An improved attribute control chart for monitoring non-conforming proportion in high quality processes

Processes with very low rate of nonconformities are frequently observed in practice. These processes are known as “high quality processes”. Traditionally, the study of the rate of nonconformities was carried out using the conventional 3-sigma p control chart (Shewhart), constructed by the normal approximation. But this p chart suffers a serious inaccuracy in the modeling process and in control limits specification when the true rate of nonconforming items is small. This paper shows that, with simple adjustments to the control limits of the p-chart, achieving equal or even better improvement while still working on the original data scale, is feasible. In particular, an improved p chart which can provide a large improvement over the usual p chart for attributes is presented. This new chart, based on the Cornish–Fisher quantile correction, is also better than a previous simpler correction proposed in the literature. The improved p chart is compared with both, normal-based chart and modified p chart with one correction term and the benefits of including a new term of correction for monitoring high-quality processes is illustrated with real data.

► In high quality processes p charts have serious drawbacks in detecting nonconforming.
► The Cornish-Fisher expansion can improve probabilistic properties of p charts.
► The improved p chart allows monitoring lower values of p.
► The choice of the appropriate control limits in p charts is presented.
► The practical advantage is illustrated with real data.