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Western Electric Rules (statistical tests in control charts)

1956
  • Western Electric Company
Quality control analyst monitoring Shewhart control chart for non-random patterns.

(generated image for illustration only)

A set of four decision rules for detecting non-random patterns on Shewhart control charts, indicating an out-of-control process even if no points are outside the 3-sigma limits. These rules identify unnatural runs, trends, or clustering of data points that signal the presence of a special cause of variation. They increase the sensitivity of control charts.

The most basic signal of a special cause on a control chart is a single point falling outside the upper or lower control limits. However, a process can be out of control even when all data points lie within these 3-sigma boundaries. The Western Electric Rules, detailed in a 1956 handbook, provide a more sensitive system for detecting such situations by identifying non-random patterns. These rules are based on dividing the area between the control limits into zones, with Zone A being the area between 2 and 3 sigma from the center line, Zone B between 1 and 2 sigma, and Zone C within 1 sigma.

The four primary rules are: 1. Any single data point falls outside the 3-sigma limits. 2. Two out of three consecutive points fall in Zone A or beyond, on the same side of the center line. 3. Four out of five consecutive points fall in Zone B or beyond, on the same side of the center line. 4. Nine (or sometimes eight) consecutive points fall on the same side of the center line. A violation of any of these rules suggests that the process has shifted or is exhibiting a trend, and that a special cause is likely at play. While these rules increase the chart’s sensitivity, they also slightly increase the rate of false alarms. They are a powerful diagnostic tool used to trigger an investigation into the process before major defects occur.

UNESCO Nomenclature: 1209
– Statistics

Type

Software/Algorithm

Disruption

Substantial

Usage

Widespread Use

Precursors

  • shewhart control charts
  • probability theory
  • statistical run tests
  • industrial experience with process monitoring at western electric

Applications

  • manufacturing quality control
  • software performance testing
  • network traffic monitoring
  • healthcare process monitoring
  • financial transaction analysis

Patents:

NA

Potential Innovations Ideas

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Related to: Western Electric Rules, Nelson rules, control chart rules, process shift, trend detection, non-random patterns, SPC, quality control, zone rules, out-of-control.

Historical Context

Western Electric Rules (statistical tests in control charts)

1950
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1956
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1943
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1960
1967
1970

(if date is unknown or not relevant, e.g. "fluid mechanics", a rounded estimation of its notable emergence is provided)

Related Invention, Innovation & Technical Principles

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