Multivariate process and quality monitoring applied to an electrolysis process: Part I. Process supervision with multivariate control charts

Abstract

Multivariate statistical process control (MSPC) is applied to an electrolysis process. The process produces extremely pure copper, and to monitor its quality the levels of eight metal impurities were recorded twice a day. These quality data are analysed adopting an (1) `intuitive' univariate approach, and (2) with multivariate techniques. It is demonstrated that the univariate analysis gives confusing results with regards to outlier detection, while the multivariate approach identifies two types of outliers. Moreover, it is shown how the results from the multivariate principal component analysis (PCA) method can be displayed graphically in multivariate control charts. Multivariate Shewhart, cumulative sum (CUSUM) and exponentially weighted moving average (EWMA) control charts are used and compared. Also, an informationally powerful control chart, the simultaneous scores monitoring and residual tracking (SMART) chart, is introduced and used.