Power approximations in the economic design of control charts

A new approximate method is proposed for the economic design of control charts based on an estimate of the power of the control chart at optimality. Multiple linear regression is employed for the derivation of the approximate formula expressing the power of the control chart as a function of the model parameters. A simple optimization procedure is then used to determine the economic design of the control chart for the predicted value of the chart's detection power. The application of the new approach is illustrated through Duncan's models for variables control charts for processes subject to single and multiple assignable causes. Evaluation of the performance of the approximate method indicates that the approximate control chart design is very close to the exact optimum while its implementation requirements are reduced.     

Quality control chart design under Jidoka

We consider design of control charts in the presence of machine stoppages that are exogenously imposed (as under jidoka practices). Each stoppage creates an opportunity for inspection/repair at reduced cost. We first model a single machine facing opportunities arriving according to a Poisson process, develop the expressions for its operating characteristics and construct the optimization problem for economic design of a control chart. We, then, consider the multiple machine setting where individual machine stoppages may create inspection/repair opportunities for other machines. We develop exact expressions for the cases when all machines are either opportunity‐takers or not. On the basis of an approximation for the all‐taker case, we then propose an approximate model for the mixed case. In a numerical study, we examine the opportunity taking behavior of machines in both single and multiple machine settings and the impact of such practices on the design of an X – Q C chart. Our findings indicate that incorporating inspection/repair opportunities into QC chart design may provide considerable cost savings. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

On the exponentially weighted moving variance

MacGregor and Harris (J Quality Technol 25 (1993) 106–118) proposed the exponentially weighted mean squared deviation (EWMS) and the exponentially weighted moving variance (EWMV) charts as ways of monitoring process variability. These two charts are particularly useful for individual observations where no estimate of variability is available from replicates. However, the control charts derived by using the approximate distributions of the EWMS and EWMV statistics are difficult to interpret in terms of the average run length (ARL). Furthermore, both control charting schemes are biased procedures. In this article, we propose two new control charts by applying a normal approximation to the distributions of the logarithms of the weighted sum of chi squared random variables, which are respectively functions of the EWMS and EWMV statistics. These new control charts are easy to interpret in terms of the ARL. On the basis of the simulation studies, we demonstrate that the proposed charts are superior to the EWMS and EWMV charts and they both are nearly unbiased for the commonly used smoothing constants. We also compare the performance of the proposed charts with that of the change point (CP) CUSUM chart of Acosta‐Mejia (1995). The design of the proposed control charts is discussed. An example is also given to illustrate the applicability of the proposed control charts. © 2009 Wiley Periodicals, Inc. Naval Research Logistics, 2009     

A novel gradient approach for optimal design and sensitivity analysis of EWMA control charts

Conventional control charts are often designed to optimize out‐of‐control average run length (ARL), while constraining in‐control ARL to a desired value. The widely employed grid search approach in statistical process control (SPC) is time‐consuming with unsatisfactory accuracy. Although the simulation‐based ARL gradient estimators proposed by Fu and Hu [Manag Sci 45 (1999), 395–413] can alleviate this issue, it still requires a large number of simulation runs to significantly reduce the variance of gradient estimators. This article proposes a novel ARL gradient estimation approach based on integral equation for efficient analysis and design of control charts. Although this article compares with the results of Fu and Hu [Manag Sci 45 (1999), 395–413] based on the exponentially weighted moving average (EWMA) control chart, the proposed approach has wide applicability as it can generally fit into any control chart with Markovian property under any distributions. It is shown that the proposed method is able to provide a fast, accurate, and easy‐to‐implement algorithm for the design and analysis of EWMA charts, as compared to the simulation‐based gradient estimation method. Moreover, the proposed gradient estimation method facilitates the computation of high‐order derivatives that are valuable in sensitivity analysis. The code is written in Matlab, which is available on request. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 223–237, 2014     

Kurtosis correction method for X̄ and R control charts for long‐tailed symmetrical distributions

This paper proposes a kurtosis correction (KC) method for constructing the X? and R control charts for symmetrical long‐tailed (leptokurtic) distributions. The control charts are similar to the Shewhart control charts and are very easy to use. The control limits are derived based on the degree of kurtosis estimated from the actual (subgroup) data. It is assumed that the underlying quality characteristic is symmetrically distributed and no other distributional and/or parameter assumptions are made. The control chart constants are tabulated and the performance of these charts is compared with that of the Shewhart control charts. For the case of the logistic distribution, the exact control limits are derived and are compared with the KC method and the Shewhart method. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Monitoring poisson count data with probability control limits when sample sizes are time varying

This article considers the problem of monitoring Poisson count data when sample sizes are time varying without assuming a priori knowledge of sample sizes. Traditional control charts, whose control limits are often determined before the control charts are activated, are constructed based on perfect knowledge of sample sizes. In practice, however, future sample sizes are often unknown. Making an inappropriate assumption of the distribution function could lead to unexpected performance of the control charts, for example, excessive false alarms in the early runs of the control charts, which would in turn hurt an operator's confidence in valid alarms. To overcome this problem, we propose the use of probability control limits, which are determined based on the realization of sample sizes online. The conditional probability that the charting statistic exceeds the control limit at present given that there has not been a single alarm before can be guaranteed to meet a specified false alarm rate. Simulation studies show that our proposed control chart is able to deliver satisfactory run length performance for any time‐varying sample sizes. The idea presented in this article can be applied to any effective control charts such as the exponentially weighted moving average or cumulative sum chart. © 2013 Wiley Periodicals, Inc. Naval Research Logistics 60: 625–636, 2013     

Economic design of a two-stage control chart based on both performance and surrogate variables

The traditional approach to economic design of control charts is based on the assumption that a process is monitored using only a performance variable. If, however, the performance variable is costly to measure and a less expensive surrogate variable is available, the process may be more efficiently controlled by using both performance and surrogate variables. In this article we propose a model for economic design of a two-stage control chart which uses a highly correlated surrogate variable together with a performance variable. The process is assumed to be monitored by the surrogate variable until it signals out-of-control behavior, then by the performance variable until it signals out-of-control behavior or maintains in-control signals for a prespecified amount of time, and the two variables are used in alternating fashion. An algorithm based on the direct search method of Hooke and Jeeves [6] is used to find the optimum values of design parameters. The proposed model is applied to the end-closure welding process for nuclear fuel to compute the amount of reduction in cost compared with the current control procedure. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 958–977, 1999     

Economic design of X¯ control charts for two manufacturing process models

Control charts are widely used for process surveillance. The design of a control chart refers to the choice of sample size, the width of the control limits, and the interval between samples. Economic designs have been widely investigated and shown to be an effective method of determining control chart parameters. This article describes two different manufacturing process models to which the X¯ control chart is applied: The first model assumes that the process continues in operation while searches for the assignable cause are made, and the second assumes that the process must be shut down during the search. Economic models of the control chart for these two manufacturing process models are developed, and the sensitivity of the control chart parameters to the choice of model is explored. It is shown that the choice of the proper manufacturing process model is critical because selection of an inappropriate process model may result in significant economic penalties.     

高超声速飞行器保预设性能的反演控制方法

为了解决高超声速飞行器纵向运动模型的稳定轨迹控制问题,设计了一种在非仿射模型基础上保证预设性能的反演控制方法。对于速度子系统,直接设计非仿射控制律,保证预设性能,通过合理的变换将高度子系统转化为严格的反馈形式,便于反演控制步骤的设计。基于动态性能和稳态精度,设计了预设性能函数,将跟踪误差的稳定性限制在预设范围内,引入指令滤波器,有效克服了传统反演控制中虚拟信号重复推导的问题。控制器的设计不依赖于精确的模型。引入径向基函数来逼近过程中的未知函数,使得控制律具有令人满意的鲁棒性和实用性。基于李雅普诺夫稳定性理论,证明了所有闭环系统的稳定性。仿真结果表明,该控制器能够稳定地跟踪参考信号。     

Performance analysis of queue length monitoring of M/G/1 systems

This study investigates the statistical process control application for monitoring queue length data in M/G/1 systems. Specifically, we studied the average run length (ARL) characteristics of two different control charts for detecting changes in system utilization. First, the nL chart monitors the sums of successive queue length samples by subgrouping individual observations with sample size n. Next is the individual chart with a warning zone whose control scheme is specified by two pairs of parameters, (upper control limit, d_u) and (lower control limit, d_l), as proposed by Bhat and Rao (Oper Res 20 (1972) 955–966). We will present approaches to calculate ARL for the two types of control charts using the Markov chain formulation and also investigate the effects of parameters of the control charts to provide useful design guidelines for better performance. Extensive numerical results are included for illustration. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

一类非线性系统的自适应模糊反推近似滑模控制

针对一类含有未知非线性函数项和外界干扰的不确定纯反馈非线性系统,提出了一种自适应模糊反推近似滑模变结构控制方法。采用中值定理和隐函数定理使未知非仿射输入函数拥有显式的控制输入,利用模糊系统逼近未知非线性函数,动态面控制技术解决了反推设计中出现的"微分爆炸"问题。所提出的自适应近似滑模控制方案削弱了传统滑模控制中的抖振现象。从理论上证明了所设计的控制器能够保证闭环系统所有信号半全局一致终结有界。仿真算例验证了算法的有效性。     

The effect of process adjustment error on X̄ chart design

The existing literature on economic design of X̄ process control charts generally assumes perfect process adjustment, such that the process mean is returned to an exactly centered “in control” state following any real or false alarm control chart signal. This paper presents a model which demonstrates the effects of imperfect process adjustment on the economically designed control chart parameters. The model demonstrates that the optimal control limit width depends fundamentally on the precision with which the process can be adjusted. The greater the process adjustment error, all else constant, the wider will be the optimal control limits, in order to alleviate the potential for process overcontrol and tampering effects. By endogenously modeling these effects, the new model helps to rectify the problem of poor statistical properties for which the economic design approach has been criticized. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 597–612, 1999     

Selection of the optimal setup policy

A model is developed taking into consideration all the costs (namely cost of sampling, cost of not detecting a change in the process, cost of a false indication of change, and the cost of readjusting detected changes) incurred when a production process, using an unscheduled setup policy, utilizes fraction-defective control charts to control current production. The model is based on the concept of the expected time between detection of changes calling for setups. It is shown that the combination of unscheduled setups and control charts can be utilized in an optimal way if those combinations of sample size, sampling interval, and extent of control limits from process average are used that provide the minimum expected total cost per unit of time. The costs of a production process that uses unscheduled setups in conjunction with the appropriate optimal control charts are compared to the costs of a production process that uses scheduled setups at optimum intervals in conjunction with its appropriate control charts. This comparison indicates the criteria for selecting production processes with scheduled setups using optimal setup intervals over unscheduled setups. Suggestions are made to evaluate the optimal process setup strategy and the accompanying optimal decision parameters, for any specific cost data, by use of computer enumeration. A numerical example for assumed cost and process data is provided.     

Skewness correction X̄ and R charts for skewed distributions

This paper proposes a skewness correction (SC) method for constructing the and R control charts for skewed process distributions. Their asymmetric control limits (about the central line) are based on the degree of skewness estimated from the subgroups, and no parameter assumptions are made on the form of process distribution. These charts are simply adjustments of the conventional Shewhart control charts. Moreover, the chart is almost the same as the Shewhart chart if the process distribution is known to be symmetrical. The new charts are compared with the Shewhart charts and weighted variance (WV) control charts. When the process distribution is in some neighborhood of Weibull, lognormal, Burr or binomial family, simulation shows that the SC control charts have Type I risk (i.e., probability of a false alarm) closer to 0.27% of the normal case. Even in the case where the process distribution is exponential with known mean, not only the control limits and Type I risk, but also the Type II risk of the SC charts are closer to those of the exact and R charts than those of the WV and Shewhart charts. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 555–573, 2003     

A semieconomic method for the determination of optimal lot sizes

The construction of lot sizes usually depends upon factors influencing homogeneity. When these factors are not a function of lot quantity, it is possible to determine an optimal lot size. The optimization process balances the cost of sampling against the expected cost of lot rejection for some specified procurement quantity. The rationale for balancing the two costs is contingent upon the fact that rejection criteria waivers frequently occur when the lot size is large. This concept implies that the lot size should be as small as possible, whereas the cost of sampling drives the lot size up. Hence, trade-offs may be made. The formulation is termed a semieconomic one because it combines a pure economic objective function with a pure statistical constraint. This constraint is necessary because the nature of the items under study dictates that the cost of accepting defective material cannot be explicitly stated. The paper presents the formulation, describes when it should be used, derives a good analytical approximation under certain assumptions and gives various ramifications when it is used.     

A spatial rank‐based multivariate EWMA control chart

Nonparametric control charts are useful in statistical process control when there is a lack of or limited knowledge about the underlying process distribution, especially when the process measurement is multivariate. This article develops a new multivariate self‐starting methodology for monitoring location parameters. It is based on adapting the multivariate spatial rank to on‐line sequential monitoring. The weighted version of the rank‐based test is used to formulate the charting statistic by incorporating the exponentially weighted moving average control scheme. It is robust to non‐normally distributed data, easy to construct, fast to compute and also very efficient in detecting multivariate process shifts, especially small or moderate shifts which occur when the process distribution is heavy‐tailed or skewed. As it avoids the need for a lengthy data‐gathering step before charting and it does not require knowledge of the underlying distribution, the proposed control chart is particularly useful in start‐up or short‐run situations. A real‐data example from white wine production processes shows that it performs quite well. © 2012 Wiley Periodicals, Inc. Naval Research Logistics 59: 91–110, 2012     

Design and control of agile automated CONWIP production lines

In this article, we study the design and control of manufacturing cells with a mix of manual and automated equipment, operating under a CONWIP pull protocol, and staffed by a single agile (cross‐trained) worker. For a three‐station line with one automated station, we fully characterize the structure of the optimal control policy for the worker and show that it is a static priority policy. Using analytical models and extensive simulation experiments, we also evaluate the effectiveness of practical heuristic control policies and provide managerial insights on automation configuration design of the line. This characterization of the worker control policy enables us to develop managerial insights into the design issues of how best to locate and concentrate automation in the line. Finally, we show that, in addition to ease of control and greater design flexibility, the CONWIP protocol also offers higher efficiency and robustness than does the push protocol. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

多目标的分布式协同进化MDO算法

通过引入非优超排序和排挤的多目标处理机制 ,将分布式协同进化MDO算法的能力扩展到多目标的多学科设计优化问题。多目标的分布式协同进化MDO算法在保持各学科充分自治和各学科并行设计优化协同的基础上 ,通过一次运行即可获得具有良好分布的多个Pareto最优解 ,逼近整个Pareto最优前沿。应用于导弹气动 /发动机 /控制三学科两目标设计优化问题 ,与约束法计算结果的对比表明算法能够有效逼近该问题的Pareto最优前沿 ,为设计决策提供了丰富的信息     

基于制导与控制一体化的导弹编队队形控制

为了提高导弹编队协同作战队形控制能力,研究了基于制导与控制一体化思想的编队队形控制器设计问题。根据领弹-从弹的动力学以及运动学方程,推导出了领弹-从弹的相对运动模型,建立了领弹姿态信息与从弹舵偏角之间的关系,将从弹通道间的耦合项作为不确定项进行处理,并利用自适应神经网络理论设计了补偿器,对不确定项进行了处理。根据反演理论设计了编队队形控制器,能够对导弹编队队形进行有效的控制。     

压水型核反应堆功率控制系统的优化设计

在分析了压水型反应堆功率控制系统的前提下,针对其特殊的控制要求,运用基于输出反馈的次最优控制的设计方法和Matlab中的NCD模块,最终实现了系统的优化设计,并对系统进行了某一功率水平下的仿真试验和其它工况下的鲁棒性试验.结果表明,改进后的系统性能有了较大改善.