What are X Bar R Control Charts?
X Bar R charts are widely used control charts for variable data to examine process stability in many industries (e.g., hospital patients’ blood pressure over time, customer call handle times, length of a part in a production process).
Selection of the appropriate control chart is essential in control chart mapping; otherwise, you will end up with inaccurate control limits for the data.

The X-bar R chart is used to monitor the process performance of continuous data. You can also use it to collect data from subgroups at set time periods. It is actually two plots to monitor the process mean and the process variation over time and is an example of statistical process control. These combination charts help to understand the stability of processes and detect special-cause variation.
The cumulative sum (CUSUM) and the exponentially weighted moving average (EWMA) charts also monitor the process’s mean, but the primary difference is unlike the X bar chart. They consider the previous value means at each point.
X Bar R Control Chart Definitions
X bar chart: The mean or average change in a process over time from subgroup values. The control limits on the X̄ consider the sample’s mean and center.
R chart: The range of the process over time from subgroup values. This monitors the spread of the process over time.
Notation Used in X-bar R Charts
- m = Number of subgroups
- n = Number of observations per subgroup
- X̄ = Mean of one subgroup
- X̄̄ = Grand mean (average of all X̄ values)
- R = Range of one subgroup
- R̄ = Average range (average of all R values)
For example, if you measure 5 parts each day for 25 days:
- n = 5
- m = 25
Use X Bar R Control Charts When:
- Even a very stable process may have some minor variations which cause instability. An X-bar R chart will help identify these variations over time.
- When the data is assumed to be normally distributed.
- An X-bar R chart is for a subgroup size of more than one (for an I-MR chart, the subgroup size is one only), and it is generally used when rationally collecting measurements in a subgroup size between two and ten observations.
- The X Bar S Control chart should be considered once the subgroup size reaches roughly 9 or more; some references cite 10 as the cutoff, but around 9 is where the sample standard deviation becomes a more efficient estimator of variation than the range.
- When the collected data is continuous (i.e., Length, Weight), it captures data in time order.
How to Interpret the X Bar R Control Charts
- To correctly interpret an X-bar R chart, always examine the R chart first.
- The X bar chart controls limits derived from the R bar (average range) values. If the R chart’s values are out of control, the X bar chart control limits are inaccurate.
- If the points in the R chart are out of control, stop the process. Identify the special cause and address the issue. Then, remove those subgroups from the calculations.
- Once the R bar chart is in control, review the X bar chart and interpret the points against the control limits.
- All the points must be interpreted against the control limits but not specification limits. The customer or management provides specification limits, whereas control limits are derived from the average and range values of the subgroups.
- Process capability studies can only be performed after the X bar and R chart values are within the control limits. They are not necessary for an unstable process.
Steps to follow for X bar R chart
The objective of the chart and subgroup size
- Determine the aim of the chart and choose the essential variables.
- Choose the appropriate subgroup size and the sampling frequency.
- Collect a minimum of 20 to 25 sets of samples in the time sequence.
Example: In the manufacturing industry, plate thickness is one of the CTQ factors. During the Measure phase, the project team performed the process capability study and identified that the process was not capable (less than two sigmas). In the Analyze phase, they collected 20 sets of plate thickness samples with a subgroup size of 4.

Compute X̄ and R values.
- Measure the average of each subgroup, i.e., X-bar, and then compute the grand average of all X-bar values. This will be the center line for the X-bar chart.
- Compute the range of each subgroup, i.e., Range, then measure the grand averages of all range values, i.e., R bar. This will be the center line for the R chart.

Determine the Control Limits
- The first set of subgroups determines the process mean and standard deviation. These values are to be considered for creating control limits for both ranges and the mean of each subgroup.

- The process is to be under control in the early phase of production. If any of the points are out of control during the initial phase, you must identify any special causes. Also, you should remove the subgroup before the calculation.
- Sometimes, having a few points out of control on the x-bar portion would also be good in the initial phase. Otherwise, if all the values are within the control limits, it may be because of the slop in the measurement system, and the team won’t focus on it. Identify the appropriate Measurement System Evaluation (MSE).

- Where
- X is the individual value (data)
- n is the sample size (subgroup size)
- X̄ is the average reading in a sample
- R is the Range, in other words, the difference between the largest and smallest value in each sample.
- R-bar is the average of all the ranges.
- UCL is the Upper control limit
- LCL is the Lower control limit
X bar chart control limits:
UCL = X̄̄ + A₂ × R̄
LCL = X̄̄ − A₂ × R̄
R chart control limits:
UCL = D₄ × R̄
LCL = D₃ × R̄
Where A₂, D₃, and D₄ are control chart constants that depend on the subgroup size n; see the constants table below. Let m represent the number of subgroups collected and n the number of observations per subgroup.
The control chart constants below are the approximate values used to measure the control limits for the X-bar R chart and other control charts based on subgroup size.

| Subgroup size (n) | A2 | A3 | d2 | D3 | D4 | B3 | B4 |
|---|---|---|---|---|---|---|---|
| 2 | 1.880 | 2.659 | 1.128 | – | 3.267 | – | 3.267 |
| 3 | 1.023 | 1.954 | 1.693 | – | 2.574 | – | 2.568 |
| 4 | 0.729 | 1.628 | 2.059 | – | 2.282 | – | 2.266 |
| 5 | 0.577 | 1.427 | 2.326 | – | 2.114 | – | 2.089 |
| 6 | 0.483 | 1.287 | 2.534 | – | 2.004 | 0.030 | 1.970 |
| 7 | 0.419 | 1.182 | 2.704 | 0.076 | 1.924 | 0.118 | 1.882 |
| 8 | 0.373 | 1.099 | 2.847 | 0.136 | 1.864 | 0.185 | 1.815 |
| 9 | 0.337 | 1.032 | 2.970 | 0.184 | 1.816 | 0.239 | 1.761 |
| 10 | 0.308 | 0.975 | 3.078 | 0.223 | 1.777 | 0.284 | 1.716 |
| 11 | 0.285 | 0.927 | 3.173 | 0.256 | 1.744 | 0.321 | 1.679 |
| 12 | 0.266 | 0.886 | 3.258 | 0.283 | 1.717 | 0.354 | 1.646 |
| 13 | 0.249 | 0.850 | 3.336 | 0.307 | 1.693 | 0.382 | 1.618 |
| 14 | 0.235 | 0.817 | 3.407 | 0.328 | 1.672 | 0.406 | 1.594 |
| 15 | 0.223 | 0.789 | 3.472 | 0.347 | 1.653 | 0.428 | 1.572 |
| 16 | 0.212 | 0.763 | 3.532 | 0.363 | 1.637 | 0.448 | 1.552 |
| 17 | 0.203 | 0.739 | 3.588 | 0.378 | 1.622 | 0.466 | 1.534 |
| 18 | 0.194 | 0.718 | 3.640 | 0.391 | 1.608 | 0.482 | 1.518 |
| 19 | 0.187 | 0.698 | 3.689 | 0.403 | 1.597 | 0.497 | 1.503 |
| 20 | 0.180 | 0.680 | 3.735 | 0.415 | 1.585 | 0.510 | 1.490 |
| 21 | 0.173 | 0.663 | 3.778 | 0.425 | 1.575 | 0.523 | 1.477 |
| 22 | 0.167 | 0.647 | 3.819 | 0.434 | 1.566 | 0.534 | 1.466 |
| 23 | 0.162 | 0.633 | 3.858 | 0.443 | 1.557 | 0.545 | 1.455 |
| 24 | 0.157 | 0.619 | 3.895 | 0.451 | 1.548 | 0.555 | 1.445 |
| 25 | 0.153 | 0.606 | 3.931 | 0.459 | 1.541 | 0.565 | 1.435 |
Refer to common factors for various control charts.
Example cont: In the above example, n=4


Interpret X bar and R chart
- Plot both the X bar and R chart and identify the assignable causes
Example Cont: Use the above values and plot the X bar and Range chart

From both the X-bar and R charts, it is evident that most of the values are out of control; hence, the process is not stable.
Monitor the process after improvement.
- Once the process stabilizes and control limits are in place, monitor the process performance over a set period.
Example cont: Control Phase: Once the process is improved and matured, the team identifies the X-bar R chart as one of the control methods in the Control plan, which is used to monitor process performance over time.
The following are the measurement values in the Control phase of the project.

Compute X-bar and Range



Both the X-bar and R charts clearly show that the process is almost stable. During the initial phase, one value is out of control, so the team has to perform a root cause analysis for the special cause. It also seems that the process is smoothing out from data set number 16. If that continued, the chart would need new control limits from that point.
- After the process is stabilized, even if any point goes out of the control limits, it indicates an assignable cause that needs to be addressed. This is an ongoing process to monitor process performance.
https://www.youtube.com/watch?v=djEMQLS7VCc
Related Control Charts
X-bar R charts are for continuous (variable) data. If you are working with attribute data instead, see the P chart (proportion of defective units) or the NP chart (number of defective units). For a deeper look at what these control limits mean for meeting customer requirements, see Process Capability & Performance (Pp, Ppk, Cp, Cpk).
Important notes
- A process that is “in control” means that the process is stable and predictable.
- Just because a process is stable does not mean it has a zero-defect process.
- Remember NEVER to put specifications on any control chart.
- The points on the chart are comprised of averages, not individuals. Specification limits are based on individuals, not averages.
- The operator might be prone to not reacting to a point that is out of control when the point is within the specification limits.
- X bar R chart helps to avoid unnecessary adjustments in the process.
X Bar R Control Chart Videos
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