A Case Study of Quality Control Charts in A Manufacturing Industry

International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 3, March 2014
ISSN: 2278 7798 All Rights Reserved 2014 IJSETR 444

A CASE STUDY OF QUALITY CONTROL CHARTS IN A
MANUFACTURING INDUSTRY
Fahim Ahmed Touqir
1
, Md. Maksudul Islam
1
, Lipon Kumar Sarkar
2

1,2
Department of Industrial Engineering and Management
1,2
Khulna University of Engineering & Technology

Abstract Statistical Process Control (SPC) is a powerful
collection of problem solving tools and the most sophisticated
useful method in achieving process stability and improving the
process capability through the reduction of variability. In the
manufacturing process, every product doesnt meet the desired
range of quality consistently with the customer specification.
This inconsistency occurs due to several sources of variations
such as machines, operators, materials etc. The Ultimate target
of control chart is to monitor the variations, and subsequently
control the process. On account of applying SPC methods, this
study deals with the control and improvement of the quality of
bolt by inspecting the bolts height, diameter and weight from a
bolt manufacturing company. In this inspection, we have
developed X bar chart, S and Range control chart for each
three variables. Furthermore, we have also focused on
Estimated Weighted Moving Average (EWMA) for detecting
small process shifts and multivariate Hotellings T
2
for
simultaneous monitoring of height and diameter of bolt. These
inspections show that either the process is in control or out of
control. For the out of control situation, the assignable reasons
behind it should be identified and prevented by taking
necessary steps.
Keywords EWMA, Hotellings T
2
, Mean, Range, Statistical
process control.

I. INTRODUCTION
A control chart is a graphical display of quality
characteristics that has been measured or computed from a
sample versus the sample number or time. The chart
contains a centre line which represents the average value of
the quality characteristic corresponding to the in-control
state. Two control limits (UCL, LCL) are chosen so that if
the process is in control, nearly all of the sample points will
fall between them. It is also an estimating device which
exhibits statistical control of such process parameters like
the mean, standard deviation, fraction, non- conforming or
fall- out and so forth. These estimates may then be used to
determine the capability of the process to produce
acceptable products. [1]

II. METHODOLOGY
According to the approach of control chart, three
variables under study were X1 = Height (cm), X2 =diameter
(mm) and X3 = weight (mg). In dataset, there were 20
sample numbers with 5 sample size. The following
approaches based upon the principles of Statistical Quality
Control(SQC) were applied here.
A. The Range and the X bar control charts
The upper and lower control limits for Range chart are
LCL=D
3
R ,
Where,
D
3
= 1-3(d
3
/d
2
)

UCL=D
4
R
Where,
D
4
= 1+3(d
3
/d
2
)

The upper and lower control limits for mean are [4]

UCL = X + A
2
R
LCL = X - A
2
R

B. The Exponentially Weighted Moving Average
(EWMA) Control Chart

The upper and lower control limits are

3
()^0.5
2
[1 1 ]^2 X
Where ,
= 0.3

C. The Multivariate Quality Control Chart

The Hotellings T
2
statistic is [5]

T
2
= m (X j - X )
T
S
-1
(X j-X )

Plotting the T
2
values on the time axis. The lower control
limit is zero, and the upper control limit is [1]

UCL=
1(1)
+1
F
2,nm-n-p+1
(0.01)


III. RESULT AND DISCUSSION

A. X bar, Range, S, EWMA control charts for height of the bolt

Table -1 Data set for height of the specific type of Bolt

Sample
No X1(height) X2 X3 X4 X5

X

S

R
01
4.297 4.286 4.298 4.262 4.286
4.2858 0.0145 0.036
02
4.285 4.293 4.267 4.283 4.288
4.2832 0.0098 0.026
03
4.261 4.273 4.271 4.303 4.301
4.2818 0.019 0.042
04
4.273 4.287 4.303 4.304 4.296
4.2926 0.013 0.031
05
4.264 4.278 4.298 4.301 4.291
4.2864 0.0153 0.037
06
4.269 4.296 4.293 4.277 4.289
4.2848 0.0114 0.027
07
4.286 4.303 4.281 4.273 4.271
4.2828 0.0128 0.032
08
4.31 4.298 4.301 4.291 4.269
4.2938 0.0154 0.041
09
4.277 4.269 4.287 4.263 4.263
4.2718 0.0103 0.024
10
4.269 4.301 4.269 4.302 4.303
4.2888 0.0181 0.034
11
4.293 4.295 4.273 4.294 4.301
4.2912 0.0106 0.028
12
4.281 4.291 4.291 4.261 4.278
4.2804 0.0123 0.03
13
4.301 4.272 4.304 4.274 4.296
4.2894 0.0153 0.032
14
4.292 4.308 4.296 4.282 4.263
4.2882 0.0169 0.045
15
4.272 4.291 4.281 4.287 4.286
4.2834 0.0073 0.019
16
4.281 4.273 4.293 4.302 4.29
4.2878 0.0112 0.029
17
4.294 4.286 4.302 4.291 4.281
4.2908 0.0079 0.021
18
4.262 4.267 4.301 4.297 4.303
4.286 0.0198 0.041
19
4.291 4.303 4.296 4.279 4.29
4.2918 0.0088 0.024
20
4.302 4.279 4.279 4.281 4.286
4.2854 0.0097 0.023

4.28631 0.01297 0.0311

For the data set, the X bar control chart is shown in fig.1

For X bar chart, the LCL= 4.2684, UCL= 4.3043 and CL=4.2863;


Fig.1 Sample mean Control Chart for height (cm)

Any point falling outside the control limits indicates that assignable causes had affected the process and the process is out of
control. Looking into the X bar chart it is observed that all the points are falling within the control limits. It means that the
assignable cause does not affect the process.

For Range chart, the LCL= 0, UCL= 0.0657 and CL=0.0311;

Fig. 2 Range chart for height of the bolt

Looking into the R chart Fig.2 it is observed that all the points are falling within the control limits. It means that the assignable
cause does not affect the process.

For Standard Deviation chart the LCL= 0 , UCL= 0.0271 and CL=0.0130;

CL
4.2863
UCL 4.3043
LCL 4.2684
4.260
4.265
4.270
4.275
4.280
4.285
4.290
4.295
4.300
4.305
4.310
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
v
e
r
a
g
e
Sample No
X X1(height) - X5
CL 0.0311
UCL 0.0657
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R
a
n
g
e
Sample No
R X1(height) - X5

Fig.3 S chart for height of the bolt

Looking into the S chart Fig.3 it is observed that all the points are falling within the control limits. It means that the assignable

For the same dataset, Exponentially Weighted Moving Average control chart is shown in Fig.4.

Fig.4 EWMA chart for height of the bolt

Here,

UCL= 4.29379,
LCL = 4.27883,
Center line = 4.28631;
In the EWMA control chart of X, it is observed that all the points falling inside the control limits and there is no sharp shift is
observed so the process is in control.
For the same data set, Exponentially Weighted Moving Average control chart for S is shown in Fig.5

CL 0.0130
UCL 0.0271
0.000
0.005
0.010
0.015
0.020
0.025
0.030
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
S
t
d
e
v
1 - 20
S XbarS Chart
UCL
4.29379
CL 4.28631
LCL
4.27883
4.2760
4.2780
4.2800
4.2820
4.2840
4.2860
4.2880
4.2900
4.2920
4.2940
4.2960
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
v
e
r
a
g
e
1 - 20
EWMA Chart

Fig.5 EWMA chart for Standard Deviation

Here,

UCL= 0.01870,
LCL = 0.00724,
In this EWMA control chart for S it is observed that all the points falling inside the control limits and there is no sharp shift is

For the same data set, Exponentially Weighted Moving Average control chart for Range is shown in Fig.6

Fig.6 EWMA chart for Range

Here,
UCL= 0.0428,
UCL
0.01870
CL 0.01297
LCL
0.00724
0.0050
0.0070
0.0090
0.0110
0.0130
0.0150
0.0170
0.0190
0.0210
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
S
t
a
n
d
a
r
d

D
e
v
i
a
t
i
o
n
1 - 20
EWMA Chart
UCL
0.0428
CL 0.0311
LCL
0.0194
0.015
0.020
0.025
0.030
0.035
0.040
0.045
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R
a
n
g
e
1 - 20
EWMA Chart

LCL = 0.0194,
In the EWMA control chart for Range it is observed that all the points falling inside the control limits and there is no sharp shift is
B. X bar, Range, S, EWMA control charts for diameter of the bolt

Table -2 Data set for diameter of the specific type of Bolt

Sample
No
X
1
(Diameter)

X
2

X
3

X
4

X
5

X

S

R

01 7.521 7.531 7.508 7.546 7.513 7.524 0.015 0.038
02 7.592 7.503 7.521 7.581 7.529 7.545 0.039 0.089
03 7.501 7.561 7.520 7.561 7.545 7.538 0.026 0.060
04 7.543 7.556 7.569 7.508 7.541 7.543 0.023 0.061
05 7.575 7.541 7.577 7.551 7.530 7.555 0.021 0.047
06 7.583 7.543 7.526 7.546 7.536 7.547 0.022 0.057
07 7.521 7.554 7.513 7.533 7.567 7.538 0.023 0.054
08 7.503 7.509 7.505 7.526 7.581 7.525 0.033 0.078
09 7.512 7.561 7.506 7.514 7.521 7.523 0.022 0.055
10 7.569 7.567 7.519 7.559 7.525 7.548 0.024 0.050
11 7.550 7.541 7.526 7.561 7.519 7.539 0.017 0.042
12 7.521 7.509 7.567 7.545 7.504 7.529 0.026 0.063
13 7.549 7.513 7.589 7.516 7.567 7.547 0.033 0.076
14 7.589 7.589 7.582 7.521 7.581 7.572 0.029 0.068
15 7.521 7.523 7.503 7.580 7.524 7.530 0.029 0.077
16 7.531 7.540 7.509 7.560 7.532 7.534 0.018 0.051
17 7.502 7.554 7.511 7.513 7.545 7.525 0.023 0.052
18 7.530 7.534 7.536 7.519 7.551 7.534 0.012 0.032
19 7.578 7.516 7.546 7.526 7.549 7.543 0.024 0.062
20 7.545 7.505 7.560 7.543 7.561 7.524 0.015 0.042
7.5391 0.0240 0.0584

For the data set the X bar control chart is shown in Fig.7

For X bar chart, the LCL= 7.5048 , UCL= 7.5734 and CL=7.5391;

Fig.7 Sample mean for diameter of the bolt

Any point falling outside the control limits indicates that assignable causes had affected the process and the process is out of
control. Looking into the X bar chart it is observed that all the points are falling with-in the control limits. It means that the
assignable cause does not affect the process.

CL
7.5391
UCL 7.5734
LCL 7.5048
7.490
7.510
7.530
7.550
7.570
7.590
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
v
e
r
a
g
e
1 - 20
X - X5

For Standard Deviation chart, the LCL= 0, UCL= 0.0502 and CL=0.0240;

Fig.8 Standard Deviation chart for diameter of the bolt


For Range chart, the LCL= 0, UCL= 0.1235 and CL=0.0584;

Fig.9 Range chart for diameter of the bolt


For the same data set, Exponentially Weighted Moving Average control chart is shown in Fig.10

CL 0.0240
UCL 0.0502
0.000
0.010
0.020
0.030
0.040
0.050
0.060
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
S
t
d
e
v
1 - 20
S - X5
CL 0.0584
UCL 0.1235
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R
a
n
g
e
1 - 20
R XbarR Chart

Fig.10 EWMA chart for Average

Here,

UCL= 7.5532,
LCL = 7.5231,
In the EWMA control chart of X it is observed that all the points falling inside the control limits and there is no sharp shift is



Here,

UCL= 0.0320,
LCL = 0.0154,
UCL
7.5532
CL 7.5382
LCL
7.5231
7.515
7.520
7.525
7.530
7.535
7.540
7.545
7.550
7.555
7.560
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
v
e
r
a
g
e
1 - 20
EWMA Chart
UCL
0.0320
CL 0.0237
LCL
0.0154
0.010
0.015
0.020
0.025
0.030
0.035
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
S
t
a
n
d
a
r
d

D
e
v
i
a
t
i
o
n
1 - 20
EWMA Chart

For the same data set Exponentially Weighted Moving Average control chart is shown in Fig.12


Here,

UCL= 0.0763,
LCL = 0.0391,

C. X bar, Range, S, EWMA control charts for weight of the bolt

Table -3 Data set for weight of the specific type of Bolt

Sample
No.
X1(weight)mg X2 X3 X4 X5 X S R
1 15.52 15.55 15.54 15.56 15.52 15.54 0.02 0.04
2 15.51 15.54 15.51 15.55 15.55 15.53 0.02 0.04
3 15.53 15.56 15.56 15.52 15.56 15.55 0.02 0.04
4 15.52 15.54 15.53 15.53 15.53 15.53 0.01 0.02
5 15.51 15.55 15.55 15.53 15.53 15.53 0.02 0.04
6 15.53 15.53 15.51 15.54 15.52 15.53 0.01 0.03
7 15.53 15.56 15.53 15.56 15.56 15.55 0.02 0.03
8 15.53 15.57 15.54 15.55 15.54 15.55 0.02 0.04
9 15.52 15.55 15.54 15.55 15.53 15.54 0.01 0.03
10 15.51 15.54 15.52 15.52 15.54 15.53 0.01 0.03
11 15.54 15.54 15.56 15.57 15.56 15.55 0.01 0.03
12 15.51 15.55 15.54 15.56 15.51 15.53 0.02 0.05
13 15.55 15.54 15.54 15.54 15.55 15.54 0.01 0.01
14 15.54 15.56 15.54 15.55 15.56 15.55 0.01 0.02
15 15.54 15.53 15.51 15.53 15.54 15.53 0.01 0.03
16 15.53 15.56 15.52 15.56 15.52 15.54 0.02 0.04
17 15.52 15.55 15.56 15.54 15.54 15.54 0.01 0.04
18 15.53 15.55 15.53 15.52 15.56 15.54 0.02 0.04
19 15.53 15.57 15.53 15.51 15.56 15.54 0.02 0.06
20 15.54 15.53 15.54 15.56 15.57 15.55 0.02 0.04
15.539 0.015 0.035

UCL
0.0763
CL 0.0577
LCL
0.0391
0.030
0.040
0.050
0.060
0.070
0.080
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R
a
n
g
e
1 - 20
EWMA Chart

For the data set the X bar control chart is shown in Fig.13

For X bar chart, the LCL=15.519 , UCL= 15.559, and CL=15.539;

Fig.13 Sample mean chart for weight of the bolt

Looking into the X bar chart it is observed that all the points are falling with-in the control limits. It means that the assignable

For Range chart the LCL= 0, UCL= 0.1235 and CL=0.0584;

Fig.14 Range chart for weight of the bolt


For Range chart the LCL= 0, UCL= 0.1235 and CL=0.0584;
CL
15.539
UCL 15.559
LCL 15.519
15.50
15.51
15.52
15.53
15.54
15.55
15.56
15.57
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
v
e
r
a
g
e
1 - 20
X XbarR Chart
CL 0.035
UCL 0.074
0.00
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R
a
n
g
e
1 - 20
R XbarR Chart

Fig.15 Standard Deviation chart for weight of the bolt



Fig.16 EWMA chart for Average

Here,

UCL= 15.551,
LCL = 15.528,
CL
0.015
UCL 0.032
0.00
0.01
0.01
0.02
0.02
0.03
0.03
0.04
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
S
t
d
e
v
1 - 20
S XbarS Chart
UCL
15.551
CL 15.540
LCL
15.528
15.50
15.51
15.52
15.53
15.54
15.55
15.56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A
v
e
r
a
g
e
Period
EWMA Chart

For the same data set Exponentially Weighted Moving Average control chart is shown in Fig.17.


Here,

UCL= 0.021,
LCL = 0.010,
For the same data set Exponentially Weighted Moving Average control chart is shown in Fig.18


Here,

UCL= 0.047,
UCL
0.021
CL 0.016
LCL
0.010
0.00
0.01
0.01
0.02
0.02
0.03
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
S
t
a
n
d
a
r
d

D
e
v
i
a
t
i
o
n
1 - 20
EWMA Chart
UCL
0.047
CL 0.035
LCL
0.023
0.00
0.01
0.01
0.02
0.02
0.03
0.03
0.04
0.04
0.05
0.05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
R
a
n
g
e
1 - 20
EWMA Chart

LCL = 0.023,

D. Multivariate control chart (Hotellings T
2
)

Multivariate control charts monitor multiple process characteristics. Independent variables can be put individually. But, when we
observe a relationship between two or more variables, we can use this chart to determine whether the process is in control.
Multivariate control charts can detect shifts in the mean or the relationship between several related variables. But, one difficulty
encountered with any multivariate control chart is practical interpretation of out-of-control signal that means if the process is out
of control, it is difficult to find the assignable cause.

In this case study, we have used Hotellings T
2
chart to represent the dual inspection result between two variables (height,
diameter) of our samples.

From the following chart, we came to the conclusion that all the points are in controlled region except a point which almost
touched the UCL. This irregular behaviour has occurred for some assignable causes indicating that the process is not fully in
control.

Fig.19 Hotellings T
2
chart for height and diameter

IV. CONCLUSION

Control charts are among the most effective management control tools, and they are as important as cost control and
material control. This verifies, graphically, variation in output quality characteristics against pre-fixed upper and lower limits. In
our case study, we exactly did the same thing by experimenting with three variables; height, diameter and weight of our samples
from bolt manufacturing industry and put them in different control charts to inspect the quality of the samples. We have come in
the settlement that in all the figures, points are within the control limit representing the process is in control. All the figures have
been plotted by popular PC based statistics package.

V. APPENDIX

0.0000
1.0000
2.0000
3.0000
4.0000
5.0000
6.0000
7.0000
8.0000
9.0000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
T
2

C
h
a
r
t
Period
T2 Chart T2
T12
UCL1

REFERENCES

[1] D.C.Montgomery,[2002] Introduction To Statistical Quality Control, 4th Edition,Willey,New York,
[2] A.J.Duncan, [1986] Quality control and Industrial statistics, 5th edition,Irwin,Homewood,Illinois .
[3] W.A.Shewhart, Statistical Method From The Viewpoint Of Quality Control,Dover Publications,Inc,New York
[4] Dr.M.Ahsan Akhtar Hasin,[2007] Quality control and Management,1st Edition,Bangladesh Business Solutions,Dhaka
[5] Muhammad Riaz and Faqir Muhammad, [2012], An Application of Control Charts in Manufacturing Industry, Journal of
Statistical and Econometric Methods, vol.1, no.1, 2012, 77-92

First Author Fahim Ahmed Touqir, Department of Industrial Engineering & Management, Khulna University of Engineering &
Technology (KUET), Khulna-9203, Bangladesh.
Completed project is Automation of Material Handling with Bucket Elevator and Belt Conveyor ( last semester); upcoming project
on Sensitivity Analysis for financial performance improvement , currently a member of IEM Association of KUET.

Second Author Md. Maksudul Islam, Department of Industrial Engineering & Management, Khulna University of Engineering
& Technology (KUET), Khulna-9203, Bangladesh.
Completed project is the implementation of dynamo generator for storage electricity in a battery (last semester); upcoming projects
are sensitivity analysis and six sigma for lean production; currently a member of IEM Association of KUET, having technical
scholarship throughout the semester.

Third Author Lipon Kumar Sarkar, Department of Industrial Engineering & Management, Khulna University of Engineering
& Technology (KUET), Khulna-9203, Bangladesh.
Completed project is the implementation of dynamo ge nerator for storage electricity in a battery (last semester); upcoming projects
on supply chain management, currently a member of IEM Association of KUET; having Govt. scholarship for brilliant result.

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International Journal of Science, Engineering and Technology Research (IJSETR), Volume 3, Issue 3, March 2014

ISSN: 2278 7798 All Rights Reserved 2014 IJSETR 444

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