Nonparametric quality control charts based on the sign statistic

Nonparametric control chart are presented for the problem of detecting changes in the process median (or mean), or changes in the process variability when samples are taken at regular time intervals. The proposed procedures are based on sign-test statistics computed for each sample, and are used in Shewhart and cumulative sum control charts. When the process is in control the run length distributions for the proposed nonparametric control charts do not depend on the distribution of the observations. An additional advantage of the non-parametric control charts is that the variance of the process does not need to be established in order to set up a control chart for the mean. Comparisons with the corresponding parametric control charts are presented. It is also shown that curtailed sampling plans can considerably reduce the expected number of observations used in the Shewhart control schemes based on the sign statistic.     

A new approach for monitoring process variance

ABSTRACT

Control charts are effective tools for signal detection in both manufacturing processes and service processes. Much service data come from a process with variables having non-normal or unknown distributions. The commonly used Shewhart variable control charts, which depend heavily on the normality assumption, should not be properly used in such circumstances. In this paper, we propose a new variance chart based on a simple statistic to monitor process variance shifts. We explore the sampling properties of the new monitoring statistic and calculate the average run lengths (ARLs) of the proposed variance chart. Furthermore, an arcsine transformed exponentially weighted moving average (EWMA) chart is proposed because the ARLs of this modified chart are more intuitive and reasonable than those of the variance chart. We compare the out-of-control variance detection performance of the proposed variance chart with that of the non-parametric Mood variance (NP-M) chart with runs rules, developed by Zombade and Ghute [Nonparametric control chart for variability using runs rules. Experiment. 2014;24(4):1683–1691], and the nonparametric likelihood ratio-based distribution-free exponential weighted moving average (NLE) chart and the combination of traditional exponential weighted moving average (EWMA) mean and EWMA variance (CEW) control chart proposed by Zou and Tsung [Likelihood ratio-based distribution-free EWMA control charts. J Qual Technol. 2010;42(2):174–196] by considering cases in which the critical quality characteristic has a normal, a double exponential or a uniform distribution. Comparison results showed that the proposed chart performs better than the NP-M with runs rules, and the NLE and CEW control charts. A numerical example of service times with a right-skewed distribution from a service system of a bank branch in Taiwan is used to illustrate the application of the proposed variance chart and of the arcsine transformed EWMA chart and to compare them with three existing variance (or standard deviation) charts. The proposed charts show better detection performance than those three existing variance charts in monitoring and detecting shifts in the process variance.     

The monitoring of simple linear regression profiles with two observations per sample

We evaluate and compare the performance of Phase II simple linear regression profile approaches when only two observations are used to establish each profile. We propose an EWMA control chart based on average squared deviations from the in-control line, to be used in conjunction with two EWMA control charts based on the slope and Y-intercept estimators, to monitor changes in the three regression model parameters, i.e., the slope, intercept and variance. Simulations establish that the performance of the proposed technique is generally better than that of other approaches in detecting parameter shifts.     

Multivariate Control Charts Based on Hybrid Novelty Scores

We propose a new nonparametric multivariate control chart that integrates a novelty score. The proposed control chart uses as its monitoring statistic a hybrid novelty score, calculated based on the distance to local observations as well as on the distance to the convex hull constructed by its neighbors. The control limits of the proposed control chart were established based on a bootstrap method. A rigorous simulation study was conducted to examine the properties of the proposed control chart under various scenarios and compare it with existing multivariate control charts in terms of average run length (ARL) performance. The simulation results showed that the proposed control chart outperformed both the parametric and nonparametric Hotelling's T ² control charts, especially in nonnormal situations. Moreover, experimental results with real semiconductor data demonstrated the applicability and effectiveness of the proposed control chart. To increase the capability to detect small mean shift, we propose an exponentially weighted hybrid novelty score control chart. Simulation results indicated that exponentially weighted hybrid score charts outperformed the hybrid novelty score based control charts.     

Analysis of means using ranks for the randomized complete block design

A nonparametric test procedure is proposed for the analysis of randomized complete block designs. Such a procedure may be carried out graphically in the form of a Shewhart control chart. Exact and asymptotic critical values are given for the implementation of the proposed procedure. A Monte Carlo study is made to compare the powers of the proposed procedure to those of analysis of variance, the analysis of means, and the Friedman procedures. Results of the study indicate that the proposed procedure has superior power performance when testing against slippage alternative hypotheses under heavy-tailed distributions such as the Cauchy distribution. However, when testing against symmetric alternatives under light-tailed distributions, the proposed procedure does not perform well     

The Generally Weighted Moving Average Variance Chart

This article extends the generally weighted moving average (GWMA) technique for detecting changes in process variance. The proposed chart is called the generally weighted moving average variance (GWMAV) chart. Simulation is employed to evaluate the average run length (ARL) characteristics of the GWMAV and EWMA control charts. An extensive comparison of these control charts reveals that the GWMAV chart is more sensitive than the EWMA control charts for detecting small shifts in the variance of a process when the shifts are below 1.35 standard deviations. Additionally, the GWMAV control chart performs little better when the variance shifts are between 1.35 and 1.5 standard deviation, and the 2 charts performs similar when the variance shifts are above 1.5 standard deviation. The design of the GWMAV chart is also discussed.     

Data driven choice of control charts

Standard control charts are often seriously in error when the distributional form of the observations differs from normality. Recently, control charts have been developed for larger parametric families. A third possibility is to apply a suitable (modified version of a) nonparametric control chart. This paper deals with the question when to switch from the control chart based on normality to a parametric control chart, or even to a nonparametric one. This model selection problem is solved by using the estimated model error as yardstick. It is shown that the new combined control chart asymptotically behaves as each of the specific control charts in their own domain. Simulations exhibit that the combined control chart performs very well under a great variety of distributions and hence it is recommended as an omnibus control chart, nicely adapted to the distribution at hand. The combined control chart is illustrated by an application on real data. The new modified nonparametric control chart is an attractive alternative and can be recommended as well.     

A Phase I nonparametric Shewhart-type control chart based on the median

A nonparametric Shewhart-type control chart is proposed for monitoring the location of a continuous variable in a Phase I process control setting. The chart is based on the pooled median of the available Phase I samples and the charting statistics are the counts (number of observations) in each sample that are less than the pooled median. An exact expression for the false alarm probability (FAP) is given in terms of the multivariate hypergeometric distribution and this is used to provide tables for the control limits for a specified nominal FAP value (of 0.01, 0.05 and 0.10, respectively) and for some values of the sample size (n) and the number of Phase I samples (m). Some approximations are discussed in terms of the univariate hypergeometric and the normal distributions. A simulation study shows that the proposed chart performs as well as, and in some cases better than, an existing Shewhart-type chart based on the normal distribution. Numerical examples are given to demonstrate the implementation of the new chart.     

A new distribution-free control scheme based on order statistics

We establish a class of nonparametric Shewhart-type control charts based on a reference sample drawn from the process. The proposed nonparametric control chart takes advantage of the location of two different order statistics of the reference and test sample respectively. The decision rule of the new monitoring scheme is filled out by the number of test observations that are located between the control limits. The general setup of the new class of control charts is presented in detail, while the operating characteristic function is studied for both in- and out-of-control processes. Closed formulae for the evaluation of the alarm rate and the average run length are concluded for plausible shift in the underlying distribution to Lehmann alternatives. Several numerical results, displayed for the new family of nonparametric control charts, depict that the proposed control scheme attains competitive performance.     

Progressive Variance Control Charts for Monitoring Process Dispersion

In a process, the deviation from location or scale parameters affects the quality of the process and waste resources. So it is essential to monitor such processes for possible changes due to any assignable causes. Control charts are the most famous tool used to meet this intention. It is useless to monitor process location until the assurance that process dispersion is in-control. This study proposes some new two-sided memory control charts named as progressive variance (PV) control charts which are based on sample variance to monitor changes in process dispersion assuming normality of quality characteristic to be monitored. Simulation studies are made, and an example is discussed to evaluate the performance of the proposed charts. The comparison of the proposed chart is made with exponentially weighted moving average- and cumulative sum-type charts for process dispersion. The study shows that performance of the proposed charts are uniformly better than its competitors for detecting positive shifts while for detecting negative shift in the variance their performance is better for small shifts and reasonably good for moderated shifts.     

Bootstrap-Based T 2 Multivariate Control Charts

Control charts have been used effectively for years to monitor processes and detect abnormal behaviors. However, most control charts require a specific distribution to establish their control limits. The bootstrap method is a nonparametric technique that does not rely on the assumption of a parametric distribution of the observed data. Although the bootstrap technique has been used to develop univariate control charts to monitor a single process, no effort has been made to integrate the effectiveness of the bootstrap technique with multivariate control charts. In the present study, we propose a bootstrap-based multivariate T ² control chart that can efficiently monitor a process when the distribution of observed data is nonnormal or unknown. A simulation study was conducted to evaluate the performance of the proposed control chart and compare it with a traditional Hotelling's T ² control chart and the kernel density estimation (KDE)-based T ² control chart. The results showed that the proposed chart performed better than the traditional T ² control chart and performed comparably with the KDE-based T ² control chart. Furthermore, we present a case study to demonstrate the applicability of the proposed control chart to real situations.     

Dimension reduction for the conditional mean and variance functions in time series

This paper deals with the nonparametric estimation of the mean and variance functions of univariate time series data. We propose a nonparametric dimension reduction technique for both mean and variance functions of time series. This method does not require any model specification and instead we seek directions in both the mean and variance functions such that the conditional distribution of the current observation given the vector of past observations is the same as that of the current observation given a few linear combinations of the past observations without loss of inferential information. The directions of the mean and variance functions are estimated by maximizing the Kullback–Leibler distance function. The consistency of the proposed estimators is established. A computational procedure is introduced to detect lags of the conditional mean and variance functions in practice. Numerical examples and simulation studies are performed to illustrate and evaluate the performance of the proposed estimators.     

An adaptive exponentially weighted moving average control chart for monitoring process variances

The exponentially weighted moving average (EWMA) control chart is efficient in detecting small changes in process parameters but less efficient when the changes are relatively large, due to what is known as the inertia problem. To diminish the inertia, an adaptive EWMA (AEWMA) chart has been proposed for monitoring process locations to improve over the traditional EWMA charts. The basic idea of the AEWMA scheme is to dynamically weight the past observations according to a suitable function of the current prediction error. This article extends the idea of the AEWMA chart for monitoring process locations to the case of monitoring process dispersion. A Markov chain model is established to analyze and design the suggested chart. It is shown that the AEWMA dispersion chart performs better than the EWMA and other dispersion charts in terms of its ability to perform relatively well at both small and large changes in process dispersion.     

Univariate fast initial response statistical process control with taut strings

We present a novel real-time univariate monitoring scheme for detecting a sustained departure of a process mean from some given standard assuming a constant variance. Our proposed stopping rule is based on the total variation of a nonparametric taut string estimator of the process mean and is designed to provide a desired average run length for an in-control situation. Compared to the more prominent CUSUM fast initial response (FIR) methodology and allowing for a restart following a false alarm, the proposed two-sided taut string (TS) scheme produces a significant reduction in average run length for a wide range of changes in the mean that occur at or immediately after process monitoring begins. A decision rule for when to choose our proposed TS chart compared to the CUSUM FIR chart that takes into account both false alarm rate and average run length to detect a shift in the mean is proposed and implemented. Supplementary materials are available online.     

ARL Performance of the Tukey's Control Chart

A Tukey's control chart was designed to monitor single observation data. Its easy control-limits setting and simple statistical concept are the most important advantages. In this study, we setup the Tukey's control chart based on known probability distribution and construct its average run length calculator. ARL performance of the Tukey's control chart is evaluated under a normal distribution and non normal distributions, respectively. The comparison of ARL performance reveals that Tukey's control chart is not sensitive to shift detection when the process heavily violates the normal assumption. The number of observations needed for Tukey's control chart setup is less than Shewhart's control chart. Tukey's control chart is a better choice for the process mean monitoring.     

The EWMA sign chart revisited: performance and alternatives without and with ties

The EWMA Sign control chart is an efficient tool for monitoring shifts in a process regardless the observations'' underlying distribution. Recent studies have shown that, for nonparametric control charts, due to the discrete nature of the statistics being used (such as the Sign statistic), it is impossible to accurately compute their Run Length properties using Markov chain or integral equation methods. In this work, a modified nonparametric Phase II EWMA chart based on the Sign statistic is proposed and its exact Run Length properties are discussed. A continuous transformation of the Sign statistic, combined with the classical Markov Chain method, is used for the determination of the chart''s in- and out-of-control Run Length properties. Additionally, we show that when ties occur due to measurement rounding-off errors, the EWMA Sign control chart is no longer distribution-free and a Bernoulli trial approach is discussed to handle the occurrence of ties and makes the proposed chart almost distribution-free. Finally, an illustrative example is provided to show the practical implementation of our proposed chart.     

Monitoring prespecified changes in linear profiles using control charts with supplementary runs rules

In profile monitoring, some methods have been developed to detect the unspecified changes in the profiles. However, detecting changes away from the “normal” profile toward one of several prespecified “bad” profiles is one possible and challenging purpose. In this article, control charts with supplementary runs rules are developed to detect the prespecified changes in linear profiles. A control chart is first developed based on the Student's t-statistic in t test, and two runs rules are then supplemented to this chart, respectively. Simulation studies show that the proposed control schemes are effective and stable. Moreover, the control schemes are better than the existing alternative charts when the number of observations per sample profile is large. Finally, two illustrative examples indicate that our proposed schemes are effective and easy to be implemented.     

The effect of Phase I sample size on the run length performance of control charts for autocorrelated data

Traditional control charts assume independence of observations obtained from the monitored process. However, if the observations are autocorrelated, these charts often do not perform as intended by the design requirements. Recently, several control charts have been proposed to deal with autocorrelated observations. The residual chart, modified Shewhart chart, EWMAST chart, and ARMA chart are such charts widely used for monitoring the occurrence of assignable causes in a process when the process exhibits inherent autocorrelation. Besides autocorrelation, one other issue is the unknown values of true process parameters to be used in the control chart design, which are often estimated from a reference sample of in-control observations. Performances of the above-mentioned control charts for autocorrelated processes are significantly affected by the sample size used in a Phase I study to estimate the control chart parameters. In this study, we investigate the effect of Phase I sample size on the run length performance of these four charts for monitoring the changes in the mean of an autocorrelated process, namely an AR(1) process. A discussion of the practical implications of the results and suggestions on the sample size requirements for effective process monitoring are provided.     

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.