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Development of a cost-effective adaptive sampling system considering process yield and quality loss

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  • Chien-Wei Wu

    (National Tsing Hua University)

  • To-Cheng Wang

    (Republic of China Air Force Academy)

Abstract

Acceptance sampling plans serve as a valuable tool for verifying product quality, with the most fundamental plan being the single sampling plan (SSP). Numerous studies have recently explored acceptance sampling systems that combine two SSPs with distinct decision rules to enhance sampling inspection efficiency. The current literature categorises these systems into quick-switching sampling systems (QSSs) and two-plan sampling systems (TSSs). This study constructs a TSS based on the process capability index Cpmk. Compared to existing methods, including SSPs and QSSs, the proposed TSS demonstrates superior performance in terms of cost-effectiveness and discriminatory power regarding lot quality, significantly improving the efficiency of product quality verification. Finally, a practical case study illustrates the advantages of the proposed method, demonstrating that this method can reduce sample sizes by up to 71.05% compared to existing methods, offering a promising approach to advancing industrial practices.

Suggested Citation

  • Chien-Wei Wu & To-Cheng Wang, 2025. "Development of a cost-effective adaptive sampling system considering process yield and quality loss," Operational Research, Springer, vol. 25(2), pages 1-16, June.
    • Handle: RePEc:spr:operea:v:25:y:2025:i:2:d:10.1007_s12351-025-00945-x
    DOI: 10.1007/s12351-025-00945-x
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    References listed on IDEAS

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    1. W L Pearn & Chien-Wei Wu, 2006. "Variables sampling plans with PPM fraction of defectives and process loss consideration," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 57(4), pages 450-459, April.
    2. Sardesai, Saskia & Klingebiel, Katja, 2023. "Maintaining viability by rapid supply chain adaptation using a process capability index," Omega, Elsevier, vol. 115(C).
    3. Chien-Wei Wu & Ming-Hung Shu & Bi-Min Hsu & To-Cheng Wang, 2025. "Optimum design of an efficient variables sampling system for validating process yield with Six-Sigma quality requirement and creation of a cloud-computing too," European Journal of Industrial Engineering, Inderscience Enterprises Ltd, vol. 19(1), pages 86-107.
    4. To-Cheng Wang & Ming-Hung Shu, 2023. "Development of an adaptive sampling system based on a process capability index with flexible switching mechanism," International Journal of Production Research, Taylor & Francis Journals, vol. 61(21), pages 7233-7247, November.
    5. Lepore, A. & Palumbo, B. & Castagliola, P., 2018. "A note on decision making method for product acceptance based on process capability indices Cpk and Cpmk," European Journal of Operational Research, Elsevier, vol. 267(1), pages 393-398.
    6. Wu, Chien-Wei & Pearn, W.L. & Kotz, Samuel, 2009. "An overview of theory and practice on process capability indices for quality assurance," International Journal of Production Economics, Elsevier, vol. 117(2), pages 338-359, February.
    7. Pearn, W.L. & Wu, Chien-Wei, 2007. "An effective decision making method for product acceptance," Omega, Elsevier, vol. 35(1), pages 12-21, February.
    8. Zih-Huei Wang & Chien-Wei Wu & Pei-Yi Li, 2025. "An improved skip-lot sampling scheme with resampling mechanism using an advanced capability index," International Journal of Production Research, Taylor & Francis Journals, vol. 63(1), pages 104-118, January.
    9. Lee, Amy H.I. & Wu, Chien-Wei & Wang, To-Cheng & Kuo, Ming-Han, 2024. "Construction of acceptance sampling schemes for exponential lifetime products with progressive type II right censoring," Reliability Engineering and System Safety, Elsevier, vol. 243(C).
    10. Wu, Chien-Wei & Pearn, W.L., 2008. "A variables sampling plan based on Cpmk for product acceptance determination," European Journal of Operational Research, Elsevier, vol. 184(2), pages 549-560, January.
    11. Michele Scagliarini, 2022. "A sequential test and a sequential sampling plan based on the process capability index Cpmk," Computational Statistics, Springer, vol. 37(3), pages 1523-1550, July.
    12. Zih-Huei Wang & Chien-Wei Wu & Jhen-Jia Jhu, 2023. "Design and construction of a quick-switching sampling system with a third-generation capability index," Communications in Statistics - Theory and Methods, Taylor & Francis Journals, vol. 52(11), pages 3633-3651, June.
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