Types of acceptance plans to choose from
Definitions of basic Acceptance Sampling terms
The final choice is a tradeoff decision |
A lot acceptance sampling plan (LASP) is a sampling scheme
and a set of rules for making decisions. The decision, based on counting
the number of defectives in a sample, can be to accept the lot, reject
the lot, or even, for multiple or sequential sampling schemes, to take
another sample and then repeat the decision process.
LASPs fall into the following categories:
-
Single sampling plans:. One sample
of items is selected at random from a lot and the disposition of the lot
is determined from the resulting information. These plans are usually denoted
as (n,c) plans for a sample size n, where the lot is rejected
if there are more than
c defectives. These are the most common
(and easiest) plans to use although not the most efficient in terms of
average number of samples needed.
-
Double sampling plans: After the first sample is tested, there
are three possibilities:
-
Accept the lot
-
Reject the lot
-
No decision
If the outcome is (3), and a second sample is taken, the procedure is to
combine the results of both samples and make a final decision based on
that information.
-
Multiple sampling plans: This is
an extension of the double sampling plans where more than two samples are
needed to reach a conclusion. The advantage of multiple sampling
is smaller sample sizes.
-
Sequential sampling plans:. This
is the ultimate extension of multiple sampling where items are selected
from a lot one at a time and after inspection of each item a decision is
made to accept or reject the lot or select another unit.
-
Skip lot sampling plans:. Skip lot
sampling means that only a fraction of the submitted lots are inspected.
Deriving a plan, within one of the categories listed above, is discussed
in the pages that follow. All derivations depend on the properties you
want the plan to have. These are described using the following terms:
-
Acceptable Quality Level (AQL):
The AQL is a percent defective that is the base line requirement for the
quality of the producer's product. The producer would like to design a
sampling plan such that there is a high probability of accepting
a lot that has a defect level less than or equal to the AQL.
-
Lot Tolerance Percent
Defective (LTPD): The LTPD is a designated high defect level that
would be unacceptable to the consumer. The consumer would like the sampling
plan to have a low probability of accepting a lot with a defect
level as high as the LTPD.
-
Type I Error (Producers Risk):
This is the probability, for a given (n,c) sampling plan, of rejecting
a lot that has a defect level equal to the AQL. The producer suffers when
this occurs, because a lot with acceptable quality was rejected. The symbol
a
is commonly used for the Type I error and typical values for a
range from .2 to .01.
-
Type II Error (Consumers Risk):
This
is the probability, for a given (n,c) sampling plan, of accepting
a lot with a defect level equal to the LTPD. The consumer suffers when
this occurs, because a lot with unacceptable quality was accepted. The
symbol b is commonly used for the Type II error
and typical values range from .2 to .01.
-
Operating Characteristic
(OC) Curve: This curve plots the probability of accepting the lot
(Y-axis) versus the lot fraction or percent defectives (X-axix). The
OC curve is the primary tool for displaying and investigating the properties
of a LASP.
-
Average Outgoing Quality (AOQ):
A
common procedure, when sampling and testing is non-destructive, is to 100%
inspect rejected lots and replace all defectives with good units. In this
case, all rejected lots are made perfect and the only defects left are
those in lots that were accepted. AOQ's refer to the long term defect level
for this combined LASP and 100% inspection of rejected lots process. If
all lots come in with a defect level of exactly p, and the
OC curve for the chosen (n,c) LASP indicates a probability pa
of accepting such a lot, over the long run the AOQ can easily be shown
to be:
where N
is the lot size.
-
Average Outgoing Quality
Level (AOQL): A plot of the AOQ (Y-axis) versus the incoming lot
p
(X-axis) will start at 0 for p = 0, and return to 0 for
p
= 1 (where every lot is 100% inspected and rectified). In between, it will
rise to a maximum. This maximum, which is the worst possible long term
AOQ, is called the AOQL.
-
Average Total Inspection (ATI):
When
rejected lots are 100% inspected, it is easy to calculate the ATI if lots
come consistently with a defect level of p. For a LASP (n,c)
with a probability pa of accepting a lot with defect
level p, we have
ATI = n + (1 - pa) (N - n)
where N is the lot size.
-
Average Sample Number (ASN):
For
a single sampling LASP (n,c) we know each and every lot has a sample
of size n taken and inspected or tested. For double, multiple and
sequential LASP's, the amount of sampling varies depending on the the number
of defects observed. For any given double, multiple or sequential plan,
a long term ASN can be calculated assuming all lots come in with a defect
level of p. A plot of the ASN describes the sampling efficiency of a given
LASP scheme.
Making a final choice between single or multiple sampling plans that have
acceptable properties is a matter of deciding whether the average sampling
savings gained by the various multiple sampling plans justifies the additional
complexity of these plans and the uncertainty of not knowing how much sampling
and inspection will be done on a day by day basis. |