statistical quality control - gbv

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Statistical Quality Control Sixth Edition Eugene L. Grant Professor of Economics of Engineering, Emeritus Stanford University Richard S. Leavenworth Professor of Industrial and Systems Engineering University of Florida 1 8 ; 8 ; 8 Ш KD T E А Я S I • 9 • 8 • 8 McGraw-Hill Book Company New York St. Louis San Francisco Auckland Bogota Caracas Colorado Springs Hamburg Lisbon London Madrid Mexico Milan Montreal New Delhi Oklahoma City Panama Paris San Juan Säo Paulo Singapore Sydney Tokyo Toronto

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Page 1: Statistical Quality Control - GBV

Statistical Quality Control

Sixth Edition Eugene L. Grant

Professor of Economics of Engineering, Emeritus Stanford University

Richard S. Leavenworth Professor of Industrial and Systems Engineering

University of Florida

1 • 8 ; 8 ; 8

Ш KD T E А Я S

I • 9 • 8 • 8

McGraw-Hill Book Company New York St. Louis San Francisco Auckland Bogota Caracas

Colorado Springs Hamburg Lisbon London Madrid Mexico Milan Montreal New Delhi Oklahoma City Panama Paris

San Juan Säo Paulo Singapore Sydney Tokyo Toronto

Page 2: Statistical Quality Control - GBV

Contents List of Examples xiii

Preface xv

1 Introduction 1

Part One Statistical Process Control 29

2 Why the Control Chart Works; Some Statistical Concepts frequency distributions; averages and measures of dispersion; statistics and parameters; normal curve; estimating parameters 31

3 Why the Control Chart Works; Some Examples control-chart limit factors; Shewhart's normal bowl; lack of control; interpreting patterns of variation 74

4 Directions for Simple X and R Charts control-chart objectives; subgrouping; recording measurements; plotting control charts; drawing conclusions; revising control limits; use of computer software 115

5 Rational Subgrouping; Analyzing Process Capability sources of variation; isolating variation sources; using control charts to analyze variation; process capability indexes; other statistical techniques 154

6 Some Fundamentals of the Theory of Probability definitions and concepts; basic theorems; hypergeometric, binomial, and Poisson distributions; normal distribution and Central Limit Theorem; estimating parameters; extreme runs; computer programs 181

7 The Control Chart for Fraction Rejected p chart; trial limits; standard

Page 3: Statistical Quality Control - GBV

X Contents

values; revising control limits; steps for control-chart setup; np chart; interpretation of lack of control 239

8 The Control Chart for Nonconformities с chart; и chart; probability limits; Pareto Analysis; Cause and Effect Analysis; weighting nonconformities 274

9 Some Special Process Control Procedures variations on the standard Shewhart chart; charts for medians; homogeneity tests; probability limits; charts for moving averages; linear trend charts; narrow limit gauging; reject limits; acceptance control charts 302

10 Cumulative Sum Control Charts X chart and mask construction; Average Run Length; R chart mask construction 348

11 Some Aspects of Specifications and Tolerances setting design specifications; interpreting pilot runs; combinations of tolerances; measurement error 361

Part Two Acceptance Sampling 391

12 Some Fundamental Concepts in Acceptance Sampling operating characteristic curves; distribution assumptions; indexing systems of acceptance plans; single-, double-, and multi-level plans 393

13 The Dodge-Romig System for Lot-by-Lot Acceptance Sampling by Attributes indexing plans by Lot Tolerance Percent Defective and Average Outgoing Quality Limit; calculation of AOQ; Average Fraction Inspected; plan operation; minimizing total inspection 426

14 An AQL System for Lot-by-Lot Acceptance Sampling by Attributes (ABC-STD-105) indexing by Acceptable Quality Level (AQL); operation of a system of plans; plan ОС curves vs. system ОС curves; Average Sample Number (ASN); classification of defects; Limiting Quality (LQ); ANSI standard Z 1.4 450

15 Certain Other Plans for Lot-by-Lot Acceptance Sampling by Attributes custom sampling plans; sequential sampling; Philips Standard Sampling System; a simplified AQL system; chain sampling 492

16 Acceptance Inspection for Continuous Production continuous sampling plans CSP-1, CSP-2, and CSP-3; multilevel continuous sampling; skip-lot sampling Plans SkSP-1 and SkSP-2 520

17 Acceptance Sampling by Variables Lot Plot method; ОС curves for known o- variables sampling plans; MIL-STD-414 system of plans, known and unknown о-; ANSI standard Z1.9; proof testing 537

18 Some Aspects of Life Testing and Reliability relationship of life testing to acceptance sampling; constant failure rate assumption; ОС curves;

Page 4: Statistical Quality Control - GBV

Contents xi

estimating mean life; government publications; reliability functions other than negative exponential 580

Part Three Some Related Topics 613

19 Some Economic Aspects of Quality Decisions 615 20 Demonstrating the Operation of Systems of Chance Causes 635 21 The Widespread Usefulness of Control Charts and Acceptance Sampling

Procedures 640

Appendixes 646

1 Glossary of Symbols 646

2 Bibliography 656

3 Tables 665

A Area under the normal curve 666 В Right tail area of the \2 distribution 668 С Factors for estimating a from R, J, or CTRMS and aR from R . _669 D Factors for determining from R the 3-sigma control limits for X and

R charts 670 E Factors for determining from J and crRMs the 3-sigma control limits

for X and s or aRMS charts 671 F Factors for determining from a the 3-sigma control limits for X, R,

and л or <7RMS charts 672 G Summation of terms of Poisson's exponential binomial limit 673 H Logarithms of factorials 678 J Logarithms of numbers 683 К Sample size code letters—MIL-STD-105D (ABC standard) 685 L Master table for normal inspection (single sampling)—

MIL-STD-105D (ABC standard) 686 M Master table for tightened inspection (single sampling)—

MIL-STD-105D (ABC standard) 687 N Master table for reduced inspection (single sampling)—

MIL-STD-105D (ABC standard) 688 О Master table for normal inspection (double sampling)—

MIL-STD-105D (ABC standard) 689 P Master table for tightened inspection (double sampling)—

MIL-STD-105D (ABC standard) 690 Q Master table for reduced inspection (double sampling)—

MIL-STD-105D (ABC standard) 691

Page 5: Statistical Quality Control - GBV

xi i Contents

R Master table for normal inspection (multiple sampling)— MIL-STD-105D (ABC standard) 692

S Master table for tightened inspection (multiple sampling)— MIL-STD-105D (ABC standard) 694

T Master table for reduced inspection (multiple sampling)— MIL-STD-105D (ABC standard) 696

U Average Outgoing Quality Limit factors for normal inspection (single sampling)—MIL-STD-105D (ABC standard) 698

V Average Outgoing Quality Limit factors for tightened inspection (single sampling)—MIL-STD-105D (ABC standard) 699

W Limit Numbers for reduced inspection—MIL-STD-105D (ABC standard) 700

X Random numbers 701

Index 703