Statistics for Quality and Productivity: A New Graduate-Level Statistics Course

The growing popular realization that American product quality and productivity are no longer without challenge for world leadership presents an opportunity for the American statistical community to make stronger contributions to sound industrial practice than it has in the past. Management consultants, such as Deming and Juran, are promoting philosophies that contain strong statistical components and are being heard by top U.S. executives. There are thus growing opportunities for industrial statisticians. Upon reviewing the content of typical graduate-level statistical quality control courses and books in the light of the present situation, we find them to be inadequate and in some cases to suffer from inappropriate emphases. In this article we discuss our perceptions of what is needed in the way of a new graduate-level course in statistics for quality and productivity (SQP). We further offer for discussion a syllabus for such a course (which is a modification of one used at Iowa State in the 1983 spring semester), some comments on how specific topics might be approached, and also a partially annotated list of references for material that we believe belongs in a modern SQP course.     

On constructing T 2 control charts for retrospective examination

In this paper we consider the issue of constructing retrospective T ² control chart limits so as to control the overall probability of a false alarm at a specified value. We describe an exact method for constructing the control limits for retrospective examination. We then consider Bonferroni-adjustments to Alt's control limit and to the standard x ² control limit as alternatives to the exact limit since it is computationally cumbersome to find the exact limit. We present the results of some simulation experiments that are carried out to compare the performance of these control limits. The results indicate that the Bonferroni-adjusted Alt's control limit performs better that the Bonferroni-adjusted x ² control limit. Furthermore, it appears that the Bonferroni-adjusted Alt's control limit is more than adequate for controlling the overall false alarm probability at a specified value.     

Zone control charts with estimated parameters for detecting prespecified changes in linear profiles

ABSTRACT

In profile monitoring, control charts are proposed to detect unanticipated changes, and it is usually assumed that the in-control parameters are known. However, due to the characteristics of a system or process, the prespecified changes would appear in the process. Moreover, in most applications, the in-control parameters are usually unknown. To overcome these issues, we develop the zone control charts with estimated parameters to detect small shifts of these prespecified changes. The effects of estimation error have been investigated on the performance of the proposed charts. To account for the practitioner-to-practitioner variability, the expected average run length (ARL) and the standard deviation of the average run length (SDARL) is used as the performance metrics. Our results show that the estimation error results in the significant variation in the ARL distribution. Furthermore, in order to adequately reduce the variability, more phase I samples are required in terms of the SDARL metric than that in terms of the expected ARL metric. In addition, more observations on each sampled profile are suggested to improve the charts' performance, especially for small phase I sample sizes. Finally, an illustrative example is given to show the performance of the proposed zone control charts.     

An improved graphical procedure for multivariate-quality control

In an earlier article (Kulkarni and Paranjape 1984) we proposed a procedure based on Andrews' function plot technique for the quality control of multivariate process. It was shown that this procedure may lead to an erroneous conclusions regarding the status of the process. This article presents an improved method which avoids the above drawback. A heuristic justification is provided to show that the new method is free from the error. Simulation studies are carried out to support the claim. An example is included to illustrate the use of the new technique.     

On the α-risks for shewhart control charts

The performance of the usual Shewhart control charts for monitoring process means and variation can be greatly affected by nonnormal data or subgroups that are correlated. Define the α_k-risk for a Shewhart chart to be the probability that at least one “out-of-control” subgroup occurs in k subgroups when the control limits are calculated from the k subgroups. Simulation results show that the α_k-risks can be quite large even for a process with normally distributed, independent subgroups. When the data are nonnormal, it is shown that the α_k-risk increases dramatically. A method is also developed for simulating an “in-control” process with correlated subgroups from an autoregressive model. Simulations with this model indicate marked changes in the α_k-risks for the Shewhart charts utilizing this type of correlated process data. Therefore, in practice a process should be investigated thoroughly regarding whether or not it is generating normal, independent data before out-of-control points on the control charts are interpreted to be due to some real assignable cause.     

Short run spc based upon the second order dynamic linear model for trend detection

Recently, several new applications of control chart procedures for short production runs have been introduced. Bothe (1989) and Burr (1989) proposed the use of control chart statistics which are obtained by scaling the quality characteristic by target values or process estimates of a location and scale parameter. The performance of these control charts can be significantly affected by the use of incorrect scaling parameters, resulting in either an excessive "false alarm rate," or insensitivity to the detection of moderate shifts in the process. To correct for these deficiencies, Quesenberry (1990, 1991) has developed the Q-Chart which is formed from running process estimates of the sample mean and variance. For the case where both the process mean and variance are unknown, the Q-chaxt statistic is formed from the standard inverse Z-transformation of a t-statistic. Q-charts do not perform correctly, however, in the presence of special cause disturbances at process startup. This has recently been supported by results published by Del Castillo and Montgomery (1992), who recommend the use of an alternative control chart procedure which is based upon a first-order adaptive Kalman filter model Consistent with the recommendations by Castillo and Montgomery, we propose an alternative short run control chart procedure which is based upon the second order dynamic linear model (DLM). The control chart is shown to be useful for the early detection of unwanted process trends. Model and control chart parameters are updated sequentially in a Bayesian estimation framework, providing the greatest degree of flexibility in the level of prior information which is incorporated into the model. The result is a weighted moving average control chart statistic which can be used to provide running estimates of process capability. The average run length performance of the control chart is compared to the optimal performance of the exponentially weighted moving average (EWMA) chart, as reported by Gan (1991). Using a simulation approach, the second order DLM control chart is shown to provide better overall performance than the EWMA for short production run applications     

Hayter and Tsui's test with double sampling for the vector mean of multivariate normal population

Abstract

In this paper, we introduce a version of Hayter and Tsui's statistical test with double sampling for the vector mean of a population under multivariate normal assumption. A study showed that this new test was more or as efficient than the well-known Hotelling's T² with double sampling. Some nice features of Hayter and Tsui's test are its simplicity of implementation and its capability of identifying the errant variables when the null hypothesis is rejected. Taking that into consideration, a new control chart called HTDS is also introduced as a tool to monitor multivariate process vector mean when using double sampling.     

The robust economic statistical design of the Hotelling's T2 chart

ABSTRACT

Economic statistical designs aim at minimizing the cost of process monitoring when a specific scenario or a set of estimated process and cost parameters is given. But, in practice the process may be affected by more than one scenario which may lead to severe cost penalties if the wrong design is used. Here, we investigate the robust economic statistical design (RESD) of the T² chart in an attempt to reduce these cost penalties when there are multiple scenarios. Our method is to employ the genetic algorithm (GA) optimization method to minimize the total expected monitoring cost across all distinct scenarios. We illustrate the effectiveness of the method using two numerical examples. Simulation studies indicate that robust economic statistical designs should be encouraged in practice.     

A Design of s Control Charts with a Combined Double Sampling and Variable Sampling Interval Scheme

In this paper, we propose new estimation techniques in connection with the system of S-distributions. Besides “exact” maximum likelihood (ML), we propose simulated ML and a characteristic function-based procedure. The “exact” and simulated likelihoods can be used to provide numerical, MCMC-based Bayesian inferences.