An Enhanced Control Chart for Start-Up Processes and Short Runs

Abstract

Classic charting procedures are usually designed assuming that process parameters are known or may be estimated using large Phase I samples gathered before a production run. However, in some manufacturing settings, such as during the process start-up, historical data cannot be collected to accurately estimate the in-control process parameters. In this article, we suggest a new self-starting control chart which uses consecutive observations to jointly update the parameter estimates and check for out-of-control conditions. In particular, we introduce a charting procedure, ACUSCORE, that updates the reference pattern of a type-CUSCORE chart using an adaptive EWMA. The proposed control chart seems to outperform traditional self-starting control charts which neglect the dynamic pattern of the mean change.