Run length distributions for estimated attributes charts

Attributes control charts, such as c and p charts, are popular methods for detecting out of control signals when it is practical only to obtain qualitative information about a process; in such cases, variables control charts, such as the , s and R charts, cannot be used. The run length distributions have previously been studied for variables charts when the control limits have been estimated. Little has been done in the case of attributes charts. In this paper, the run length distributions for the c chart and p chart are derived for the case when the control limits are estimated. It is shown that, as for variables charts, the effect of estimation on quantities such as the average run length (ARL) can be quite dramatic, but when the underlying process is in control, the ARL is potentially misleading as a basis for comparison. Received: September 1998     

A new procedure for monitoring the range and standard deviation of a quality characteristic

The Shewhart and the Bonferroni-adjustment R and S chart are usually applied to monitor the range and the standard deviation of a quality characteristic. These charts are used to recognize the process variability of a quality characteristic. The control limits of these charts are constructed on the assumption that the population follows approximately the normal distribution with the standard deviation parameter known or unknown. In this article, we establish two new charts based approximately on the normal distribution. The constant values needed to construct the new control limits are dependent on the sample group size (k) and the sample subgroup size (n). Additionally, the unknown standard deviation for the proposed approaches is estimated by a uniformly minimum variance unbiased estimator (UMVUE). This estimator has variance less than that of the estimator used in the Shewhart and Bonferroni approach. The proposed approaches in the case of the unknown standard deviation, give out-of-control average run length slightly less than the Shewhart approach and considerably less than the Bonferroni-adjustment approach.     

Run length distributions and economic design of [`(X)]\bar X charts with unknown process variance

The run length distribution of charts with unknown process variance is analized using numerical integration. Both traditional chart limits and a method due to Hillier are considered. It is shown that setting control limits based on the pooled standard deviation, as opposed to the average sample standard deviation, provides better run length performance due to its smaller mean square error. The effect of an unknown process variance is shown to increase the area under both tails of the run length distribution. If Hillier’s method is used instead, only the right tail of the run length distribution is increased. Collani’s model for the economic design of charts is extended to the case of unknown process variance by writing his standardized objective function in terms of average run lengths.     

A process control method based on five-parameter generalized lambda distribution

The use of control charts in statistical quality control, which are statistical measures of quality limits, is based on several assumptions. For instance, the process output distribution is assumed to follow a specified probability distribution (normal for continuous measurements and binomial or Poisson for attribute data) and the process supposed to be for large production runs. These assumptions are not always fulfilled in practice. This paper focuses on the problem when the process monitored has an output which has unknown distribution, or/and when the production run is short. The five-parameter generalized lambda distributions (GLD) which are subject to estimating data distributions, as a very flexible family of statistical distributions is presented and proposed as the base of control parameters estimation. The proposed chart is of the Shewhart type and simple equations are proposed for calculating the lower and upper control limits (LCL and UCL) for unknown distribution type of data. When the underlying distribution cannot be modeled sufficiently accurately, the presented control chart comes into the picture. We develop a computationally efficient method for accurate calculations of the control limits. As the vital measure of performance of SPC methods, we compute ARL’s and compare them to show the explicit excellence of the proposed method.     

Comparisons of control schemes for monitoring the means of processes subject to drifts

Although statistical process control (SPC) techniques have been focused mostly on detecting step (constant) mean shift, drift which is a time-varying change frequently occurs in industrial applications. In this research, for monitoring drift change, the following five control schemes are compared: the exponentially weighted moving average (EWMA) chart and the cumulative sum (CUSUM) charts which are recommended detecting drift change in the literature; the generalized EWMA (GEWMA) chart proposed by Han and Tsung (2004) and two generalized likelihood ratio based schemes, GLR-S and GLR-L charts which are respectively under the assumption of step and linear trend shifts. Both the asymptotic estimation and the numerical simulation of the average run length (ARL) are presented. We show that when the in-control (IC) ARL is large (goes to infinity), the GLR-L chart has the best overall performance among the considered charts in detecting linear trend shift. From the viewpoint of practical IC ARL, based on the simulation results, we show that besides the GLR-L chart, the GEWMA chart offers a good balanced protection against drifts of different size. Some computational issues are also addressed.     

Asymmetric control limits for small samples

When designing control charts, it is usually assumed that the measurement in the subgroups are normally distributed. The assumption of normality implies that the control limits for a chart for sample averages will be symmetrical about the centerline of the chart. However, the assumption of an underlying normal distribution of the data may not hold in some processes. If the measurements are asymmetrically distributed then the decision maker may choose different actions. One thing that can be done is to consider the degree of skewness. If the nature of the underlying distribution is skewed, then the traditional Shewhart individuals chart may not be valid. This paper presents a technique for constructing appropriate asymmetric control limits when the distribution of data cannot be assumed to be a normal distribution. Meanwhile, it proposes a skewness correction method for the generated Burr, lognormal and exponential distributions. Some numerical calculations are generated for n  =  2, 3, 4 by using MATLAB.     

Monitoring the cross-covariances of a multivariate time series

In this paper sequential procedures are proposed for jointly monitoring all elements of the covariance matrix at lag 0 of a multivariate time series. All control charts are based on exponential smoothing. As a measure of the distance between the target values and the actual values the Mahalanobis distance is used. It is distinguished between residual control schemes and modified control schemes. Several properties of these charts are proved assuming the target process to be a stationary Gaussian process. Within an extensive Monte Carlo study all procedures are compared with each other. As a measure of the performance of a control chart the average run length is used. An empirical example about Eastern European stock markets illustrates how the autocovariance and the cross-covariance structure of financial assets can be monitored by these methods.     

基于Wilcoxon秩和检验的多元非参数控制图

在统计过程控制(SPC)中,对多元数据的监测仍然是一个重要且具有挑战性的问题。当缺乏或有限的关于潜在过程分布的认知时,特别是当过程测量是多变量的时候,非参数控制图在统计过程控制(SPC)中是有用的。文章基于Wilcoxon秩和检验结合广义加权移动平均(GWMA)控制方案来制定图表统计量,得到一个新的多元非参数控制图,用于监测多元数据的位置参数变化。文章的理论和数值研究表明,所提出的控制图能够为任意数据分布位置偏移检测提供令人满意的性能。     

Run length analysis of Shewhart charts applied to drifting processes under an integrative SPC/EPC model

Engineering Process Controllers (EPC) are frequently based on parametrized models. If process conditions change, the parameter estimates used by the controllers may become biased, and the quality characteristics will be affected. To detect such changes it is adequate to use Statistical Process Control (SPC) methods. The run length statistic is commonly used to describe the performance of an SPC chart. This paper develops approximations for the first two moments of the run length distribution of a one-sided Shewhart chart used to detect two types of process changes in a system that is regulated by a given EPC scheme: i) changes in the level parameter; ii) changes in the drift parameter. If the drift parameter shifts, it is further assumed that the form of the drift process changes from a linear trend under white noise (the in-control drift model) into a random walk with drift model. Two different approximations for the run length moments are presented and their accuracy is numerically analyzed. Received: August 1998     

Self-adapting control charts

When the distributional form of the observations differs from normality, standard control charts are often prone to serious errors. Such model errors can be avoided by using (modified) nonparametric control charts. Unfortunately, these control charts suffer from large stochastic errors caused by estimation. In between these two types are the so-called parametric control charts. All three of them, as well as a combined chart, which chooses one of the three control charts according to the appropriate model assumption on the underlying distribution are discussed in this paper. The data indicate which of the three control charts to select. Readymade formulas for the several control charts are presented accompanied by an application on real data. Apart from bias removal, criteria based on exceedance probability and semi-variance are investigated.     

Monitoring the mean and the variance of a stationary process

We deal with the problem of how deviations in the mean or the variance of a time series can be detected. Several simultaneous control charts are introduced which are based on EWMA (exponentially weighted moving average) statistics for the mean and the empirical variance. The combined X − S² EWMA chart is extended to time series. Further simultaneous charts are considered. The comparision of these schemes shows that the residual attempt must be favored if a variance change is present.     

Why and how to use vector autoregressive models for quality control: the guideline and procedures

While quality control on multivariate and serially correlated processes has attracted research attentions, a number of very detailed problems need to be overcome in order to construct practical control charts. We suggest guidelines for construction of control charts based on vector autoregressive (VAR) residuals. We discuss why VAR model is reasonable for real processes in nature, the use of VAR models to approximate multivariate serially correlated processes, residual estimation, selecting the number of variables, and selecting appropriate orders, among other issues. In addition, we illustrate an example employing VAR techniques to approximate a multivariate process previously examined and construct a control chart to monitor residuals. Last, we illustrate the potential development and use of the VAR residual chart to assist quality control and improvement.     

Economic Process Management and Its Application on Bank Industry

A renewal equation approach is proposed to derive the multiple special-cause cost model for a system with two dependent subprocesses. The economic individual X control chart and simple cause-selecting control chart are thus constructed to monitor the two subprocesses. They may be used to maintain the whole process with minimum cost and effectively distinguish which component of the subprocesses is out of control. The economic design parameters of these two control charts can be determined by minimizing the cost model using a simple grid search method. An example of its application on controlling service quality in the bank industry is given to illustrate the design procedure and its application. It shows that these control charts may be used to control not only manufacturing dependent subprocesses but also service organisations with dependent subprocesses.     

Mixture cumulative count control chart for mixture geometric process characteristics

A statistical process control chart named the mixture cumulative count control chart (MCCC-chart) is suggested in this study, motivated by an existing control chart named cumulative count control chart (CCC-chart). The MCCC-chart is constructed based on the distribution function of a two component mixture of geometric distributions using the number of items inspected until a defective item is observed ‘n’ as plotting statistics. We have observed that the MCCC-chart has the ability to perform equivalent to the CCC-chart when number of defective items follows geometric distribution and better than the CCC-chart when the number of defective items produced by a process follows a mixture geometric model. The MCCC-chart may be considered as a generalized version of CCC-chart.     

Performance monitoring of credit portfolios using survival analysis

We are interested in detecting changes in the performance of a credit portfolio quickly and robustly. The portfolio is dynamic: customers can either default or pay the full amount, and new customers can be taken on. Robust detection means that changing the number of new customers taken on should not lead to either a false or delayed signal. We investigate the performances of monitoring schemes via a simulation study that uses several scenarios. We consider monitoring based on default rates estimated through a gliding window, cumulative sum (CUSUM) charts based on default rates, CUSUM charts based on defaults within a given follow-up time after arrival, and a survival analysis CUSUM chart. We conclude that using a survival analysis approach is preferable to using the other approaches.     

Monitoring process mean level using auxiliary information

In this study, a Shewhart‐type control chart is proposed for the improved monitoring of process mean level (targeting both moderate and large shifts which is the major concern of Shewhart‐type control charts) of a quality characteristic of interest Y. The proposed control chart, namely the M_r chart, is based on the regression estimator of mean using a single auxiliary variable X. Assuming bivariate normality of (Y, X), the design structure of M_r chart is developed for phase I quality control. The comparison of the proposed chart is made with some existing control charts used for the same purpose. Using power curves as a performance measure, better performance of the proposedM_r chart is observed for detecting the shifts in mean level of the characteristic of interest.     

Estimation in Shewhart control charts: effects and corrections

The influence of the estimation of parameters in Shewhart control charts is investigated. It is shown by simulation and asymptotics that (very) large sample sizes are needed to accurately determine control charts if estimators are plugged in. Correction terms are developed to get accurate control limits for common sample sizes in the in-control situation. Simulation and theory show that the new corrections work very well. The performance of the corrected control charts in the out-of-control situation is studied as well. It turns out that the correction terms do not disturb the behavior of the control charts in the out-of-control situation. On the contrary, for moderate sample sizes the corrected control charts remain powerful and therefore, the recommendation to take at least 300 observations can be reduced to 40 observations when corrected control charts are applied.Acknowledgements. The authors would like to thank Sri Nurdiati for doing the Monte Carlo studies.     

Multivariate statistical process control—recent results and directions for future research

The performance of a product often depends on several quality characteristics. These characteristics may have interactions. In answering the question “Is the process in control?”, multivariate statistical process control methods take these interactions into account. In this paper, we review several of these multivariate methods and point out where to fill up gaps in the theory. The review includes multivariate control charts, multivariate CUSUM charts, a multivariate MMA chart, and multivariate process capability indices. The most important open question from a practical point of view is how to detect the variables that caused an out-of-control signal. Theoretically, the statistical properties of the methods should be investigated more profoundly.     

CUMIN charts

Classical control charts are very sensitive to deviations from normality. In this respect, nonparametric charts form an attractive alternative. However, these often require considerably more Phase I observations than are available in practice. This latter problem can be solved by introducing grouping during Phase II. Then each group minimum is compared to a suitable upper limit (in the two-sided case also each group maximum to a lower limit). In the present paper it is demonstrated that such MIN charts allow further improvement by adopting a sequential approach. Once a new observation fails to exceed the upper limit, its group is aborted and a new one starts right away. The resulting CUMIN chart is easy to understand and implement. Moreover, this chart is truly nonparametric and has good detection properties. For example, like the CUSUM chart, it is markedly better than a Shewhart X-chart, unless the shift is really large.     

Constructing a fuzzy Shewhart control chart for variables when uncertainty and randomness are combined

In this paper we introduce a fuzzy chart for variables which is used in situations when uncertainty and randomness are combined. It is showed that the Shewhart chart’s control limits must be adjusted in these situations. However, this chart is based on a fuzzy acceptance region and this method arises when a decision should be made by referring to the grade of a sample statistic belonging to the fuzzy acceptance region.