A reviewer approving or rejecting a machine decision is a binary outcome per item. That is exactly the data type the p-chart was designed for: proportions of non-conforming units in samples that can vary in size between periods, with limits computed from the binomial distribution rather than from assumptions about normality the Six Sigma Study Guide p-chart guide. Reviewer queues vary in length day to day, so the varying-sample-size version of the formula matters here.
The formulas are small enough to keep in a notebook:
p_bar = total approvals / total items reviewed (center line)
UCL = p_bar + 3 * sqrt(p_bar * (1 - p_bar) / n) (upper limit)
LCL = p_bar - 3 * sqrt(p_bar * (1 - p_bar) / n) (lower limit, floored at 0)
A worked example using the standard method: if 68 approvals come out of 2,150 reviewed items, p_bar is 0.0316, and for a sample of 100 items the upper limit is 0.0841 while the lower limit is negative and therefore set to zero the p-chart formula walkthrough. The same source sets the practical starting conditions: at least 20 to 25 periods to establish limits, and samples of 50 or more items so the proportions mean something the p-chart formula walkthrough.
That last point is the first decision rule for your own setup. If your approval rate sits near 90%, the binomial standard deviation is small and a 200-item day will produce limits only a couple of points wide, so ordinary noise will trip the chart. Do not chase it by widening the limits. Instead note that p-charts assume the probability of non-conformance is the same for each item and that each unit is independent of the others the p-chart guide. Reviewer decisions violate independence when the queue is sorted by score: a run of high-confidence items produces a run of approvals that reflects sort order, not reviewer behavior. Shuffle the sample, or stratify by confidence band, before you plot.



