Statistical

Quality
Control

What is

SQC ?

Statistical quality control (SQC)

is the term used to describe the set
of statistical tools used by quality
professionals.

Characteristics of S.Q.C.

Designed to control quality standard of goods

produced

Exercise by the producers during production to

assess the quality of goods

Carried out with the help of certain statistical tools

like Mean Chart, Range Chart, P-Chart, C-Chart etc.

Designed to determine the variations in quality of

the goods & limits of tolerance.

Variation in Quality

No two items are exactly alike.

Some sort of variations in the two items is

bound to be there. In fact it is an integral part
of any manufacturing process.

This difference in characteristics known as

variation.

This variation may be due to substandard

quality of raw material, carelessness on the
part of operator, fault in machinery system etc..

Types Of Variations
Variation due to CHANCE CAUSES

Variation due to ASSIGNABLE

CAUSES

Variation due to chance

causes/common causes

Variation occurred due to chance.

This variation is NOT due to defect in

machine, Raw material or any other
factors.

Behave in random manner.

Negligible but Inevitable

The process is said to be under the

state of statistical control.

Variation due to Assignable

causes
Nonrandom

causes like:

Difference in quality of raw material

Difference in machines

Difference in operators

Difference of time

SQC Categories
Descriptive statistics
Statistical process control (SPC)
Acceptance sampling

Descriptive Statistics

Descriptive statistics are used to

describe quality characteristics and
relationships.

Descriptive Statistics
The Mean
measure of central tendency
The Range
difference between largest/smallest
observations in a set of data
Standard Deviation
measures the amount of data dispersion
around mean

The Mean

To compute the mean we simply sum all the observations and

divide by the total no. of observations.

The Range

Range, which is the difference between

the largest and smallest observations.

tandard

eviation

Standard deviation is a measure of dispersion of a curve.

It measures the extent to which these values are scattered

around the central mean.

Process Control

Quality of the products is controlled while the products are in

the process of production.

The process control is secured with the technique of control

charts. Control charts are also used in the field of advertising,
packing etc. They ensures that whether the products confirm
to the specified quality standard or not.

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Control Chart
A control chart is a time plot of a statistic, such as a sample mean,
range, standard deviation, or proportion, with a center line and upper
and lower control limits. The limits give the desired range of values
for the statistic.
When the statistic is outside the bounds, or when its time plot reveals
certain patterns, the process may be out of control.
Value
This
This point
point is
is out
out of
of the
the control
control limits
limits

UCL
3
3

Center
Line
LCL
Time

Purpose & Uses of Control

Charts
1.

Helps in determining the quality standard of the products.

2.

Helps in detecting the chance & assignable variations in the

quality standards by setting two control limits.

3.

Reveals variations in the quality standards of the products

from the desired level.

4.

Indicates whether the production process is in control or not.

5.

Ensures less inspection cost & time in the process control.

Types Control
Charts
Types of
Control
Charts

Control
Charts for
Variables

Chart

R-Chart

Control
Charts for
Attributes

-Chart

p-Chart

npChart

C-Chart

Control Charts For

Variables
CHART/ MEAN CHART
This chart is constructed for controlling the variations
in the average quality standard of the products in a
production process.

R-CHART
This chart is constructed for controlling the variations
in the dispersion or variability of the quality standards
of the products in a production process.

Example
Sample
no.

Weights (X)
15 10 11
14
21 18 10 8 22
21 19 17 10
13
22 12 19 14
20
20 19 26 12
23

Total
Weights
(X)

=(X/5)

Range
R=(L-S)

14
14
16
16
20

10
14
11
8
14

=80

R=57

20

1
2
3
4
5
K=5

70
70
80
80
100

Mean chart

Control limits

UCL = Grand + A2
= 16 + 0.577 x 11.4
= 22.577
LCL = Grand - A2
= 16 0.577 x 11.4
= 9.423

MEAN CHART
25
SAMPLE MEANS

Grand = /K
= 80/5
=16
Grand = 16 (Central line)

UCL=22.57

20
15

CL=16
LCL=9.423

10
0 51

SAMPLE NOS.

RANGE CHART
= R/K = 57/5 = 11.4
= 11.4 (Central line)

Control limits
UCL = D4.
= 2.115 x 11.4
= 24.09
LCL = D3.
= 0 x 11.4
=0

RANGE CHART

25

UCL=24.09

SAMPLE RANGE

20
.

15 .

10
0 1
5

CL=11.4

LCL=0

SAMPLE NOS.

 Chart
chart is constructed to get a better picture
of the variations in the quality standard in a
process than that is obtained from the range
chart provided the standard deviation() of
the various samples are readily available.

Control Charts for

Attributes

p-CHART

This chart is constructed for controlling the quality

standard in the average fraction defective of the products
in a process when the observed sample items are
classified into defectives & non-defectives.

np-CHART

This chart is constructed for controlling the quality

standard of attributes in a process where the sample size
is equal & it is required to plot the no. of defectives in
samples instead of fraction defectives.

Example
Sample
No.
1
2
3
4
5
6
7
8
9
10

K = 10

No. of
Size of
defectives
sample (n)
(d)
100
100
100
100
100
100
100
100
100
100

5
3
3
6
5
6
8
10
10
4

d = 60

Fraction
defectives
(d/n)
0.05
0.03
0.03
0.06
0.05
0.06
0.08
0.1
0.1
0.04

 = Total no. of defectives/Total no. of units

UCL = + 3 . q/n
= 0.06 + 30.06x0.94/100
= 0.1311
LCL = - 3 . q/n

= 0.06 - 3 0.06x0.94/100
= -0.0111 = 0

p-CHART
.16

FRACTION DEFECTIVE

= 60/1000
= 0.06 (central line)

UCL=0.1311

.12

.08 .

. .

. . .

CL=0.06
.

.04 0 1 2 3 4 5 6 7 8 9 10
SAMPLE NOS.

LCL=0

An inspection of 10 samples of size 400 each from 10 lots reveal

the
following number of defectives:
17, 15, 14, 26, 9, 4, 19, 12, 9, 15
Calculate control limits for the no. of defective units.
Solution:

n = 400, k (No. of samples) = 10, d (total no. of defectives) = 140

n = d/k = 140/10 = 14
= n/n = 14/400 = 0.035,

np-CHART

n = 14 (central line)
UCL= n + 3 n q
= 14 + 3400x0.035x0.965
= 25.025
LCL= n - 3 n q
= 14 - 3400x0.035x0.965

FRACTION DEFECTIVE

q = 1- = 1- 0.035 = 0.965

25
20
15

UCL=25.025
.

.
.

.
.

10 0 1 2 3 4 5 6 7 8 9 10
SAMPLE NOS.

CL=14
LCL=2.975

C-Chart
C-chart is used for the control of no. of defects per unit say a
piece of cloth/glass/paper/bottle which may contain more than
one defect. The inspection unit in this chart will be a single
unit of product. The probability of occurrence of each defect
tends to remain very small.
The following are the field of application of C-Chart:

Number of defects of all kinds of aircraft final assembly.

Number of defects counted in a roll of coated paper, sheet of
photographic film, bale of cloth etc.

Process Capability

Evaluating the ability of a production process to meet

or exceed preset specifications. This is called process
capability.

Product specifications, often called tolerances, are

preset ranges of acceptable quality characteristics,
such as product dimensions.

Two parts of process capability:

1.

Measure the variability of the output of a process, and

2.

Compare that variability with a proposed specification or

product tolerance.

Measuring Process Capability

To produce an acceptable product, the

process must be capable and in control
before production begins.

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Cp
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Cp 1

Cp 1

Six Sigma Principles

The term Six Sigma was coined by the Motorola Corporation in the 1980s
to describe the high level of quality the company was striving to achieve.

Sigma () stands for the number of standard deviations of the process

3 sigma () means that 2600 ppm are defective.

The level of defects associated with Six Sigma is approximately 3.4 ppm

PPM defective for 3

versus
6 quality

Acceptance Sampling

Acceptance sampling refers to the process of randomly

inspecting a certain number of items from a lot or batch in
order to decide whether to accept or reject the entire batch.

Acceptance sampling is performed either before or after the

process, rather than during the process.

Acceptance sampling before the process involves sampling

materials received from a supplier (E.g.: Raw materials for
tablet manufacture)

Sampling after the process involves sampling finished items

that are to be shipped either to a customer or to a distribution
centre (E.g.: Packed tablet bottles in warehouse)

Acceptance sampling is used when inspecting every item is

not physically possible or would be overly expensive, or when
inspecting a large number of items would lead to errors due to
worker fatigue

Another example of when acceptance sampling would be used is

in destructive testing (E.g.: Measuring crushing strength of
tablets)

Acceptance sampling can be used both for variables and

attributes, though, it is more frequently used for attributes

Sampling Plans in Acceptance Sampling

Sampling Plan

A plan for acceptance sampling that precisely specifies the

parameters of the sampling process and the
acceptance/rejection criteria.

The variables to be specified include the size of the lot (N), the
size of the sample inspected from the lot (n), the number of
defects above which a lot is rejected (c), and the number of
samples that will be taken.

In single sampling, in which a random sample is drawn from

every lot, each item is classified as either good or bad

Depending on number of bad items found, the entire batch is

rejected

Another type of acceptance sampling is called double

sampling

This provides an opportunity to sample the lot a

second time if the results of the first sample are
inconclusive.

In double sampling we first sample a lot of goods

according to pre-set criteria for definite acceptance or
rejection.

However, if the results fall in the middle range, they

are considered inconclusive and a second sample is
taken

Operating Characteristic (OC)

Curves
A graph that shows the probability or chance of
accepting a lot given various proportions of defects in
the lot.

OC Curves

Acceptable quality level (AQL)

The small percentage of defects that consumers are
willing to accept.

Lot tolerance percent defective (LTPD)

The upper limit of the percentage of defective items
consumers are willing to tolerate.

OC Curves

Consumers risk

The chance of accepting a lot that

contains a greater number of defects than
the LTPD limit.
This is the probability of making a Type II
errorthat is, accepting a lot that is truly
bad.

Consumers risk or Type II error is

generally denoted by beta ().

OC Curves

Producers risk
The chance that a lot containing an
acceptable quality level will be rejected.

This is the probability of making a Type I error

that is, rejecting a lot that is good.

It is generally denoted by alpha ().

Average Outgoing Quality (AOQ)

The expected proportion of defective items that will be

passed to the customer under the sampling plan.

From the OC curves, higher the quality of the lot, the higher is
the chance that it will be accepted

Conversely, lower the quality of the lot, the greater is the

chance that it will be rejected.

Given that some lots are accepted and some rejected, it is useful
to compute the average outgoing quality (AOQ) of lots to get a
sense of the overall outgoing quality of the product.

Average Outgoing Quality

(AOQ)
Assuming that all lots have the same proportion of defective
items, the average outgoing quality can be computed as

Usually we assume the fraction in the previous equation to equal 1

and simplify the equation to the following form:

Advantages Of S.Q.C.
I.

Helpful in controlling quality of a product

II.

Eliminates Assignable causes of variation

III. Better

quality at lower inspection cost

IV. Useful

to both consumers & producers

V.

It makes workers quality conscious

VI. Helps

in earn goodwill

LIMITATIONS
I.

Does not serve as a PANACEA for all quality

evils.

II.

It cannot be used to all production process.

III.

It involves mathematical & statistical

problems in the process of analysis &
interpretation of variations in quality.

IV.

Provides only an information services.

Statistical Quality Control in

Services

Statistical quality control (SQC) tools have been widely used in

manufacturing organizations for quite some time.

Service organizations have lagged behind manufacturing firms in

their use of SQC. The primary reason is that statistical quality
control requires measurement, and it is difficult to measure the
quality of a service.

A way to measure the quality of services is to devise quantifiable

measurements of the important dimensions of a particular
service.

For example, the number of complaints received per month, the

number of telephone rings after which a response is received, or
customer waiting time can be quantified.

Another issue that complicates quality control in service

organizations is that the service is often consumed during the
production process.

Thank You