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IS 397-1: Method for Statistical Quality Control During Production, Part 1: Control Charts for Variables PDF

29 Pages·2003·2.3 MB·English
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इंटरनेट मानक Disclosure to Promote the Right To Information Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. “जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न’ 5 तरफ” Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru “The Right to Information, The Right to Live” “Step Out From the Old to the New” IS 397-1 (2003): Method for Statistical Quality Control During Production, Part 1: Control Charts for Variables [MSD 3: Statistical Methods for Quality and Reliability] “!ान $ एक न’ भारत का +नम-ण” Satyanarayan Gangaram Pitroda ““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee”” “!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै” Bhartṛhari—Nītiśatakam “Knowledge is such a treasure which cannot be stolen” IS 397 (Patt 1) :2003 W?dkmFm ml Indian Standard METHODS FOR STATISTICAL QUALITY CONTROL DURING PRODUCTION PART 1 CONTROL CHARTS FOR VARIABLES . 1 (Second Revision) , ICS03.120.30 0 BIS2003 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 December 2003 Price Group 9 ... ,,%. ! Statistical Methods for Quality and Reliability Sectional Committee, MSD 3 FOREWORD This Indian Standard (Part 1)(Second Revision) wasadopted bythe Bureau of Indian Standards, atler the draft finalized by the Statistical Methods for Quality and Reliability Sectional Committee had been approved by the Management and Systems Division Council. Controlling the quality ofproducts soastomaintain itatagiven level isamajor problem with allthe producers. Fromtheearlydaysofindustrial production manufacturers havetried tousethesamemen,machines andmethods and similar raw materials inthe hope of turning out products ofuniform quality. But neither men nor machines are infallible and causes of irregularity often creep inadvertently. Asaresult, rejections infinished materials are rarely eliminated and inspection and screening become necessary to varied extents determined by the nature of the product and the goodwill and policy of the manufacturer. Sincescreening isnot aneffective control, thequestion remained alively issuewith the production management andvarious systemsofcontrol weredevised fromtime-to-time. In 1924Dr. W.A. Shewhart oftheBellTelephone Laboratories, USA developed the control chart method of controlling the quality during production which is meant to be an integral part of the production process, This technique based on statistical methods, however, does notprovide anautomatic corrective action inthewaymechanical or electrical systems do. Instead, itgives awarning signal to the operator that hemust take here and nowthe corrective action on his machine or process to ensure maintenance of quality in further production. Its effectiveness, therefore, depends on the promptness withwhichthewarning isheeded to andaction taken, keeping inviewthefactthat thework involved inapplying themethod islargely basedonjudgement, knowledge oftheprocessandtechnical skill intracing downassignable causes ofvariation to their source. Thisstandard, wasoriginally published in 1952,waslargelyareproduction oftheAmerican Defence Emergency Standard Z 1.3-1942 ‘Control chart method of controlling quality during production’ which had proved quite useful inthe military stores purchases during second war. The first revision of this standard had been taken up with aview to make the standard more comprehensive by including control charts for medians and mid-ranges whicharequicker, easytooperate andatthesametimequiteefficient forsmallsamples. Further, themethodology ofadopting control charts techniques for usewhenmanufacturing isundertaken to apredetermined specification was also included. As the original standard was bulky, itwas split into two parts during this revision, namely, Part 1dealing with control charts for variables and Part 2dealing with control charts for attributes. This second revision ofthe standard has beentaken upto inc)ude: a) difference between assignable causes and chance causes inatabular form, b) choice of measuring equipment during the preliminaries to installation of control charts, c) tiu-therguidance for deciding the frequency during the preliminaries to installation of control charts, d) explanation for not considering lower control limit (LCZ,)for homogenization of range values in R-chart and further necessary actions, e) conditions under which modified control chart should not be used, f) many editorial corrections, and g) amendment issued to this standard at appropriate place. Further inthis revision the text on process capability and itscomparison with the tolerance have been suitably modified and reference has been given m 1S 10645 :2002 ‘Methods for estimation of process capability and process performance’, isthe necessary adjunct to this standard. Inaddition tothis Part 3, 1S397 has the four parts. The other parts are: (Part O):2003 Guidelines for selection of control charts (#h-strevision) (Part 2) :2003 Control charts for attributes (third revision) (Part 3): 2003 Special control charts by variables (first revision) (Part 4): 2003 Special control charts by attributes (first revision) The composition of the Committee responsible for the formulation ofthis standard isgiven in Annex I). - *.” .. . IS397 (part 1) :2003 Indian Standard METHODS FOR STATISTICAL QUALITY CONTROL DURING PRODUCTION PART 1 CONTROL CHARTS FOR VARIABLES (Second Revision) 1SCOPE ISNo. Title applications: Part 2 Continuous 1.1Thisstandard(Part 1)outlinesthemethodofcontrol models (first revision) chart by variables for controlling the quality during production. The principles of procedure pertaining to 10645:1998 Method for estimation ofprocess control charts for individual observations, averages, capability (first revision) medians, mid-ranges, ranges and standard deviations 5420 Guideonprecisionoftestmetho& (Part 1): 1969 Principles and applications are given ingeneral terms. (Part 2): 1973 Inter laboratory testing 1.2 The standard also lays down the procedures for 3TERMINOLOGY the construction of modified control charts which can be usefully adopted when the manufacture is For the purpose of this standard the definitions given undertaken to predetermined specifications. inIS 7920 (Part 1)and IS 7920 (Part 2) shall apply. 1.3 The principles of control charts have been 4BASICCONCEPTS UNDERLYING CONTROL illustrated with a variety of examples. Certain broad CHART TECHNIQUE guidelines astothe interpretation ofthe data resulting 4.1 Variation and ItsCauses from control charts are also included. In the repetitive making of a product so often met in 2REFERENCES the present day industrial production, variation inany The following standards contain provisions, which chosen quality characteristic is an ever present through reference inthis text constitute provisions of phenomenon. Although such variation may be due to this standard. At the time of publication, the editions a variety of causes and their interaction known and indicated were valid. All standards are subject to unknown,which constantly influence theprocess, they revision and parties to agreements based on this can be broadly classified into following two distinct standard are encouraged to investigate the possibility categories: of applying the most recent editions of the standards a) Variation due to assignable causes, such as, indicated below: different settings of a machine, different 1SNo. Title batches of raw materials that are being fed, 7920 Statistical vocabulary and andchanges inoperators whohavetien over symbols: inanew shift. (Part 1): 1994 Probability andgeneral statistical b) Variation due to chance (non-assignable or terms (second revision) common) causeswhichareunavoidable inthe (Part 2): 1994 Statistical qualitycontrol (second process due to such inherent variation that revision) existinrawmaterials, machines, atmospheric 9300 (Part 2): 1989 Statistical models for industrial conditions, etc. ,.. ~“..- IS397 (Part 1): 2003 4.2 Difference Between Chance Causes and Assignable Causes sl Chance (Non-assignable) Causes Assignable Causes No. (1) (2) (3) i) Consists ofmany individual causes. Consists of one orjust afew individual causes. ii) Any one chance cause results in a minute Any one assignable cause can result in a large amount of variation (but many chance causes amount of variation. acttogether toyield asubstantial total). iii) Cannot economically be eliminated from a Can be detected. Action to eliminate the cause(s) is process. usually economically justified. iv) When only chance cause is present, the If assignable variation is present the process isnot process isoperating at itsbest. operating at itsbest. v) An observation within the control limits of An observation beyond control limitsusually means random variation means the process should the process should be investigated and corrected. not be adjusted. vi) Under chance causes, the process is With assignable causes present, the process is not sufficiently stable to use sampling procedures suftlciently stable to use sampling procedures for to predict the quality of total production or prediction. make process optimization studies. 4.3 Process Under Statistical Control from aprocess follow a statistical law inthe form of a known distribution, if samples of given size are taken Whennoassignable causes of variation arepresent in fromthesameprocess atmore or lessregular intewals, aprocess and itoperates only under asystem ofnon- then sample statistic, such as average or standard assignable or chance causes, the process issaid to be deviation, also follow known distributions. Of course, inastate of statistical control. Such variations due to thisdistribution isnot thesameastheone obtained for chance causes occur in a random fashion and are theindividualobsewations fromtheprocess. Generally usually found to obey certain statistical laws. If large speaking the distribution of the sample statistics that numberofobservations obtained fromaprocess,which isunder astate ofstatistical control, are studied inthe aredealtwithinthisstandardareofthenormalorknown form of afrequency distribution, itwill generally fall type whoseparameters canbe estimated. into a bell shaped symmetrical pattern wherein most 4.5 Control Charts of the observations cluster around the average value 4.5.1 The above mentioned behaviour of the sample and fewer observations are found as one moves away statistics obtaining fkoma process !nfluenced only by from the average value. random causes is the foundation on which the control 4.4 Normal Distribution chart technique is based. Essentially it is a graphical 4.4.1ThebelIshapedsymmetricpatternthatisobtained method representing a sequence (in time) of sample by the observations emanating from a process under statistics.Itconsistsof a central line(CL)denotingthe statistical control is generally well represented by the averagevalueofthestatisticbeingplottedandithastwo normaldistribution.Thisdistributionischaracterizedby controllimitsoneithersideofthecentrallinewhichare twoparameters,namelythemeanvalueandthestandard calleduppercontrol limit@VCLa)ndlowercontrollimit deviation. It is symmetrical and 99,73 percent of the (LCL).Thecontrollimitsaredeterminedstatisticallyfrom observationsliewithinthreestandarddeviationsfi-omthe theprobabilitydistributionofthesamplestatistic. mean on both sides. Thus, less than 3 in a thousand 4.5.2 The purpose of control chart isto obtain astate observationsareexpectedtofallbeyondthethreestandard of statistical control by locating and eliminating the deviations from the mean on both sides. For fiwther assignable causes and then to maintain theproduction description about the properties of this distribution, in this state so as to ensure the manufacture of attentionininvitedtoIS9300(Part2).Henceinaprocess consistent products of acceptable quality. For this understatisticalcontrolifanysinglemeasurementistaken purpose the variation due to non-assignable causes is and itdoesnotfallwithin*3CTtlom themean, itcanbe estimated and then used asthe basis for the detection regarded asnot belongingto that dkribution orto that of the variation due to assignable causes by plotting cause system and the presence of an assignable cause thesample statistic onthecontrol chart. Aslongasthe affectingtheprocessmaybeinferred. plotted point iswithin thecontrol limits,theprocess is 4.4.2Justasalargenumberofindividualmeasurements lefl alone. However, if a point falls either below the 2 ?.. “. *_ IS397 (part 1): 2003 lowercontrol limit or above the upper control limitor found within the sample items should be due to non- depicts other unnatural pattern (see 7.2) there is a assignableorrandomcauseswhereasthevariationfound possibility oftheexistence ofsomeassignable cause(s) between samples should be ascribable to some and an investigation is made for taking action to assignable causes. The division ofthe production flow eliminate such causes. insuchamannerthateachportionyieldsasamplehaving this property is known as ‘rational sub-grouping’. 5 PRELIMINARIES TO THE INSTALLATION A natural sub-group for example would be the output OF CONTROL CHARTS of a short time period since the variation in items 5.1 Choice of Quality Characteristic manufactured close to each other inthe time sequence Tostartwith,adecision hastobetaken withregard to aremuch more likelyto represent chance fluctuations. the quality characteristics for which a control 5.3.2 Theproblem offormingrational sub-groupsalso programme is desired. Characteristics affecting the depends onthe technical knowledge of the production performance of the product should normally be the process and the familiarity with the conditions under object of first attention. These may be the features of whichtheproduct isto bemanufactured. Whereas itis the materials used or components or parts of the notpossibletogiveexact instructions fortheformation products, forexample, tensile strength ofthecorewire of rational sub-groups that will cover all cases, a few ofcablesorthickness ofthe insulation. Sometimes the illustrations may be helpfhl in this direction. Thus, if characteristic may be for the finished product as a different machine settingshave aneffect onthequality whole likethe life of incandescent lamps. characteristicthatisbeingstudied,alltheunitsinasingle sub-group should come from the same setting. Again, 5.2 Choice ofthe Place for Control ifdifferent batches of material have an effect, then all 5.2.1 In any production process it is of utmost units inone sub-group should be from the samebatch. importance that proper checks through control charts Extendingthis,itmaygenerallybeadvisablenottoform areexercized atstrategic points. Topinpoint theplace sub-groups suchthat asingle sub-group willconsistof for suchcontrols itisdesirable to determine the areas itemsmanufacturedindifferent shifts,fromcomponents ofmaximum potential for return inthe form of direct obtained from different sources, from different profits, reduction in scraps, increase in productivity, production lines, from different machines, moulds, etc.Apropervalueanalysisofalltheperformance may operators, etc.Inmany situations asmallsampletaken be quite helpful inthe context. intheorderofproduction meetstheprincipleofrational sub-groups, sinceitislikelytorepresent theimmediate 5.2.2 Itmayalsobeworthwhiletostudytheproduction state of the process at the time sample was selected. process to determine the nature and location of the However, itshould be noted that this isnot auniversal causes that tend to give rise to deviations in the recommendation.Ifoneisttilng samplefromamachine characteristic chosen. The method of inspecting with multiple spindles or multiple positions or heads, individual article or produ ct for the selected thenaseriesofconsecutive unitsfromthemachineasa characteristic is equally important since factors like whole will not form a rational sub-group capable of inspection fatigue may give rise to errors in studyingthe variation between the different heads.For observations.Thus,irregularities evident inqualitydata example, if a filling machine has six heads which may arise from errors of inspection as well as from simultaneously fill six consecutive containers in the faults inthe production process. Errors in inspection production line,theneverysixthunittaken(andnotthe may result from a faulty test apparatus, faulty use of consecutive six units) from the process will form a otherwisecorrect apparatus, etc.Itisalsotobedecided rational sub-group, becatisethe variations within such beforehand whether the entire output of products sub-groups would be the inherent variation due to the should be considered as a single stream having a heads andthe variation between the sub-groups would common system of causes or as two or more distinct be the variation obtaining from the different heads of streams each to be treated separately in the control the machine. In such situations, precise setting of the programme because they come from different cause sixheadsbecomes verycrucial. systems such as different conveyor lines, different machines or different shifts of workmen, etc. 5.3.3Toavoidbiasintheformationofrationalsubgroups, the following two precautions must be taken in the 5,3 Choice of Rational Sub-groups selectionof consecutivesamples:(a) periodic selection 5.3.1 Sincethebasicaimofcontrolchartsistoseparate shouldnot coincidewith any relevant-periodic features the variation due to assignable and non-assignable intheprocess,and(b)selectionofsamplesshouldnotbe causes, it is evident that each sample should be madeon a fixedtime schedule ifforeknowledgeofthe representative of a homogeneous segment of the selectiontime would have an influence on the quality production flow.Sointhe idealcondition thevariation characteristicofthearticleselected. 3 IS397 (Part 1) :2003 5.4 Frequency and Size of Samples tolerable depending uponthe application. Ifit exceeds 30 percent, the equipment should be regarded as 5.4.1Nogeneral rules maybe laiddown forfrequency inappropriate. Inaddition, themeasurementuncertainty of sub-groups. Each case must be decided on its own ofthe measuring equipment should be much lessthan meritsconsidering boththecostoftakingandanalyzing the tolerance ofthe characteristic. measurements and the benefits to be derived from action based on control charts. Inthe initial useofthe 5.6 Choice of the Types of Control Charts control chart for analyzing a process, it may be In the case of measurable quality characteristics it is desirable to arrive at conclusions quickly by taking generally the common practice to maintain a pair of frequent sampIes. Later on, if troubles have been control charts — one for the control of average level diagnosedandcorrected andthefunction ofthecontrol of the process (average chart or median chart or chart has become the maintenance of the process mid-range chart) and the other for the control of control on current production, it may be advisable to reducethefrequency ofsampling. Asaguideline, sub- dispersion (range chart or standard deviation chart). Of course, when a chart for individtial measurements group frequencies for ongoing production monitoring is maintained, there is no possibility of keeping the could betwice per shift, hourly or some other feasible companion chart for dispersion. rate,however, interval between twosub-groups should be half of the known duration of trouble free 6SETTING UP OF THE CONTROL CHART performance. 6.1 Preliminary Data Collection 5.4.2 The sizeofthe sample to betaken depends ona numberofpracticalconsiderations. However,generally After having decided upon the quality characteristic speaking, largesamples taken atlessfrequent intervals whichistobecontrolled andthe frequency andsizeof may detect a small shift in the process average more the sample to be taken, some initial inspection data quickly, but small samples taken at more frequent has to be collected and analyzed for the purpose of intervalswilldetect alarge shiftmore quickly. Inmost determining the central line and control limits of the ofthe industrial use of the control charts, samples of static. The preliminary data may be colIected sample size 4 or 5 are found to be quite common. A sample bysample(in sub-groups ofsize asdecided in5.4)till sizeof5isrecommended sincethe computation ofthe about 25 samples are obtained from the continuous average in this case can be considerably simplified. run ofthe production process. Care isto be exercised Whenmedian charts are used, samples of size 3 or 5 during thecourse ofthis initial data collection thatthe aremostconvenient since they avoid the computation process is not unduly influenced intermittently by altogether for the calculation of the median value. In extraneous factors like change in the feed of raw casethemid-range isused, then alsothecomputations materials, operators and machine settings. are considerably simplified since the average of only two observations (Iargest and smallest) are to be 6.2 Analysis of Preliminary Data obtained. It may, however, be noted that the use of 6.2.1 Analysis of the preliminary data is undertaken median or mid-range in place of average results in a firstly by homogenizing the dispersion (range or slight lossof efficiency but this loss ismarginal inthe standard deviation) ofthevarious sub-groups andthen case of small samples. Samples of smailer size may by homogenizing the central tendency (such as havetobeusedifthecostofmeasurements istoohigh. average, median or mid-range). This order for Inmostofthe chemical industries using batch process homogenization process becomes necessary sincethe the samples of size 1or 2 are frequently preferred. It ranges (or standard deviation) also enter into the may,however, benoted that larger the sample sizethe calculations needed for homogenizing the averages. moredesirable itistousethestandard deviation rather than range as a measure of sub-group dispersions, 6.2.2 Homogenization for Dispersion 5.5 Choice of Measuring Equipment 6.2.2.1 Using range method The measuring equipment used for measuring the test Ifthe sample size chosen isnot more than 6, then for results should be calibrated whose least count should each of the sub-groups, the range (R) shall be first bepreferably 1/1Ohoftolerance orprocess capability. calculated and the average range value (~ ) shall be The variation due to measuring system should be computed from these ranges. Depending upon the quantified and minimized [see IS 5420 (Part 1) and IS 5420 (Part 2)]. This variation due to measuring samplesize,thevalueoffactor D1shallbechosenfrom Annex A. Ifal!theranges are found to be lessthan or system should be less than 10 percent of the total process variation ofthe characteristic. Ifthis variation equaltoDd ~ theinitialdata collected shallbedeemed is between 10 percent to 30 percent, it may still be tobe homogeneous and acceptable for the purpose of 4 ..,... IS397 (Part 1): 2003 further calculation ofthe control limits. Incaseoneor size. Ifanyoftheaverages are found to lieoutside the more range valuesare foundtoexceedthevalueDq~, interval ~ ~ A2~ then the observations in the sub- the observations inthesub-group corresponding tothis groups corresponding to these averages shall be range shall be discarded. For the remaining data, the discarded. From the remaining data, a fresh grand above procedure shall be repeated (that is, the average shall be computed and the above procedure calculation of the new average range R and shall be repeated till all the average values are found comparison of all the remaining ranges with D~ ~ ) to lie within Y k Az ~. In case the data has earlier been homogenized by using standard deviation tilalllthe range values are lessthan DA~. (see 6.2.1.2), then instead of A2~ the quantity Al F 6.2.2.2 Using standard deviation method shall be used in the above homogenization process In case the sample size chosen is fairly large, it is where the factor A~is suitably chosen tlom Annex A advisabletousestandard deviation insteadoftherange for the corresponding sample size. since the later is less efficient for large samples. The 6.2.3.2 Using median method procedure, however, is almost similar to that given in 6.2.2.1. For each of the sub-groups, the standard From the homogenized data for dispersion deviations shall be computed and from these values (see6.2.1.1), themedian foreachsample (M,)shallbe the average standard deviation F shall be computed. calculated andtheaverage ofthese medians(~~ )shall If all the individuals values are less than or equal to --i thenbecomputed. Aquantity F2 ~ shallbecalculated EdT (where Ed is a factor chosen from Annex A for where the value of factor F2 is chosen from Annex A thecorrespondingsamplesize)thentheinitialdatashall depending uponthe sample size. Ifanyofthemedians beconsidered tobehomogeneous. However, ifoneor are found to lie outside the interval fi, ~ F2 R then more s values are found to be exceeding B~I the observations corresponding to these sub-groups shall the sub-groups corresponding to those medians shall be discarded. For the remaining data the above be discarded. From the remaining sub-groups, afresh procedure shall be repeated (that is, the calculation averagemedianvalueshallbecomputed andtheabove procedure shall be repeated till all the median values of a new average standard deviation F. and the comparison of the remainings values with Bi F) till are found to liewithin ~, ~ Fz ~. allthe standard deviation values are lessthan Ed F. 6.2.3.3 Using mid-range method NOTE — LCL is notconsideredfor the homogenizationof The process of homogenization inthis case issimilar rangesorstandarddeviationsvaluesasminimum variationin to that for the homogenization of the medians except theprocessisintendedandthereforeisalwayswelcome.The onlypointtobeinvestigatedattha t stageisthecorrectnessof that the mid-range (M) has to be calculated for each thislessvalueof rangeorstandardde viation. If sucha low sub-groups (instead of median) and the factor Fz has valuehasreallybeenobtainedthensuchsituationsshouldbe tobereplaced by G2.The value offactor G2ischosen institutionalizedforfuture, from Annex A depending upon the sample size. 6,2.2.3 In the above process of homogenization, if more than 25 percent of the sub-groups are discarded 6.3 Control Limits for being out of control, the entire set of data maybe 6.3.1 Control Limits for Measures of Dispersion discarded. The fresh data should be collected after checking the process and eliminating the assignable 6.3.1.1 Range (R) chart cause(s) which were responsible for the high rate of The central line for the range chart is given by the outliers inthe preliminary data. homogenized average range value (ii ) obtained 6.2.3 Homogenization for Central Tendenqv according to 6.2.2.1. The upper control limit (UCL) and the lower control limit (LCL) for the range chart 6.2.3.1 Using average method areobtainedasD~ ~ andDJ ~ wherevaluesoffactors Fromthehomogenized datafordispersion (see6.2.2.1 D~andD~areobtained fromAnnex Adepending upon or 6.2.2.2), the average of each sub-group (X ) shall the sample size. be calculated. The average of these averages or the NOTE — ML fortherangechartcoincideswiththeX-axisas D,= O. grand average (~) for all the sub-groups shall then be calculated. In case the data has earlier been 6.3.1.2 Standard deviation (s) chart homogenized by using ranges (see 6.2.2.1) then a Thecentrallineforthestandarddeviationchartisgiven quantityA2 ~ shallbecalculated, where the factorAz bythehomogenized average standard deviation value ischosen fromAnnexAforthe corresponding sample 5 .. ,,

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