Quality and Process Methods • Control Chart Builder • Control Chart Types • Rare Event Control Charts

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Rare Event Control Charts
A Rare Event chart is a control chart that provides information about a process where the data comes from rarely occurring events. Tracking processes that occur infrequently on a traditional control chart tend to be ineffective. Rare event charts were developed in response to the limitations of control charts in rare event scenarios. The Control Chart Builder provides two types of rare event charts (g- and t-charts).
A g-chart is used to count the number of events between rarely occurring errors or nonconforming incidents, and creates a chart of a process over time. Each point represents the number of units between occurrences of a relatively rare event. For example, in a production setting, where an item is produced daily, an unexpected line shutdown can occur. You can use a g-chart to look at the number of units produced between line shutdowns. A traditional plot of data such as this is not conducive to control chart interpretation. The g-chart helps visualize such data in traditional control chart form.
A t-chart measures the time elapsed since the last event and creates a picture of a process over time. Each point on the chart represents an amount of time that has passed since a prior occurrence of a rare event. A traditional plot of this data might contain many points at zero and an occasional point at one. A t-chart avoids flagging numerous points as out of control. The t-chart helps identify special and common cause variation, so that appropriate improvements can be made.
A t-chart can be used for numeric, nonnegative data, date/time data, and time-between data:
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Numeric, nonnegative data contain the number of intervals between events. The number of intervals can be continuous or integer-valued.
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Date/time data contain records of the date and time of each event. Each data value must be greater than or equal to the preceding value.
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Time-between data (also known as elapsed-time data) represent the elapsed time between event i and event i-1.
Like the g-chart, the t-chart is used to detect changes in the rate at which the adverse event occurs. When reading the t-chart, the points above the upper control limit indicate that the amount of time between events has increased. Thus, the rate of the events has decreased. Points below the lower control limit indicate that the rate of adverse events has increased.
Because of how time is measured for these charts, one fundamental difference is that a point flagged as out of control above the limits is generally considered a desirable effect because it represents a significant increase in the time between events. The difference between a g- and t-chart is the scale used to measure distance between events. The g-chart uses a discrete scale, whereas the t-chart uses a continuous scale.
Table 3.2 Rare Event Chart Determination 
Statistic
Sigma
Count
Negative Binomial
g-chart
Weibull
t-chart

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Help created on 3/19/2020