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Article

A multivariate adaptive control chart for simultaneously monitoring of the process parameters

ORCID Icon & ORCID Icon
Pages 2031-2049 | Received 31 Jan 2022, Accepted 01 Apr 2022, Published online: 22 Apr 2022

Abstract

There have been some advances in multivariate control charts in recent years. This paper presents a new simultaneous scheme for monitoring both the mean and variability of a multivariate normal process in a single chart, which is developed by improving and modifying another recently proposed scheme. We not only propose a new control scheme but also make it adaptive by varying all control chart parameters. Our scheme, for the first time, considers the process variability in two forms: “covariance matrix” and “multivariate coefficient of variation (MCV)”. This scheme, again for the first time, considers simultaneous monitoring of the MCV with another process parameter (in our case, the mean vector). In addition, we develop a Markov chain model to compute the average run length and average time to signal values. We conduct extensive numerical analyses to measure the performance of the proposed scheme in two scenarios of process variability. At last, we present a numerical example by using a real dataset from a healthcare process to illustrate how the scheme can be implemented in practice.

1. Introduction

Process monitoring is performed to control the variability of the process to ensure that good quality products/services are delivered. Process control charts are the main tools for this purpose. They come in many forms and are being improved constantly by researchers. If the product/service consists of only one quality characteristic, univariate control charts are used, while in the case of more than one quality characteristic, multivariate control charts are employed. To be able to detect assignable causes which lead to small and moderate shifts in the process parameters (mean and variability), extra measures should be taken or some special control charts should be used. One way of doing this is by allowing the control charts’ parameters (sample size, sampling interval and control limits) to vary throughout process monitoring. There are different types of adaptive control charts but the best one allows all the chart’s parameters to vary (Sabahno, Amiri, and Castagliola Citation2021), namely, the variable parameters (VP) scheme. Chen (Citation2007), Faraz et al. (Citation2014) and Seif et al. (Citation2016) were among the researchers who considered the VP adaptive feature on multivariate control charts. For other types of adaptive features used on multivariate control charts, one can refer to Aparisi, Jabaloyes, and Carrion (Citation2001), Grigoryan and He (Citation2005), Sabahno, Amiri, and Castagliola (Citation2018a, Citation2018b), Aparisi and Haro (Citation2003), and Lee and Khoo (Citation2015). All of the above researchers used adaptive features on multivariate control charts in monitoring either the process mean or process variability.

Simultaneous monitoring of the process parameters (mean and variability) has been proven to reduce the false alarm rates and improve the performance of the monitoring procedure. In general, control charts for simultaneous monitoring can be divided into single-chart and double-chart (one for each parameter) schemes. Concerning multivariate control charts, in which two separate charts were used, one may refer to Reynolds and Cho (Citation2006), Hawkins and Maboudou-Tchao (Citation2008), and Zhang and Chang (Citation2008). For researches in which single multivariate charts were used, one may refer to Khoo (Citation2005), Zhang, Li, and Wang (Citation2010), Wang, Yeh, and Li (Citation2014) and Sabahno, Amiri, and Castagliola (Citation2021). Concerning using adaptive features in simultaneous monitoring schemes, see Reynolds and Kim (Citation2007), Reynolds and Cho (Citation2011), and Sabahno, Castagliola, and Amiri (Citation2020a, Citation2020b) and Sabahno, Amiri, and Castagliola (Citation2021).

Sometimes the estimators for the mean and variability are not independent even though their independence is usually assumed. In these cases, the variability is measured in the form of the coefficient of variation (CV), which is simply computed by dividing the standard deviation by the mean. Monitoring the CV is mostly important in chemical and biological processes (Reed, Lynn, and Meade Citation2002) and also in the fields of materials engineering and manufacturing (Castagliola, Celano, and Psarakis Citation2011). For the examples of developing univariate control charts for monitoring the CV, please refer to Kang et al. (Citation2007), Hong et al. (Citation2008), Calzada and Scariano (Citation2013), Castagliola et al. (Citation2013a), and Zhang et al. (Citation2014); and for adaptive based CV control charts to Castagliola et al. (Citation2013b) and Khaw et al. (Citation2017).

There are several definitions of multivariate coefficient of variation but the most commonly used one was defined by Voinov and Nikulin (Citation1996). The first control chart for the MCV was introduced by Yeong et al. (Citation2016). Adaptive features were later added to their scheme by Nguyen et al. (Citation2019) and Khaw et al. (Citation2018).

In monitoring the CV, the shift in the CV may change the relationship between the mean and the standard deviation. In this case, it is possible that the process mean goes out-of-control but the ratio of σ to μ is still in-control. Noor-ul-Amin, Tariq, and Hanif (Citation2019) is the only research in the literature that considered simultaneous monitoring of the CV and the mean and it was for a univariate scheme. To the best of our knowledge, there is no such scheme for the multivariate case.

Sabahno, Amiri, and Castagliola (Citation2021). proposed a new simultaneous scheme for monitoring the process mean vector and covariance matrix. They also added adaptive features and computed several performance measures using a Markov chain model. They, for the first time on SPC control charts, used a statistic to represent the process variation. However, the distribution of the said statistic increasingly loses its fitness for data with more than two quality characteristics.

In this research, we not only solve the abovementioned issue by suggesting a new statistic with a deterministic distribution, but our statistic can be used for MCV monitoring as well. In fact, this is the first research that simultaneously monitors the process mean and MCV. Our scheme is such that variation in two forms can be considered; Scenario 1: covariance matrix and Scenario 2: MCV. We also develop a new Markov chain model to compute the performance measures. Several numerical analyses and simulation runs will be conducted in the two mentioned variability scenarios. Based on a real data set from a health care process, at last, we show how the scheme can be implemented in practice.

The structure of this paper is as follows: In Sec. 2, the proposed multivariate control chart for simultaneous monitoring of the mean and variability is developed. The VP adaptive features are developed for the proposed scheme in Sec. 3. In Sec. 4, performance measures are derived using a Markov chain model. Numerical analyses are performed to examine the proposed scheme in Sec. 5. An illustrative example is presented in Sec. 6. Finally, concluding remarks are given in Sec. 7.

2. Multivariate control charts for a simultaneous monitoring of the mean and variability

Sabahno, Amiri, and Castagliola (Citation2021) developed a novel scheme to simultaneously monitor the mean and variability of multivariate normal processes. However, the distribution they used for the process variability statistic, loses its fitness for cases with more than two dimensions (quality characteristics), as when the dimension increases, the less accurate their scheme becomes. They used the Wi=(n1)|Si|1/p|Σ0|1/p statistic (its parameters will be introduced later on in this section) for monitoring the variability, whose distribution when p>2 is unknown, but it approximatelly follows the gamma Γ(a,b) distribution with parameters a=p(np)/2 and b=2p(1(p1)(p2)2n)1/p. As mentioned before, as p (the number of quality charactristics) increases, the Wi statistic deviates more from this gamma distribution (Gnanadesikan and Gupta Citation1970).

Wijsman (Citation1957) has shown that letting Ti2=nX¯iTSi1X¯i, gives (1) ϒi=Ti2n1.npp:Fp,np,δ0(x),(1) where Fp,np,δ0() is the non-central Fisher distribution with p and n − p degrees of freedom and non-centrality parameter δ0=nμ0TΣ01μ0 when the process is in-control, n is the sample (subgroup) size, X¯i is the ith sample mean vector, and Si is the ith sample covariance matrix.

A transformation of the statistic ϒi has been used by Yeong et al. (Citation2016) for monitoring the multivariate coefficient of variation. When the in-control process parameters (μ0 and Σ0) are known, the population MCV is computed as γ0=(μ0TΣ01μ0)12, while for sample i, the sample MCV is obtained as γ˜i=(X¯iTSi1X¯i)12.

We use ϒi instead of Sabahno, Amiri, and Castagliola (Citation2021)’s method, which is based on the generalized variance statistic for monitoring the process variability. The ϒi statistic, if the process mean and variability are not independant, can be used for monitoring the MCV (γ0) as well (it was primarily used for that purpose in control charts). However, we want to broaden its application for all kinds of variability and not only for the MCV. Substituting nγ˜i2 for Ti2 in EquationEq. (1), gives nγ˜i2n1.npp:Fp,np,δ0(x), where δ0=nγ02. In this way, ϒi in EquationEq. (1) can be used for monitoring the MCV.

To monitor the process mean, the Hotelling’s T2 statistic (note that the small prime in T2 is to distinguish it from the Ti2 statistic in EquationEq. (1) is computed for each subgroup i=1,2,, as (2) Ti2=n(X¯i-μ0)T(Σ0)1(X¯i-μ0),(2) where Ti2χ2(p), i.e., a chi-square distribution with p degrees of freedom when the process is in-control and p is the number of quality characteristics.

To monitor the mean and variability simultaneously, we use the following transformations of T2 and ϒi: (3) Mi=Φ1[Hp(Ti2)]N(0,1), i=1,2,,(3) and (4) CVi=Φ1[Fp,np,δ(ϒi)]N(0,1), i=1,2,,(4) where Φ() is the standard normal cumulative distribution function, Hp() is the chi-square cumulative distribution function with p degrees of freedom and Fp,np,δ() denotes the Fisher cumulative distribution function with p and n − p degrees of freedom and non-centrality parameter δ.

Then, we use the following max-type statistic: (5) MVi=max{|Mi|,|CVi|}.(5)

By assuming the independence of Mi and CVi, the upper control limit (UCL) of this chart can be obtained as follows: P(MViUCL)=P(max{|Mi|,|CVi|}UCL)=P(UCLMiUCL)P(UCLCViUCL)=(2Φ(UCL)1)(2Φ(UCL)1)=(2Φ(UCL)1)2.

As P(MViUCL)=1α, then (6) UCL=Φ1[1α+12],(6) where α is the probability of a Type-I error.

We have confirmed via simulation runs that EquationEq. (6) provides a good approximation of UCL for this control chart.

3. Simultaneous monitoring scheme with variable parameters control chart

For a variable parameters (VP) control chart, all the chart’s parameters are variable. In this paper, we assume that there are two different (i) sample sizes (ns:s{1,2} with n1<n2), (ii) sampling intervals (ts:s{1,2} with t2<t1) and (iii) Type-I error probabilities (αs:s{1,2} with α1<α2).

Since our max-type control chart is one-sided, we also assume that there are two upper control limits UCL1 (related to α1) and UCL2 (related to α2), and two upper warning limits UWL1 and UWL2, satisfying UWL1<UCL1 and UWL2<UCL2.

The VP strategy for choosing the next sampling scheme works as follows:

  • If MVi[0,UWL], the process is declared as in-control and the parameters for the next sample must be Ω1=(n1,t1,UCL1,UWL1), i.e., the small sample size, long sampling interval and higher control (UCL) and warning (UWL) limits.

  • If MVi(UWL,UCL], the process is also declared as in-control but the parameters for the next sample must be Ω2=(n2,t2,UCL2,UWL2), i.e., the large sample size, short sampling interval and lower control (UCL) and warning (UWL) limits.

  • If MVi(UCL,), the process is declared as out-of-control and corrective actions have to be taken.

In the VP scheme, the following equations should be satisfied: (7) ASS=n1P0+n2(1P0),(7) (8) ASI=t1P0+t2(1P0),(8) (9) ATE=α1P0+α2(1P0),(9)

Note that ASS is the average sample size, ASI is the average sampling interval and ATE is the average Type-I error, where P0 is the probability MVi of being in the safe state (Ω1) while the process is in-control, i.e., (10) P0=P(MViUWL)P(MViUCL)=P(max{|Mi|,|CVi|}UWL)P(max{|Mi|,|CVi|}UCL)=P(|Mi|UWL)P(|CVi|UWL)P(|Mi|UCL)P(|CVi|UCL)=[2Φ(UWL)1]2[2Φ(UCL)1]2(10)

By solving EquationEqs. (7)–(10) simultaneously, we can obtain the chart’s parameters as follows: (11) α2=ATE(n1n2)α1(ASSn2)n1ASS,(11) (12) t1=ASI(n1n2)t2(n1ASS)ASSn2,(12) (13) UWLs=Φ1((2Φ(UCLs)1)P0+12),(13) where P0 is obtained from EquationEq. (7) as P0=ASSn2n1n2.

4. Performance measures

In general, there are two types of performance measures, i.e., initial-state and steady-state performance measures. In the initial-state performance measures, it is assumed that the process is out-of-control at the beginning of process monitoring. On the contrary, in the steady-state performance measures, the assumption is that the process is in-control at the beginning of process monitoring but it will become out-of-control later on. In the steady-state performance measures, an additional complexity will be added to the model, that is approximating the time that the process goes out-of-control. In this paper, we only consider the initial-state performance measures, as they are sufficient for our performance measure agenda.

We use a Markov chain model to derive the performance measures. In an initial-state condition, this approach requires the definition of the following three states for the proposed control scheme:

  • State 1: MVi[0,UWL],

  • State 2: MVi(UWL,UCL],

  • State 3: MVi(UCL,).

The first two states are transient, while the third one is absorbing. The Markov chain transition probability matrix P corresponding to the VP chart is equal to P=[p11p12p13p21p22p23p31p32p33], where pij is the probability of transitioning from state i to state j. Note that for a steady-state performance measure, we have more states and consequently the dimension of the transition probability matrix is larger.

Since it is mathematically very complicated (if not impossible) to show the independence of Mi and CVi (we need them to be independent to be able to compute the following probabilities), we have confirmed their independence via simulation runs (by comparing the performances computed by simulation and the following Markov chain methods), and consequently, concluded that Mi and CVi are somewhat independent.

Therefore, the transient state probabilities p11, p12, p21 and p22 for the proposed multivariate max-type chart are equal to (14) ps1=P(MViUWL)=P(max{|Mi|,|CVi|}UWL) =P(UWLMiUWL)P(UWLCViUWL),(14) (15) ps2=P(UWL<MViUCL)=P(UWL<max{|Mi|,|CVi|}UCL)=P(UCLMiUCL)P(UCLCViUCL)P(UWLMiUWL)P(UWLCViUWL).(15)

Concerning the other transition probabilities, we simply have p13=1p11p12 , p23=1p21p22, p31=p32=0  and  p33=1.

As it can be seen, EquationEqs. (14) and Equation(15) are both sums of products P(m1Mim2) by P(cv1CVicv2), where m1,m2,cv1 and cv2 stand for +/−UWL and +/−UCL. In general, these terms can be evaluated using EquationEqs. (18) and Equation(20) when the process is out-of-control and using EquationEqs. (19) and Equation(21) when the process is in-control. Let us first derive EquationEqs. (18) and Equation(19) for P(m1Mim2). We have (16) P(m1Mim2)=P(m1Φ1[Hp(Ti2)]m2)=P(Φ(m1)[Hp(Ti2)]Φ(m2)) =P(Hp1(Φ(m1))Ti2Hp1(Φ(m2))).(16)

As in Sabahno, Amiri, and Castagliola (Citation2021), in an out-of-control case, we have the non-centrality parameter λ equal to (17) λ=ns(μ1μ0)T(Σ1)1(μ1μ0).(17)

Note that the non-centrality parameter λ can be influenced by both the mean vector and the variance-covariance matrix shifts, however, there should be a mean vector shift first in order for the variance-covariance shift to be effective.

In this paper, for simplicity and also to be able to keep track of the coefficient of variability in the scheme, we assume that Σ1=τ1Σ0, and therefore, λ changes to λ=ns(μ1μ0)T(τ1Σ0)1(μ1μ0).

As a result, we have (18) P(m1Mim2)=Hp,λ(Hp1(Φ(m2))×(1/τ1))Hp,λ(Hp1(Φ(m1))×(1/τ1)).(18)

If we monitor the MCV for variability, τ2 is obtained as follows: τ2=γ1γ0=(μ1T(τ1Σ0)1μ1)12(μ0TΣ01μ0)12τ1=τ22(μ1TΣ01μ1)(μ0TΣ01μ0).

When the process is in-control, i.e., λ=0 and τ1=τ2=1, EquationEq. (18) reduces to (19) P(m1Mim2)=Hp(Hp1(Φ(m2)))Hp(Hp1(Φ(m1)))=Φ(m2)Φ(m1).(19)

Similarly, for P(cv1CVicv2), we have P(cv1CVicv2)=P(cv1Φ1[Fp,np,δ(ϒi)]cv2) =P(Φ(cv1)[Fp,np,δ(ϒi)]Φ(cv2)) =P(Fp,np,δ01(Φ(cv1))ϒiFp,np,δ01(Φ(cv2))) 

To obtain the distribution of ϒi when the process is out-of-control, we have (20) P(cv1CVicv2)=Fp,np,δ1(Fp,np,δ01(Φ(cv2)))Fp,np,δ1(Fp,np,δ01(Φ(cv1))).(20)

When the process is in-control, i.e., δ1=δ0, EquationEq. (20) reduces to (21) P(cv1CVicv2)=Fp,np,δ0(Fp,np,δ01(Φ(cv2)))Fp,np,δ0(Fp,np,δ01(Φ(cv1))) =Φ(cv2)Φ(cv1).(21)

One can easily compute EquationEqs. (14) and Equation(15) using the terms P(m1Mim2) and P(cv1CVicv2), by replacingm1,m2,cv1 and cv2 in EquationEqs. (18)–(21) with ±UWL and ±UCL.

Finally, the performance measures, i.e., the average run length (ARL) and average time to signal (ATS) can be computed. For an adaptive scheme, there could be additional performance measures based on the number of observations to signal and the number of switches between the in-control states before a signal is issued, but these measures will not be considered. Since time is the most important element in process monitoring schemes, ATS is by far the most important performance measure that should not be ignored.

Thus, for performance measures, we have (22) ARL=bT(I-Q)11,(22) (23) ATS=bT(I-Q)1t,(23) where bT = (b1,b2) is the vector of starting probabilities such that b1+b2=1, I is the identity matrix of order 2, Q is a 2×2 transition probability matrix for the transient states, 1 is a 2×1 unit column vector, t=(t1,t2)T is the vector of sampling intervals.

In the beginning, when the process is assumed to be in-control (μ1=μ0&τ1=1),  b1 and b2 are obtained as follows: b1=p11p11+p12, b2=p22p21+p22.

5. Numerical analyses

To analyze the performance of the developed simultaneous scheme, we consider two scenarios.

  • Scenario 1: In the first scenario, μ1 can be any vector and as mentioned in the previous section, we have Σ1=τ1Σ0.

  • Scenario 2: In this scenario, μ1 again can be any vector and in addition, we assume that the variation occurs in the form of the MCV. Therefore, we only make assumptions about the shifted values of μ0 and γ0, i.e. μ1 and γ1=τ2γ0.

5.1. First scenario

We will conduct analyses for cases with p = 2 and 4. For all of our analyses, we assume that α1 = 0.0045, ATE = 0.005 (which results in UCL1= 3.0547), in-control ASS = 10 and in-control ASI = 1.

For the case p = 2: Σ0=[10.50.51],Σ1=[τ10.5τ10.5τ1τ1],τ1{0.25,0.5,1,1.5,2} μ1μ0{(0,0),(0.1,0),(0.1,0.1),(0.5,0),(0.5,0.5),(1,1),(2,2)}.

The results of this analysis which are presented in show that:

Table 1. ARL and ATS values for Scenario 1 (mean vector and covariance matrix shift) with p = 2.

  • When either the mean or covariance matrix shifts from their in-control values, the chart signals. The larger the shift, the faster the chart signals. For instance, in the case of τ1=1, in the first column, for μ1μ0=(0.1,0.1), ATS is 179.486 and for μ1μ0=(0.5,0.5), ATS is 4.659.

  • The chart detects an upward variability shift faster than a downward variability shift, for the same size of the shift. For instance, again for the first column and when μ1μ0=(0,0), for the in-control value of τ1=1, the ATS is 200; for τ1=0.5, the ATS becomes 62.5239 and for τ1=2, the ATS becomes 9.8238. Even for τ1=1.5, the ATS value is much lower (i.e., 35.5238) compared to that for τ1=0.5.

  • The performance of the chart for large mean shifts (μ1μ0{(1,1),(2,2)}) is almost similar for all variations of the chart's parameter, as well as τ1.

  • For an upward variability shift τ1>1, having more variables with shifts in their mean values, the chart’s performance slightly deteriorates (or there are only small differences in the performances). For instance, in the case of τ1=1.5, in the first column, for μ1μ0=(0.1,0), the ATS is 37.1952, and for μ1μ0=(0.1,0.1), the ATS is 41.7440. This is not the case in a no (τ1=1) or downward (τ1<1) variability shift. For instance, when τ1=0.5, in the first column, for μ1μ0=(0.1,0), the ATS is 43.3671 and for μ1μ0=(0.1,0.1), the ATS is 29.0740.

  • Using different values of the chart’s parameters (Ω), changes the chart’s performance slightly, but its behavior remains the same. However, the best overall performance is achieved in the third set of parameter values (third column). This is because the differences of n1 (n2), and also t1 (t2), from their respective average in-control values (ASS and ASI) are the same.

  • ARL and ATS trends are very close in most cases.

For the case p = 4:

Similar to the case of p = 2, for the in-control covariance matrix, the variances are equal to one and the covariances to 0.5. Also, τ1{0.25,0.5,1,1.5,2}, μ1μ0{(0,0,0,0),(0.1,0,0,0),(0.1,0.1,0.1,0.1),(0.5,0,0,0),(0.5,0.5,0.5,0.5),(1,1,1,1),(2,2,2,2)}..

From , in the case of having more quality characteristics, the conclusions for p = 2 can also be applied. In addition,

Table 2. ARL and ATS values for Scenario 1 (mean vector and covariance matrix shift) with p = 4.

  • In the case of no or a downward variability shift, the chart performs worse (except for no mean shift and τ1=0.5) when more quality characteristics shift. On the other hand, in the case of an upward covariance matrix shift, the chart signals faster if there are more quality characteristics that shift.

5.2. Second scenario

In scenario 2, where the mean and MCV are being monitored, we also ran the same analyses for the cases of p = 2 and 4. In this scenario, we have τ2 ∈ {0.25, 0.5, 1, 1.5, 2} and mean shifts μ1μ0{(0,0,0,0),(0.1,0,0,0),(0.1,0.1,0.1,0.1),(0.5,0,0,0),(0.5,0.5,0.5,0.5),(1,1,1,1),(2,2,2,2)}, while other assumptions are the same as that in the first scenario.

In the case of two quality characteristics, the results in show the following trend:

Table 3. ARL and ATS values for Scenario 2 (mean vector and MCV shift) with p = 2.

  • The performance of the chart for large mean shifts is similar in all cases.

  • The chart detects an upward MCV shift faster than a downward MCV shift (but not as fast as that for the covariance matrix upward versus downward shifts), for the same size of the shift. As an example, in the case of p = 2, in the first column when μ1μ0=(0,0,0,0), for the in-control value τ2=1, the ATS is 200, while for τ2=0.5, the ATS becomes 1.7744 and for τ2=2, the ATS is 1.6654.

  • When either the mean or MCV shifts from its in-control value, the chart signals. The larger the shift, the faster the signal is detected. However, the chart for the case of monitoring the MCV is faster in detecting shifts than that in Scenario 1 (examples are provided in the other paragraphs).

  • On the contrary to the previous scenario, for a downward MCV shift, the more the number of variables with mean shifts, the worse the chart performs (or there are little differences in the performances). For instance, for τ2=0.5, in the first column, for μ1μ0=(0.1,0), the ATS is 1.9975 and for μ1μ0=(0.1,0.1), the ATS is 2.0903. This is not the case in a no or upward MCV shift, where the opposite is observed. For instance, for τ2=1.5, in the first column, for μ1μ0=(0.1,0), the ATS is 4.9046, and for μ1μ0=(0.1,0.1), the ATS is 4.1019.

  • Similar to Scenario 1, using different values of the chart’s parameters (Ω) changes the chart’s performance slightly, but its behavior remains the same. The best overall performance is achieved in the third set of parameters.

The result for the case of p = 4 is shown in . In the case of four quality characteristics, the results in show that the previous conclusions can be applied here as well. In addition:

Table 4. ARL and ATS values for Scenario 2 (mean vector and MCV shift) with p = 4.

  • similar to that in Scenario 1 (but this time without exceptions), in the case of no or downward MCV shift, the chart performs poorer when more quality characteristics shift but the converse is observed for upward MCV shifts.

5.3. Additional analysis

In this section, we will perform additional graphical analysis. To do so, for the chart’s parameters n = (5,15), t = (0.1,1.9), p = 3, for small (0,0.2,0.1), moderate (0.6,0.5,0.6) and large (1.5,2,1.2) mean shifts, we will show how the chart performs when we vary τ1 (in scenario 1) and τ2 (in scenario 2) values from 0.01 to 3, with both their in-control values being 1. This time we choose α1=0.004 and ATE = 0.0005. We set μ0=(1,1.5,2) and Σ0=[1.5 0.60.50.610.70.50.72].

The behavior of the chart when both τ1 and τ2 deviate from their in-control values of 1, is shown in and , respectively. The main results from these figures are as follows:

Figure 1. ARL and ATS versus Variability Multiplier (τ1) for small, moderate and large (respectively, from top to bottom) mean vector shifts.

Figure 1. ARL and ATS versus Variability Multiplier (τ1) for small, moderate and large (respectively, from top to bottom) mean vector shifts.

Figure 2. ARL and ATS versus MCV Multiplier (τ2) for small, moderate and large (respectively, from top to bottom) mean vector shifts.

Figure 2. ARL and ATS versus MCV Multiplier (τ2) for small, moderate and large (respectively, from top to bottom) mean vector shifts.
  • For cases of large mean shifts, in the case of a covariance matrix shift, we have an increasing trend in the chart’s ARL/ATS values up to about the in-control value (τ1 or τ2=1; depending on the figure) and a steady bahavior thereafter for large mean shifts. However, in the case of a MCV shift, the chart’s ARL/ATS peaks before, but very close to, the in-control value (τ2=1) and goes down if the MCV shifts either upward or downward. The latter trend is valid for the chart with small and moderate mean shifts in both scenarios.

  • In both figures, except for the case with a large variability shift in scenario 1, all other plots are right-skewed. Once again, this confirms that the chart detects upward shifts faster than downward shifts and since in scenario 2 the charts are more right-skewed, we can again conclude that it detects MCV upward shifts faster than the covariance matrix upward shifts.

  • The ARL and ATS trends are very close in most cases.

6. An illustrative example

For the numerical example, we use a real data set originally used by Hawkins and Maboudou-Tchao (Citation2008), in regards to a healthcare process, for monitoring blood pressure and heart rate, which are in fact the main indicators of heart attack and stroke. For blood pressure and also heart rate, both variance and CV have been used before as a measure of their variation.

The variables of interest are x1= systolic blood pressure, x2= diastolic blood pressure, x3= heart rate and x4= arterial pressure. Hawkins and Maboudou-Tchao (Citation2008) concluded that the readings for these four characteristics follow the multivariate normal distribution with the below in-control parameter values. μ0=(126.61,77.48,80.95,97.97)andΣ0=[15.04 8.66 10.5112.048.66 5.835.567.510.51  5.5615.178.7912.04 7.58.7910.57].

Hawkins and Maboudou-Tchao (Citation2008) used two separate control charts for monitoring the mean vector and covariance matrix and they used a single observation in each measurement. If there are no practical restrictions, taking more than one observation, each time a measurement is taken, is always better due to instrumental and environmental issues that exist in most processes; especially for very common biological variables, such as blood pressure and heart rate, which tend to vary constantly. As for the adaptivity of the scheme, it is always better to vary the chart’s parameters, if we can handle the resulting administrative difficulty. Also, using a single chart in the monitoring always makes the procedure easier. Having mentioned these facts, we use our adaptive single chart scheme for a simultaneous monitoring of the mean and variability using the above-mentioned data set.

We assume the below chart’s parameters.

n1=5, ASS = 7, n2=10, ASI = 1 hr, t2= 15min, ATE = 0.005, α1= 0.004 (UCL1= 3.0899). By using EquationEqs. (6) and Equation(11)–(23), we obtain α1= 0.0065 (UCL2= 2.9425), UWL1= 1.2082, UWL2= 1.2957 and t1= 1.5 hrs.

We start the process monitoring by first shifting the process parameters and taking consecutive samples to test our scheme and observe when it will signal. The shifts we choose are μ1=(126.63,77.38,81,97.88)andΣ1=[15.44 8.65 10.4112.648.65 6.835.867.210.41  5.8616.078.6912.64 7.28.6911.07].

The results are shown in . For the first sample, we choose the small sample size and long sampling interval (Ω1). After taking 5 random observations, we compute the sample mean vector and covariance matrix, and by using EquationEqs. (3) and Equation(4), we compute the Mi and CV1 statistics. Then we combine them using EquationEq. (5) and compute MV1. Since MV1 falls in the warning zone UWL1<MV1UCL1, we should switch to the second set of chart parameters (Ω2) for the next sample. This is how the adaptive procedure works. The second column of the table is the sample size used for the current sample, the third column is the cumulative number of observations taken until the current sample, the fourth column is the sampling interval used for the current sample and the fifth column is the cumulative sampling time from the start of process monitoring until the current sample.

Table 5. An illustrative example.

As shown in and , in the first 15 consecutive samplings, the control chart signals at the third and twelfth samples. The chart detects the out-of-control situation after 120 mins have elapsed and 25 observations are taken.

Figure 3. The control chart for the illustrative example.

Figure 3. The control chart for the illustrative example.

7. Concluding remarks

This article proposed a new control chart for simultaneously monitoring the multivariate normal process mean and variability. Our proposed scheme is capable of monitoring variability in two forms, i.e., (i) covariance matrix and (ii) MCV. One can choose to monitor either one of them, depending on the type of process at hand. After developing the control chart, adaptive VP features are added to the scheme to make it capable of detecting small and moderate shifts effectively. The ATS and ARL performance measures are computed using a Markov chain model to accurately and quickly measure the chart’s performance. After designing the control scheme, as well as determining how its performance is measured, we conducted numerical analyses, based on two scenarios of variability ((i) covariance matrix and (ii) MCV), for two different number of quality characteristics (p = 2 and 4) and five different sets of chart’s parameters. When either the mean or variability (in any form) shifts from its in-control value, the chart signals, where the larger the shift, the faster the chart signals. However, the MCV chart acts faster. In both scenarios, the chart detects an upward variability shift faster than a downward variability shift. However, the difference is more significant in the first scenario. The performance of the chart in detecting large mean shifts is almost similar for all combinations of the chart’s parameters, different shift combinations and different number of quality characteristics. Another result is that choosing different values of the chart’s parameters will more or less affect the chart’s performance but the trend remains the same. The same goes to using different performance measures (ATS and ARL), as for both measures, the trend remains the same. In both scenarios, as the number of quality characteristics increase, in the ‘no’ or ‘downward’ variation shift, the chart performs worse in most shift situations. On the other hand, in the case of ‘upward’ variation shifts, the chart signals faster if there are more quality characteristics.

For the first scenario (mean and covariance matrix shift), in an upward covariance matrix shift, the more the number of variables where their mean values have shifted, the chart’s performance deteriorates slightly (or there are little differences in the performance). On the contrary to Scenario 1, the previous case is valid for downward MCV shifts.

We also did some additional graphical analyses, based on a set of the chart’s parameters. We presented the findings in two figures (each for one scenario), each containing plots for the small, moderate and large mean shifts when p = 3. These figures confirmed our previous analyses, as well as gave us some new perspectives. They showed that for cases with large mean shifts, in (mean and covariance matrix shift), we have an increasing trend in the chart’s performance measures (ARL and ATS) up to about the in-control value of the covariance matrix and an almost steady behavior thereafter. However, in (mean and MCV shift), the plot peaks ‘before’ but ‘very close’ to the in-control value of the MCV and it goes down for either the upward or downward shift. The latter trend occurs for all other plots in the cases with small and moderate mean shifts and in both scenarios. Finally, we presented an illustrative example based on a real dataset from a healthcare process, which contains four biological quality characteristics, to show how the proposed scheme can be used in practice.

For future extensions, researchers can develop control charts for simultaneous monitoring of the MCV with other process parameters, as this is a new concept. One may also consider measurement errors, autocorrelation and parameter estimation (together or separately) in such schemes.

Acknowledgments

The authors thank the journal’s editorial board and the reviewers for their constructive comments, which have led to significant improvements in the quality of the paper.

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