Control Charts – Detailed Notes (Statistical Quality
Control)
Theory of Control Charts
• A control chart is a statistical tool used in quality control to determine whether a manufacturing
or business process is in a state of statistical control. It helps monitor process variation over
time and distinguishes between common causes and special causes of variation.
• Main Components:
• • Central Line (CL): Represents the process average or mean.
• • Upper Control Limit (UCL): The upper boundary of acceptable variation.
• • Lower Control Limit (LCL): The lower boundary of acceptable variation.
• If sample points fall outside these limits, the process is considered out of control and
investigation is required.
Measurement Range
• The range is the difference between the largest and smallest observations in a sample.
• Range = Maximum value – Minimum value
• It measures the variability within a sample. Range is commonly used in control charts such as
the R■chart to monitor variation in small samples.
R Chart (Range Chart) – Construction and Analysis
• R charts are used to monitor the variability of a process when the sample size is small.
• Steps to Construct R Chart:
• 1. Collect samples from the process at regular intervals.
• 2. Calculate the range (R) for each sample.
• 3. Compute the average range (R■).
• 4. Determine control limits using constants from control chart tables.
• UCL = D4 × R■
• LCL = D3 × R■
• CL = R■
• Interpretation:
• • If points lie within limits → Process variation is under control.
• • If points fall outside limits → Special causes may exist.
Process Capability Study
• Process capability measures the ability of a process to produce products within specification
limits.
• Common capability indices:
• • Cp = (USL − LSL) / 6σ
• • Cpk = minimum[(USL − µ)/(3σ), (µ − LSL)/(3σ)]
• Where:
• USL = Upper Specification Limit
• LSL = Lower Specification Limit
• µ = Process Mean
• σ = Standard Deviation
• Higher Cp and Cpk values indicate a more capable process.
Uses of Control Charts
• • Monitoring production processes
• • Detecting unusual variations
• • Maintaining consistent product quality
• • Improving manufacturing efficiency
• • Reducing defective products
• • Assisting in process improvement
Attributes Control Charts
• Attribute control charts are used when data are counted rather than measured. They track
defects or defective items.
• Types:
• • p-chart (fraction defective)
• • np-chart (number of defectives)
• • c-chart (number of defects)
• • u-chart (defects per unit)
Defects
• A defect refers to a non■conformity or imperfection in a product that fails to meet quality
standards.
• Example:
• A shirt with a broken button, stain, or stitching problem contains defects.
• Difference:
• Defective item → Entire product unacceptable
• Defect → Individual flaw in product
C Chart – Construction and Analysis
• A c■chart is used to monitor the number of defects per unit when the sample size remains
constant.
• Steps:
• 1. Count number of defects in each unit.
• 2. Calculate average number of defects (c■).
• 3. Determine control limits.
• UCL = c■ + 3√c■
• LCL = c■ − 3√c■
• CL = c■
• Interpretation:
• • Points inside limits → Process stable
• • Points outside limits → Process requires investigation
Improvement by Control Charts
• Control charts help improve processes by:
• • Identifying sources of variation
• • Preventing production of defective items
• • Providing early warning signals
• • Supporting continuous quality improvement
Variable Sample Size
• When sample size changes, standard control charts cannot be used directly.
• In such cases:
• • Use adjusted control limits.
• • Use charts such as u■chart or p■chart where limits depend on sample size.