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The classical funnel experiment was used by Deming to promote the idea of statistical process control (SPC). The popular example illustrates that the implementation of simple feedback rules to stationary processes violates the independence assumption and prevents the implementation of conventional SPC. However, Deming did not indicate how to implement SPC in the presence of such feedback rules. This pedagogical gap is addressed here by introducing a simple feedback rule to the funnel example that results in a nonlinear process to which the traditional SPC methods cannot be applied. The proposed method of Markov-based SPC, which is a simplified version of the context-based SPC method, is shown to monitor the modified process well. Copyright © 2007 John Wiley & Sons, Ltd. [ABSTRACT FROM AUTHOR]

Conventional Statistical Process Control (SPC) schemes fail to monitor nonlinear and finite-state processes that often result from feedback-controlled processes. SPC methods that are designed to monitor autocorrelated processes usually assume a known model (often an ARIMA) that might poorly describe the real process. In this paper, we present a novel SPC methodology based on context modeling of finite-state processes. The method utilizes a series of context-tree models to estimate the conditional distribution of the process output given the context of previous observations. The Kullback-Leibler divergence statistic is derived to indicate significant changes in the trees along the process. The method is implemented in a simulated flexible manufacturing system in order to detect significant changes in its production mix ratio output. [ABSTRACT FROM AUTHOR]

In certain types of processes, verification of the quality of the output units is possible only after the entire batch has been processed. We develop a model that prescribes which units should be inspected and how the units that were not inspected should be disposed of, in order to minimize the expected sum of inspection costs and disposition error costs, for processes that are subject to random failure and recovery. The model is based on a dynamic programming algorithm that has a low computational complexity. The study also includes a sensitivity analysis under a variety of cost and probability scenarios, supplemented by an analysis of the smallest batch that requires inspection, the expected number of inspections, and the performance of an easy to implement heuristic. [ABSTRACT FROM AUTHOR]