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Abstract In the context of economic design, a two‐stage model is proposed that utilizes continuously variable sampling intervals. Specifically, each successive sampling interval is determined by the extremity of the latest sample. Modeling the situation as a Markov chain, the hourly cost is developed for any arbitrary set of design parameters. This proposed approach is found to be more economically desirable, possessing a smaller average out‐of‐control production time, when compared with a standard two‐stage approach where the sampling interval alternates between two fixed values. Copyright © 2009 John Wiley & Sons, Ltd.
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