control chart for application to continuous types of data, \(p=f(\mu ,\sigma )\) , and popular EWMA designs ( \(\bar{X}\) , \(\bar{X}\) - \(S^2\) ) are presented. Thus, isolines of the average run length are introduced for each scheme taking both changes in mean and standard deviation into account. Adequate extensions of the classical EWMA designs are used to make these specific comparisons feasible. The results presented are computed by using numerical methods.     

Minimum control charts

Standard control charts are very sensitive to estimation effects and/or deviations from normality. Hence a program has been carried out to remedy these problems. This is quite adequate in most circumstances, but not in all. In the present paper, the remaining complication is attacked: what to do if a nonparametric approach is indicated, but too few control observations are available for the estimation step? It is shown that grouping the observations during the monitoring phase works well. Surprisingly, rather than using the group averages, it is definitely preferable to compare the minimum for each group to a suitably chosen upper control limit. (And in the two-sided case, also the maximum to an analogous lower control limit.) This ‘minimum control chart’ is demonstrated to be quite attractive: it is easy to explain and to implement. Moreover, while it is truly nonparametric, its power of detection is comparable to that of the customary, normality assuming, charts based on averages.     

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.