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.     

CUSUM chart for detecting range shifts when monotonicity of likelihood ratio is invalid

It is often encountered in the literature that the log-likelihood ratios (LLR) of some distributions (e.g. the student t distribution) are not monotonic. Existing charts for monitoring such processes may suffer from the fact that the average run length (ARL) curve is a discontinuous function of control limit. It implies that some pre-specified in-control (IC) ARLs of these charts may not be reached. To guarantee the false alarm rate of a control chart lower than the nominal level, a larger IC ARL is usually suggested in the literature. However, the large IC ARL may weaken the performance of a control chart when the process is out-of-control (OC), compared with a just right IC ARL. To overcome it, we adjust the LLR to be a monotonic one in this paper. Based on it, a multiple CUSUM chart is developed to detect range shifts in IC distribution. Theoretical result in this paper ensures the continuity of its ARL curve. Numerical results show our proposed chart performs well under the range shifts, especially under the large shifts. In the end, a real data example is utilized to illustrate our proposed chart.     

Attribute Control Chart for Multivariate Poisson Distribution

In this study, a control chart is constructed to monitor multivariate Poisson count data, called the MP chart. The control limits of the MP chart are developed by an exact probability method based on the sum of defects or non conformities for each quality characteristic. Numerical examples are used to illustrate the MP chart. The MP chart is evaluated by the average run length (ARL) in simulation. The result indicates that the MP chart is more appropriate than the Shewhart-type control chart when the correlation between variables exists.     

CUSUM Control Charts for Multivariate Poisson Distribution

A cumulative sum control chart for multivariate Poisson distribution (MP-CUSUM) is proposed. The MP-CUSUM chart is constructed based on log-likelihood ratios with in-control parameters, Θ₀, and shifts to be detected quickly, Θ₁. The average run length (ARL) values are obtained using a Markov Chain-based method. Numerical experiments show that the MP-CUSUM chart is effective in detecting parameter shifts in terms of ARL. The MP-CUSUM chart with smaller Θ₁ is more sensitive than that with greater Θ₁ to smaller shifts, but more insensitive to greater shifts. A comparison shows that the proposed MP-CUSUM chart outperforms an existing MP chart.     

Determining Optimal Number of Samples for Constructing Multivariate Control Charts

Normally, an average run length (ARL) is used as a measure for evaluating the detecting performance of a multivariate control chart. This has a direct impact on the false alarm cost in Phase II. In this article, we first conduct a simulation study to calculate both in-control and out-of-control ARLs under various combinations of process shifts and number of samples. Then, a trade-off analysis between sampling inspection and false alarm costs is performed. Both the simulation results and trade-off analysis suggest that the optimal number of samples for constructing a multivariate control chart in Phase I can be determined.     

Accounting for phase I sampling variability in the performance of the MEWMA control chart with estimated parameters

In this article, we assess the performance of the multivariate exponentially weighted moving average (MEWMA) control chart with estimated parameters while considering the practitioner-to-practitioner variability. We evaluate the chart performance in terms of the in-control average run length (ARL) distributional properties; mainly the average (AARL), the standard deviation (SDARL), and some percentiles. We show through simulations that using estimates in place of the in-control parameters may result in an in-control ARL distribution that almost completely lies below the desired value. We also show that even with the use of larger amounts of historical data, there is still a problem with the excessive false alarm rates. We recommend the use of a recently proposed bootstrap-based design technique for adjusting the control limits. The technique is quite effective in controlling the percentage of short in-control ARLs resulting from the estimation error.     

A distribution-free multivariate CUSUM control chart using dynamic control limits

In modern quality control, it is becoming common to simultaneously monitor several quality characteristics of a process with rapid evolving data-acquisition technology. When the multivariate process distribution is unknown and only a set of in-control data is available, the bootstrap technique can be used to adjust the constant limit of the multivariate cumulative sum (MCUSUM) control chart. To further improve the performance of the control chart, we extend the constant control limit to a sequence of dynamic control limits which are determined by the conditional distribution of the charting statistics given the sprint length. Simulation results show that the novel control chart with dynamic control limits offers a better ARL performance, compared with the traditional MCUSUM control chart. Despite it, the proposed control chart is considerably computer-intensive. This leads to the development of a more flexible control chart which uses a continuous function of the sprint length as the control limit sequences. More importantly, the control chart is easy to implement and can reduce the computational time significantly. A white wine data illustrates that the novel control chart performs quite well in applications.     

A Multivariate Adaptive Exponentially Weighted Moving Average Control Chart

A multivariate extension of the adaptive exponentially weighted moving average (AEWMA) control chart is proposed. The new multivariate scheme can detect small and large shifts in the process mean vector effectively. The proposed scheme can be viewed as a smooth combination of a multivariate exponentially weighted moving average (MEWMA) chart and a Shewhart χ²-chart. The optimal design of the proposed chart is given according to a pre-specified in-control average run length and two shift sizes; a small and large shift each measured in terms of the non centrality parameter. The signal resistance of the newly proposed multivariate chart is also given. Comparisons among the new chart, the MEWMA chart, and the combined Shewhart-MEWMA (S-MEWMA) chart in terms of the standard and worst-case average run length profiles are presented. In addition, the three charts are compared with respect to their worst-case signal resistance values. The proposed chart gives somewhat better worst-case ARL and signal resistance values than the competing charts. It also gives better standard ARL performance especially for moderate and large shifts. The effectiveness of our proposed chart is illustrated through an example with simulated data set.     

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.     

Using the predictive distribution to determine control limits for the Bayesian MEWMA chart

Bayesian control charts have been proposed for monitoring multivariate processes with the multivariate exponentially weighted moving average (MEWMA) statistic. It has been suggested that we use limits based on the predictive distribution of the MEWMA statistic. This analysis, however is based on the erroneous result that the average run length (ARL) is a function of the exceedance probability, that is, the probability that the first point exceeds the control limit. We show how this result can be corrected and we discuss how the Bayesian MEWMA chart with limits based on the predictive distribution compares with other multivariate control chart procedures.     

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.     

A control chart for multivariate Poisson distribution using repetitive sampling

Control charts using repetitive group sampling have attracted a great deal of attention during the last few years. In the present article, we attempt to develop a control chart for the multivariate Poisson distribution using the repetitive group sampling scheme. In the proposed control chart, the monitoring statistic from the multivariate Poisson distribution has been used for the quick detection of the deteriorated process to avoid losses. The control coefficients have been estimated using the specified in-control average run lengths. The procedure of the proposed control chart has been explained by using the real-world example and a simulated data set. It has been observed that the proposed control chart is an efficient development for the quick detection of the nonrandom change in the manufacturing process.     

An adaptive multivariate CUSUM control chart for signaling a range of location shifts

ABSTRACT

In this work, we proposed an adaptive multivariate cumulative sum (CUSUM) statistical process control chart for signaling a range of location shifts. This method was based on the multivariate CUSUM control chart proposed by Pignatiello and Runger (1990 Pignatiello, J.J., Runger, G.C. (1990). Comparisons of multivariate CUSUM charts. J. Qual. Technol. 22(3):173–186.[Taylor & Francis Online], [Web of Science ®] , [Google Scholar]), but we adopted the adaptive approach similar to that discussed by Dai et al. (2011 Dai, Y., Luo, Y., Li, Z., Wang, Z. (2011). A new adaptive CUSUM control chart for detecting the multivariate process mean. Qual. Reliab. Eng. Int. 27(7):877–884.[Crossref], [Web of Science ®] , [Google Scholar]), which was based on a different CUSUM method introduced by Crosier (1988 Crosier, R.B. (1988). Multivariate generalizations of cumulative sum quality-control schemes. Technometrics 30(3):291–303.[Taylor & Francis Online], [Web of Science ®] , [Google Scholar]). The reference value in this proposed procedure was changed adaptively in each run, with the current mean shift estimated by exponentially weighted moving average (EWMA) statistic. By specifying the minimal magnitude of the mean shift, our proposed control chart achieved a good overall performance for detecting a range of shifts rather than a single value. We compared our adaptive multivariate CUSUM method with that of Dai et al. (2001 Dai, Y., Luo, Y., Li, Z., Wang, Z. (2011). A new adaptive CUSUM control chart for detecting the multivariate process mean. Qual. Reliab. Eng. Int. 27(7):877–884.[Crossref], [Web of Science ®] , [Google Scholar]) and the non adaptive versions of these two methods, by evaluating both the steady state and zero state average run length (ARL) values. The detection efficiency of our method showed improvements over the comparative methods when the location shift is unknown but falls within an expected range.     

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.     

Effect of Inspection Error on Out-of-Control Average Run Length of CUSUM Charts

The cumulative sum (CUSUM) chart is commonly used for detecting small or moderate shifts in the fraction of defective manufactured items. However, its construction relies on the error-free inspection assumption, which can seldom be met in practice. In this article, we discuss the construction of an upward CUSUM chart in the presence of inspection error, study the effects of inspection error on the out-of-control ARL of the CUSUM chart, and present a formula for determining the sampling size that compensates for the effect of inspection error on the out-of-control ARL.     

A control chart for monitoring process variation using multiple dependent state sampling

A control chart for monitoring process variation by using multiple dependent state (MDS) sampling is constructed in the present article. The operational formulas for in-control and out-of-control average run lengths (ARLs) are derived. Control constants are established by considering the target in-control ARL at a normal process. The extensive ARL tables are reported for various parameters and shifted values of process parameters. The performance of the proposed control chart has been evaluated with several existing charts in regard of ARLs, which empowered the presented chart and proved far better for timely detection of assignable causes. The application of the proposed concept is illustrated with a real-life industrial example and a simulation-based study to elaborate strength of the proposed chart over the existing concepts.     

A Sum of Squares Generally Weighted Moving Average Control Chart

In this article, we propose a new control chart called the sum of squares generally weighted moving average (SS-GWMA) control chart to simultaneously detect both the increase and decrease in the mean and/or variability. This new scheme is compared with the sum of squares exponentially weighted moving average (SS-EWMA) control chart. A simulation study is conducted to show that SS-GWMA control charts outperform SS-EWMA charts, in terms of the average run length (ARL), standard deviation of run length (SDRL), and diagnostic abilities. The design of SS-GWMA control charts is also discussed.     

A Double Moving Average Control Chart

The double exponentially weighted moving average (DEWMA) technique has been investigated in recent years for detecting shifts in the process mean and has been shown to be more efficient than the corresponding exponentially weighted moving average (EWMA) technique. In this article, we extend the DEWMA technique of performing exponential smoothing twice to the double moving average (DMA) technique by computing the moving average twice. Using simulation, we show that our proposed DMA chart improves upon the ARL performance of the moving average (MA) chart in detecting mean shifts of small to moderate magnitudes. It is also shown through simulation that, generally, the DMA charts with spans, w = 10 and 15 provide comparable average run length (ARL) performances to the EWMA and cumulative sum (CUSUM) charts, designed for detecting small shifts.     

Combined synthetic and |S| chart for monitoring process dispersion

This article proposes a multivariate control chart, the syn-|S| chart, which comprises a standard |S| subchart and a multivariate synthetic sample generalized variance |S| (synthetic |S|) subchart, for detecting shifts in the covariance matrix of a multivariate normally distributed process. A procedure for the optimal design of the syn-|S| chart by minimizing the average extra quadratic loss is provided. The syn-|S| chart has better overall performance compared to the synthetic |S| chart and the standard |S| chart, based on the zero-state and steady-state modes. An example is given to illustrate the operation of the synthetic |S| chart.