
Nonparametric Statistical Process Control
Description
Alles über E-Books | Antworten auf Fragen rund um E-Books, Kopierschutz und Dateiformate finden Sie in unserem Info- & Hilfebereich.
Statistical Process Control (SPC) methods have a long and successful history and have revolutionized many facets of industrial production around the world. This book addresses recent developments in statistical process control bringing the modern use of computers and simulations along with theory within the reach of both the researchers and practitioners. The emphasis is on the burgeoning field of nonparametric SPC (NSPC) and the many new methodologies developed by researchers worldwide that are revolutionizing SPC.
Over the last several years research in SPC, particularly on control charts, has seen phenomenal growth. Control charts are no longer confined to manufacturing and are now applied for process control and monitoring in a wide array of applications, from education, to environmental monitoring, to disease mapping, to crime prevention. This book addresses quality control methodology, especially control charts, from a statistician's viewpoint, striking a careful balance between theory and practice. Although the focus is on the newer nonparametric control charts, the reader is first introduced to the main classes of the parametric control charts and the associated theory, so that the proper foundational background can be laid.
* Reviews basic SPC theory and terminology, the different types of control charts, control chart design, sample size, sampling frequency, control limits, and more
* Focuses on the distribution-free (nonparametric) charts for the cases in which the underlying process distribution is unknown
* Provides guidance on control chart selection, choosing control limits and other quality related matters, along with all relevant formulas and tables
* Uses computer simulations and graphics to illustrate concepts and explore the latest research in SPC
Offering a uniquely balanced presentation of both theory and practice, Nonparametric Methods for Statistical Quality Control is a vital resource for students, interested practitioners, researchers, and anyone with an appropriate background in statistics interested in learning about the foundations of SPC and latest developments in NSPC.
More details
Other editions
Additional editions


Persons
SUBHABRATA CHAKRABORTI, PHD is Professor of Statistics and Morrow Faculty Excellence Fellow at the University of Alabama, Tuscaloosa, AL , USA. He is a Fellow of the American Statistical Association and an elected member of the International Statistical Institute. Professor Chakraborti has contributed in a number of research areas, including censored data analysis and income inference. His current research interests include development of statistical methods in general and nonparametric methods in particular for statistical process control. He has been a Fulbright Senior Scholar to South Africa and a visiting professor in several countries, including India, Holland and Brazil. Cited for his mentoring and collaborative work with students and scholars from around the world, Professor Chakraborti has presented seminars, delivered keynote/plenary addresses and conducted research workshops at various conferences.
MARIEN ALET GRAHAM, PHD is a senior lecturer at the Department of Science, Mathematics and Technology Education at the University of Pretoria, Pretoria, South Africa. She holds an Y1 rating from the South African National Research Foundation (NRF). Her current research interests are in Statistical Process Control, Nonparametric Statistics and Statistical Education. She has published several articles in international peer review journals and presented her work at various conferences.
Content
About the Authors xiii
Preface xv
About the companion website xix
1 Background/Review of Statistical Concepts 1
Chapter Overview 1
1.1 Basic Probability 1
1.2 Random Variables and Their Distributions 3
1.3 Random Sample 12
1.4 Statistical Inference 16
1.5 Role of the Computer 22
2 Basics of Statistical Process Control 23
Chapter Overview 23
2.1 Basic Concepts 23
2.1.1 Types of Variability 23
2.1.2 The Control Chart 25
2.1.3 Construction of Control Charts 29
2.1.4 Variables and Attributes Control Charts 30
2.1.5 Sample Size or Subgroup Size 31
2.1.6 Rational Subgrouping 31
2.1.7 Nonparametric or Distribution-free 34
2.1.8 Monitoring Process Location and/or Process Scale 36
2.1.9 Case K and Case U 37
2.1.10 Control Charts and Hypothesis Testing 37
2.1.11 General Steps in Designing a Control Chart 39
2.1.12 Measures of Control Chart Performance 39
2.1.12.1 False Alarm Probability (FAP) 41
2.1.12.2 False Alarm Rate (FAR) 43
2.1.12.3 The Average Run-length (ARL) 43
2.1.12.4 Standard Deviation of Run-length (SDRL) 44
2.1.12.5 Percentiles of Run-length 44
2.1.12.6 Average Number of Samples to Signal (ANSS) 48
2.1.12.7 Average Number of Observations to Signal (ANOS) 48
2.1.12.8 Average Time to Signal (ATS) 48
2.1.12.9 Number of Individual Items Inspected (I) 49
2.1.13 Operating Characteristic Curves (OC-curves) 50
2.1.14 Design of Control Charts 51
2.1.14.1 Sample Size, Sampling Frequency, and Variable Sample Sizes 51
2.1.14.2 Variable Control Limits 54
2.1.14.3 Standardized Control Limits 56
2.1.15 Size of a Shift 57
2.1.16 Choice of Control Limits 59
2.1.16.1 k-sigma Limits 59
2.1.16.2 Probability Limits 60
3 Parametric Univariate Variables Control Charts 63
Chapter Overview 63
3.1 Introduction 64
3.2 Parametric Variables Control Charts in Case K 64
3.2.1 Shewhart Control Charts 65
3.2.2 CUSUM Control Charts 67
3.2.3 EWMA Control Charts 72
3.3 Types of Parametric Variables Charts in Case K: Illustrative Examples 77
3.3.1 Shewhart Control Charts 77
3.3.1.1 Shewhart Control Charts for Monitoring Process Mean 77
3.3.1.2 Shewhart Control Charts for Monitoring Process Variation 79
3.3.2 CUSUM Control Charts 84
3.3.3 EWMA Control Charts 87
3.4 Shewhart, EWMA, and CUSUM Charts: Which to Use When 90
3.5 Control Chart Enhancements 91
3.5.1 Sensitivity Rules 91
3.5.2 Runs-type Signaling Rules 95
3.5.2.1 Signaling Indicators 97
3.6 Run-length Distribution in the Specified Parameter Case (Case K) 110
3.6.1 Methods of Calculating the Run-length Distribution 110
3.6.1.1 The Exact Approach (for Shewhart and some Shewhart-type Charts) 110
3.6.1.2 The Markov Chain Approach 111
3.6.1.3 The Integral Equation Approach 128
3.6.1.4 The Computer Simulations (the Monte Carlo) Approach 128
3.7 Parameter Estimation Problem and Its Effects on the Control Chart Performance 131
3.8 Parametric Variables Control Charts in Case U 133
3.8.1 Shewhart Control Charts in Case U 133
3.8.1.1 Shewhart Control Charts for the Mean in Case U 133
3.8.1.2 Shewhart Control Charts for the Standard Deviation in Case U 134
3.8.2 CUSUM Chart for the Mean in Case U 137
3.8.3 EWMA Chart for the Mean in Case U 137
3.9 Types of Parametric Control Charts in Case U: Illustrative Examples 138
3.9.1 Charts for the Mean 138
3.9.2 Charts for the Standard Deviation 141
3.9.2.1 Using the Estimator Sp 144
3.10 Run-length Distribution in the unknown Parameter Case (Case U) 153
3.10.1 Methods of Calculating the Run-length Distribution and Its Properties: The Conditioning/Unconditioning Method 153
3.10.1.1 The Shewhart Chart for the Mean in Case U 153
3.10.1.2 The Shewhart Chart for the Variance in Case U 169
3.10.1.3 The CUSUM Chart for the Mean in Case U 170
3.10.1.4 The EWMA Chart for the Mean in Case U 171
3.11 Control Chart Enhancements 172
3.11.1 Run-length Calculation for Runs-type Signaling Rules in Case U 172
3.12 Phase I Control Charts 174
3.12.1 Phase I X-chart 174
3.13 Size of Phase I Data 176
3.14 Robustness of Parametric Control Charts 177
Appendix 3.1 Some Derivations for the EWMA Control Chart 178
Appendix 3.2 Markov Chains 180
Appendix 3.3 Some Derivations for the Shewhart Dispersion Charts 184
4 Nonparametric (Distribution-free) Univariate Variables Control Charts 187
Chapter Overview 187
4.1 Introduction 187
4.2 Distribution-free Variables Control Charts in Case K 189
4.2.1 Shewhart Control Charts 189
4.2.1.1 Shewhart Control Charts Based on Signs 189
4.2.1.2 Shewhart Control Charts Based on Signed-ranks 196
4.2.2 CUSUM Control Charts 202
4.2.2.1 CUSUM Control Charts Based on Signs 202
4.2.2.2 A CUSUM Sign Control Chart with Runs-type Signaling Rules 203
4.2.2.3 Methods of Calculating the Run-length Distribution 203
4.2.2.4 CUSUM Control Charts Based on Signed-ranks 205
4.2.3 EWMA Control Charts 208
4.2.3.1 EWMA Control Charts Based on Signs 208
4.2.3.2 EWMA Control Charts Based on Signs with Runs-type Signaling Rules 210
4.2.3.3 Methods of Calculating the Run-length Distribution 210
4.2.3.4 EWMA Control Charts Based on Signed-ranks 214
4.2.3.5 An EWMA-SR control chart with runs-type signaling rules 216
4.2.3.6 Methods of Calculating the Run-length Distribution 216
4.3 Distribution-free Control Charts in Case K: Illustrative Examples 219
4.3.1 Shewhart Control Charts 219
4.3.2 CUSUM Control Charts 229
4.3.3 EWMA Control Charts 243
4.4 Distribution-free Variables Control Charts in Case U 253
4.4.1 Shewhart Control Charts 254
4.4.1.1 Shewhart Control Charts Based on the Precedence Statistic 254
4.4.1.2 Shewhart Control Charts Based on the Mann-Whitney Test Statistic 275
4.4.2 CUSUM Control Charts 281
4.4.2.1 CUSUM Control Charts Based on the Exceedance Statistic 281
4.4.2.2 CUSUM Control Charts Based on the Wilcoxon Rank-sum Statistic 285
4.4.3 EWMA Control Charts 287
4.4.3.1 EWMA Control Charts Based on the Exceedance Statistic 287
4.4.3.2 EWMA Control Charts Based on the Wilcoxon Rank-sum Statistic 290
4.5 Distribution-free Control Charts in Case U: Illustrative Examples 293
4.5.1 Shewhart Control Charts 293
4.5.2 CUSUM Control Charts 295
4.5.3 EWMA Control Charts 302
4.6 Effects of Parameter Estimation 307
4.7 Size of Phase I Data 307
4.8 Control Chart Enhancements 308
4.8.1 Sensitivity and Runs-type Signaling Rules 308
Appendix 4.1 Shewhart Control Charts 311
Appendix 4.1.1 The Shewhart-Prec Control Chart 311
Appendix 4.2 CUSUM Control Charts 312
Appendix 4.2.1 The CUSUM-EX Control Chart 312
Appendix 4.2.2 The CUSUM-rank Control Chart 314
Appendix 4.3 EWMA Control Charts 317
Appendix 4.3.1 The EWMA-SN Control Chart 317
Appendix 4.3.2 The EWMA-SR Control Chart 318
Appendix 4.3.3 The EWMA-EX Control Chart 319
Appendix 4.3.4 The EWMA-rank Control Chart 323
5 Miscellaneous Univariate Distribution-free (Nonparametric) Variables Control Charts 325
Chapter Overview 325
5.1 Introduction 325
5.2 Other Univariate Distribution-free (Nonparametric) Variables Control Charts 326
5.2.1 Phase I Control Charts 326
5.2.1.1 Introduction 326
5.2.1.2 Phase I Control Charts for Location 331
5.2.2 Special Cases of Precedence Charts 343
5.2.2.1 The Min Chart 343
5.2.2.2 The CUMIN Chart 346
5.2.3 Control Charts Based on Bootstrapping 348
5.2.3.1 Methodology 351
5.2.4 Change-point Models 353
5.2.5 Some Adaptive Charts 357
5.2.5.1 Introduction 357
5.2.5.2 Variable Sampling Interval (VSI) and Variable Sample Size (VSS) Charts 358
5.2.5.3 Other Adaptive Schemes 359
5.2.5.4 Properties and Performance Measures of Adaptive Charts 360
5.2.5.5 Adaptive Nonparametric Control Charts 362
Appendix A Tables 369
Appendix B Programmes 381
References 413
Index 425
1
Background/Review of Statistical Concepts
Chapter Overview
This chapter gives an overview of some key statistical concepts as they relate to statistical process control (SPC). This will aid in familiarizing the reader with concepts and terminology that will be helpful in reading the following chapters.
1.1 Basic Probability
The term probability indicates how likely an event is or what the chance is that the event will happen. Most events can't be predicted with total certainty; the best we can do is say how likely they are to happen, and quantify that likelihood or chance using the concept of probability. A probability is a real number between (and including) zero and one. When an event is certain to happen, its probability equals one, whereas when it is impossible for the event to happen, its probability equals zero. Otherwise, the event is likely to happen or occur with a certain probability, expressed as a fraction between zero and one. For example, when a coin is tossed, there are two possible outcomes, namely, that a head (H) or a tail (T) can be observed. Note that an outcome is the result of a single trial of an experiment and the sample space (S) constitutes all possible outcomes of an experiment (the sample space is exhaustive). In the coin tossing example, the sample space is given by S = {H,T}. If the coin is unbiased (or fair), the probability (P) of observing a head is the same as the probability of observing a tail, each of which equals . The probability of the set of all possible experimental outcomes in the sample space must equal one. In this example, this is evident since P(H) + P(T) = 0.5 + 0.5 = 1. When all experimental outcomes in the sample space are equally likely, this is referred to as the classical method of assigning probabilities, which is illustrated in the coin example. Another example of the classical method of assigning probabilities is when a dice is thrown. In this case, the sample space is given by S = {1,2,3,4,5,6} and if the dice is unbiased (or fair) the probability of observing a one on the dice is the same as observing any other value on the dice that equals . Mathematically, we can write
where Ei defines the ith experimental outcome, i.e.
- E1 = 1
- Observed value on the dice is a one
- E2 = 2
- Observed value on the dice is a two
- E3 = 3
- Observed value on the dice is a three
- E4 = 4
- Observed value on the dice is a four
- E5 = 5
- Observed value on the dice is a five
- E6 = 6
- Observed value on the dice is a six
Again, note that the probability of the set of possible experimental outcomes equals one since
In the two examples given above, the experimental outcomes are equally likely. Let's consider an experiment where the experimental outcomes are not equally likely. Suppose that a glass jar contains four red, eight green, three blue, and five yellow marbles. If a single marble is chosen at random from the jar, what is the probability of choosing a specific color, say, a red marble? In general, the probability of an event occurring is calculated by dividing the number of ways an event can occur by the total number of possible experimental outcomes.
- P(Red) = (Number of red marbles)/(Total number of marbles) =
- P(Green) = (Number of green marbles)/(Total number of marbles) =
- P(Blue) = (Number of blue marbles)/(Total number of marbles) =
- P(Yellow) = (Number of yellow marbles)/(Total number of marbles) =
Again, note that the probability of the set of possible experimental outcomes equals one since
When all the experimental outcomes are not equally likely, this is referred to as the relative frequency method of assigning probabilities, which is illustrated in the marble example.
Next, we consider random variables and their distributions that play the most important roles in statistics and probability.
1.2 Random Variables and Their Distributions
A random variable, denoted as , can take on a value, or, an interval of values, with an associated probability. The random variable can be univariate (one) or bivariate (two) or even multivariate (more than two). There are two major types of random variables, namely, discrete and continuous. Although there are situations where there can be a mixed random variable, which is partly discrete and partly continuous, we focus on the discrete and continuous variables here. To illustrate a discrete random variable, let's consider the coin example where either a head or a tail can be observed in a trial (a coin toss). Suppose that a coin is tossed five times and the random variable denotes the number of heads that are observed. Then can only take on integer values S = {0,1,2,3,4,5} and, accordingly, is a discrete random variable. Another example of a discrete random variable would be an that denotes the number of members in a household. Alternatively, a continuous random variable can take on values within some range. The probability of a continuous variable taking on any specific value is zero. If denotes the height of a tree, then it is possible for a tree to have a height of 2.176 m or even 2.1765482895 m; the number of decimal places depends on the accuracy of the measuring instrument. Thus can take on values other than only integer values, within some range of values and, accordingly, is a continuous random variable. Another example of a continuous random variable would be if denotes the lifetime of a light bulb.
A random variable has an associated probability mass function (pmf) if discrete or a probability density function (pdf) if continuous. First, we define the cumulative distribution function (cdf) before defining the pmf and pdf for discrete and continuous random variables, respectively.
Every random variable has a cumulative distribution function (cdf) that defines its distribution. The cdf is a function that gives the probability that a random variable is less than or equal to some real value , that is, . In the case of a discrete random variable, the cdf is calculated by adding the probabilities up to and including , whereas for a continuous random variable, the cdf is calculated by finding the area (integrating) under its pdf up to . The cdf is a monotone non-decreasing right-continuous function, which is a step function for a discrete random variable (see Figure 1.1) and is a continuous function for a continuous random variable (see Figure 1.2). For Figure 1.1 , it should be noted that with are the discrete values that the random variable can take on. For more details on the properties of a cdf see any mathematical statistics book.
Figure 1.1 The cdf for a discrete random variable.
Figure 1.2 The cdf for a continuous random variable.
The pmf of a discrete random variable is a function that gives the probability that the random variable takes on the value of , that is, . More formally, let , satisfying the following two conditions
The pdf of a continuous random variable is the first derivative of the cdf . That is, . More formally, the pdf must satisfy the following two conditions
The cdf (or equivalently the pmf and the pdf) describes the distribution of a random variable over its values or its range or domain of values, that is, how the total probability (which equals one) is distributed or spread out over the values or the range of values of the random variable(s). Probabilities may be either marginal, joint, or conditional. A marginal probability is the probability of the occurrence of a single event. It may be thought of as an unconditional probability since it is not conditioned (or dependent) on another event. An example of a marginal probability is the probability that a red card is drawn from a deck of cards, which is given by (Red) = , since 26 out of 52 cards, that is, half the cards in a deck of cards, are red. A joint probability is the probability of the joint occurrence (or the intersection) of at least two events. The probability of the intersection of two events, and , may be written as , for example, the probability of drawing a red ace from a deck of cards is given by (Red Ace) = , since there are two red aces in a deck of 52 cards, namely, the ace of hearts and the ace of diamonds. A conditional probability is the probability of event occurring, given that event occurs, and is denoted by , for example, the probability of drawing an ace, given that the card is red, is given by (Ace?|?Red) = , since there are two aces in the total of 26 red cards, namely, the ace of hearts and the ace of diamonds. The definition of a conditional probability is given by
(1.1)This formula shows the relationship between the marginal, the joint, and the conditional probability. Returning to the example of the deck of cards, for example, (Ace?|?Red) = , which is the same answer as found previously. Typically, a marginal probability relates to an event associated with a single (scalar) random variable, whereas both joint and conditional probabilities relate to events associated with two or more random variables, that is, in a...
System requirements
File format: ePUB
Copy protection: Adobe-DRM (Digital Rights Management)
System requirements:
- Computer (Windows; MacOS X; Linux): Install the free reader Adobe Digital Editions prior to download (see eBook Help).
- Tablet/smartphone (Android; iOS): Install the free app Adobe Digital Editions or the app PocketBook before downloading (see eBook Help).
- E-reader: Bookeen, Kobo, Pocketbook, Sony, Tolino and many more (not Kindle).
The file format ePub works well for novels and non-fiction books – i.e., „flowing” text without complex layout. On an e-reader or smartphone, line and page breaks automatically adjust to fit the small displays.
This eBook uses Adobe-DRM, a „hard” copy protection. If the necessary requirements are not met, unfortunately you will not be able to open the eBook. You will therefore need to prepare your reading hardware before downloading.
Please note: We strongly recommend that you authorise using your personal Adobe ID after installation of any reading software.
For more information, see our ebook Help page.