Que1

http://www.docstoc.com/docs/104804675/Quality-Management-Total-Quality-Management-andStatistical-

Ques 4 Sample_ No. 1 2 3 4 5 Obs.1 79.2 80.5 79.6 78.9 80.5 Obs.2 78.8 78.7 79.6 79.4 79.6 Obs.3 80 81 80.4 79.7 80.4 Obs.4 78.4 80.4 80.3 79.4 80.8 Obs.5 81 80.1 80.8 80.6 78.8 mean 79.48 80.14 80.14 79.6 80.02 range 2.6 2.3 1.2 1.7 2

79.7

80.6

80.5

80

81.1

80.38 79.96

1.4 1.8666 67

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since all means are within limits, we can say that process is under control

Q 12
a. construct an -chart for this process with three-sigma limits. is the process in control?

b.analyze the data using a median run test and an up/down run test. What can you conclude?
Statistics and Probability

Interpretation: No, the process is not in control because it touches the UCL at 3.98.

Q25 #5: An appliance manufacturer wants to contract with a repair shop to handle authorize repairs in Indianapolis. The company has an acceptable range of repair time of 50 minutes to 90 minutes. Two vendors have submitted bids for the work: A and B. In test trials, vendor A had a mean repair time 74 minutes with a standard deviation of 4.0 minutes, and vendor B had a repair time of 72 minutes with a standard deviation of 5.1 minutes. a. What is the tolerance range the manufacturer will accept? 40 minutes (90 50) Answer the following questions assuming the appliance manufacture wants the repair shop to meet 3-sigma quality control. b. What is the process capability for vendor A? Vendor B? Vendor A: Between 62 minutes (74 3*4) and 86 minutes (74+3*4) Vendor B: Between 56.7 minutes (72-3*5.1) and 87.3 minutes (72+3*5.1) c. Which company meets the appliance manufacturers tolerance specifications? Why? Both meet the tolerance specifications for repair times because they are between the required 50 minutes and 90 minutes d. Assuming the appliance manufacturer will only choose one vendor and all other factors are equal (e.g. price, delivery time, etc), which vendor should the company choose? Why? Vendor A because the variability of their process is less than the variability of vendor B Answer the following questions assuming the appliance manufacture wants the repair shop to meet 6-sigma quality control. e. What is the process variability a vendor should have if their average repair time is 70 minutes? Why? 3.3 minutes 6 times the process variability (standard deviation) should be within the allowable range of 20 minutes (90 70 or 70 -50). For this to occur 6*s<20 implies s<3.33 minutes. Quality Control Purpose of QC To assure that the process is performing in an acceptable manner Done through monitoring the process via inspection

Quality Assurance Relies on inspection

Inspection after production (acceptance sampling) Inspection during production (statistical process control, or SPC)

Basic Issues in Inspection: 1) How much and how often to inspect 2) At what points in the process to inspect 3) Whether to inspect in a centralized or on-site location 4) Whether to inspect attributes (counting something) or variables (measure something) Where to inspect: Raw materials and purchased parts Finished products Before a costly operation Before an irreversible process Before covering a process

Key Concepts: Variation is the enemy of quality Every process exhibits some form of variation The degree of this variation is a measure of the capability of the process Process variation can be classified as: o common cause variation - inherent in system o special cause variation - presence is detected using SPC

Control Charts Key tool for monitoring and controlling processes. A control chart is a time-ordered plot of sample statistics Purpose: used for detecting presence of special cause variation. Components of a Control Chart (1) Upper Control Limit (2) Middle Value (3) Lower Control Limit

Possible Errors in SPC Type I error Type II error Managerial Considerations Concerning Control Charts 1. At what points in the process to use control charts 2. What size samples to take 3. What type of control chart

Four Common Types of Charts A. Control charts for Variables (1) Mean chart (a.k.a x-bar chart) - used to monitor the average of the process

UCL = x +z (/ LCL = x z (/

n) n)

UCL = x + A2 R LCL = x A2 R

where : x grand mean z confidence level population standard deviation n sample size R average range A2 value from table given a sample size

(2) Range chart (a.k.a. R-chart) - used to monitor the variability of the process
UCL = D4 R LCL = D3 R

B. Control charts for Attributes (1) p-chart (proportion chart) - used to monitor the proportion of defectives

UCL = p + z LCL = p z

p (1 p ) n p (1 p ) n

where : p average proportion z confidence level

(2) c-chart (used when the goal is to control the number of defects per unit
UCL =c +z LCL =c z c c

where : c average number of defects z confidence level

Charts Illustrating a Process Not in Control

Table for A2, D3 and D4

Factor for R Chart Number of Observation s in Subgroup n 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Factor for xbar Chart A2 1.88 1.02 0.73 0.58 0.48 0.42 0.37 0.34 0.31 0.29 0.27 0.25 0.24 0.22 0.21 0.20 0.19 0.19 0.18 Lower Upper Control Control Limit Limit D3 D4 0.00 0.00 0.00 0.00 0.00 0.08 0.14 0.18 0.22 0.26 0.28 0.31 0.33 0.35 0.36 0.38 0.39 0.40 0.41 3.27 2.57 2.28 2.11 2.00 1.92 1.86 1.82 1.78 1.74 1.72 1.69 1.67 1.65 1.64 1.62 1.61 1.60 1.59

Problems 4 Control charts for Variables Mean and Range charts 6 Control chart for Attributes p-chart 7 Control chart for Attributes c-chart 8 How many to produce given a certain production survival rate

Problem 10.4 (p. 462) Computer upgrades have a nominal time of 80 minutes. Samples of 5 observations each have been taken, and the results are listed below. Determine the upper and lower control limits for mean and range charts, and decide if the process is in control. SAMPLE 3 4 79.8 78.9 79.4 79.4 80.4 79.7 80.3 79.4 80.8 80.6

1 79.2 78.8 80.0 78.4 81.0

2 80.5 78.7 81.0 80.4 80.1

5 80.5 79.6 80.4 80.8 78.8

6 79.7 80.6 80.5 80.0 81.1

Excel Solution

UCL = x + A2 R LCL = x A2 R

UCL = D4 R LCL = D3 R

Problem 10.6 (463) A medical facility does MRIs for sports injuries. Occasionally a test yields inconclusive results and must be repeated. Using the following sample data and n=200, determine the upper and lower control limits for the fraction of retests using two-sigma limits. Is the process in control? If not eliminate any values that are outside the limits and compute the revised limits. SAMPLE 6 7 8 1 2 0

1 Number of defectives 1

2 2

3 2

4 0

5 2

9 2

10 7

11 3

12 2

13 1

Excel Solution

UCL = p + z LCL = p z

p (1 p ) n p (1 p ) n

PROBLEM NO. 10 - 7 The postmaster of a small western city receives a certain number of complaints each day about mail delivery. Assume that the distribution of daily complaints is Poisson. Construct a control chart with three sigma limits using the following data. Is the process in control? SAMPLE 6 7 8 6 5 12

1 Number of complaints 4

2 10

3 14

4 8

5 9

9 13

10 7

11 6

12 4

13 2

14 10

Excel Solution

Problem 18 A production process consists of a three-step operation. The scrap rate is 10 percent for the first step and 6 percent for the other two steps. (a) If the desired daily output is 450 units, how many units must be started to allow for loss due to scrap?

(b) If the scrap rate for each step would be cut in half, how many units would this save in terms of the scrap allowance?

(c ) If the scrap represents a cost of $10 per unit, how much is it costing the company per day for the original scrap rate?