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Working with sample sizes and control charting

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  • #51601

    newbie
    Participant

    How do a reconcile sample size calculation with control charting?  For example, if I am working with binary data and I would like to use an np chart to test for stability prior to calculating capability and also wish to use the proper sample size for a given CI & CL, is the following sequence correct:

    Determine sample size using:  n = (2Z/Delta)^2 * p * q

    Example:  n = (2*1.96/.04)^2 *.5 * .5 = 2,401= n
    Choose a subgroup size (k) to ensure > 20 np points

    n = 50
    k = 48
    Plot the 48 np data points and determine np’
    Calculate the USL/LSL and look for special cause
    Recombine the data set to determine avg yield with the original CL & CI (n = 2401).
    Repeat during CONTROL to show effects of change.
    Thank you and happy holidays!

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    #179248

    Michael Mead
    Participant

    This looks like a reasonable algorithm if the process is stable or the samples are drawn from one lot.

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    #179249

    Mikel
    Member

    What nonsense.Start with what you know about the true p. Using .5 will give a worse
    case sample size and using 50 may not be a big enough sample
    based on what is known about p.np should be >/= 5.

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    #179251

    Michael Mead
    Participant

    I thought the rule was that the average number of defects per sample should be 1 or greater. If he has taken 2400 observations, he probably has a good idea what the p-bar is.  If it is less than 1, find a sample size that will make it 1.

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    #179252

    Mikel
    Member

    p and np charts assume normality. The assumption is accompanied by
    the rule that np > 5 to approximate a Poisson distribution using
    normal.

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    #179253

    newbie
    Participant

    Thanks for the feedback Stan, but I am still not fully tracking:

    I assume you are telling me it is better to take an initial sample and calculate a preliminary p, then base the sample size calculation on this value.
    I am still confused how one incorporates an overall sample size calcualtion into np chart sample size.
    And for “np should be greater than or equal to 5”, what is np?  The number of nonconformances in the sample size?  In other words, the sample size in the np chart should be large enough to ensure at least 5 nonconformances per subgroup?  Thanks for your time!

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    #179254

    Mikel
    Member

    Correct

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    #179255

    Darth
    Participant

    If the np>5 you might even consider moving to an Individuals chart as recommended by Wheeler.

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    #179256

    newbie
    Participant

    Thanks doc!

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    #179257

    newbie
    Participant

    Thanks Stan!

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