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Is Your Process Being Adjusted Too Frequently?

To be specific, let us suppose that a process output is designed to be 100. An operator measures the output and finds it to be 97. The process is adjusted by increasing its output by 3 units to correct the deficiency. This procedure is carried out from time to time. (It is related to "Rule 2" of the "funnel experiment" described by Deming (1986, p. 327)). It is "obviously" a sensible approach. Unfortunately, as we shall see, it is often not a sensible approach at all (see MacGregor (1990) for situations in continuous process industries where frequent adjustment may be called for).