(Statistical Process Control {AACSB: Analytic Skills}Required for Operations Management Control charts for variables UCL x = x + 3 LCL

L x = x - 3 If sample size is given to you then = /square root of sample size UCLR = D4 * R LCLR = D3 * R , where D4 and D3 are +/- 3 Or as accurate as: UCLR = R +3 (of the range), LCLR = R -3 (of the range) Control Charts for Attributes: defects: UCLp = p + 3

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

LCLp = p 3 defectives: where c =

mean number defective in the sample

UCLc = c bar + 3 Square root of c bar and LCLc = c bar - 3 square root of cbar

1.

2.

The defect rate for a product has historically been about 1.6%. What are the upper and lower control chart limits for a p-chart, if you wish to use a sample size of 100 and 3-sigma limits? A small, independent amusement park collects data on the number of cars with out-Standarof-state license plates. The sample size is fixed at n=25 each day. Data from the previous 10 days indicate the following number of out-of-state license plates:

Day 1 2 3 4 5 6 7 8 9 10

Out-of-state Plates 6 4 5 7 8 3 4 5 3 11

(a) Calculate the overall proportion of "tourists" (cars with out-of-state plates) and the standard deviation of proportions. (b) Using 3 limits, calculate the LCL and UCL for these data. (c) Is the process under control? Explain.

3.

The mean and standard deviations for a process are x = 90 and = 9. For the variable control chart, a sample size of 16 will be used. Calculate the standard deviation of the sampling distribution. If x = 9 ounces, = 0.5 ounces, and n = 9, calculate the 3-sigma control limits.

4. 5.

Cartons of Plaster of Paris are supposed to weigh exactly 32 oz. Inspectors want to develop process control charts. They take ten samples of six boxes each and weigh them. Based on the following data, compute the lower and upper control limits and determine whether the process is in control.
Sample Mean Range

1 2 3 4 5 6 7 8 9 10
6.

33.8 34.6 34.7 34.1 34.2 34.3 33.9 34.1 34.2 34.4

1.1 0.3 0.4 0.7 0.3 0.4 0.5 0.8 0.4 0.3

McDaniel Shipyards wants to develop control charts to assess the quality of its steel plate. They take ten sheets of 1" steel plate and compute the number of cosmetic flaws on each roll. Each sheet is 20' by 100'. Based on the following data, develop limits for the control chart, plot the control

chart, and determine whether the process is in control. Sheet 1 2 3 4 5 6 7 8 9 10 Number of flaws 1 1 2 0 1 5 0 2 0 2

7.

The mean and standard deviations for a process are x = 90 and = 9. For the variable control chart, a sample size of 16 will be used. Calculate the standard deviation of the sampling distribution. If x = 9 ounces, = 0.5 ounces, and n = 9, calculate the 3-sigma control limits. A nationwide parcel delivery service keeps track of the number of late deliveries (more than 30 minutes past the time promised to clients) per day. They plan on using a control chart to plot their results. The average is 9 per day. Which type of control chart would you recommend? And what is upper and lower control limits within 2 standard deviation?

8. 9.

10.

A quality analyst wants to construct a sample mean chart for controlling a packaging process. He knows from past experience that the process standard deviation is two ounces. Each day last week, he randomly selected four packages and weighed each. The data from that activity appears below. Day Monday Tuesday Wednesday Thursday Friday Package 1 23 23 20 18 18 Weight Package 2 Package 3 22 23 21 19 19 20 19 20 20 22 Package 4 24 21 21 19 20

(a) Calculate all sample means and the mean of all sample means. (b) Calculate upper and lower control limits that allow 2 for natural variations. (c) Is this process in control?