SUPPLEMENT 6

DISCUSSION QUESTIONS
2. The ultimate goal of the X and R-charts is to ascertain, by a sampling procedure, that the relevant parameter is kept within specific upper and lower bounds. The X bar chart alone tells us only that the average or variable values are within the appropriate limits. The combination of X and the Rcharts allows one to determine that both the average and the deviations are within the limits. A process can be out of control because of assignable variation, which can be traced to specific causes. Examples include such factors as: n Tool wear n A change in raw materials n A change in working environment (temperature or humidity, for example) n Tired or poorly trained labor Natural variations are those variations that are inherent in the process and for which there is no identifiable cause. These variations fall in a natural pattern. Assignable causes are variations beyond those that can be expected to occur because of natural variation. These variations can be traced to a specific cause. A run of 5 implies that assignable variation is present. The desired mean is used when the mean of a process being observed is unknown or out of control.

4.

6.

11. 13.

END-OF-SUPPLEMENT PROBLEMS
S6.4 n = 6 . From Table S6.1, A2 = 0.483 , D4 = 2.004 , D3 = 0 UCLX = X + A2 R = 46 + 0.483 2 = 46.966 LCLX = X A2 R = 46 0.483 2 = 45.034 UCLR = D4 R = 2.004 2 = 4.008 LCLR = D3 R = 0 2 = 0 S6.5 n = 10 . From Table S6.1, A2 = 0.308 , D4 = 1.777 , D3 = 0.233 UCLX = X + A2 R = 60 + 0.308 3 = 60.924 LCLX = X A2 R = 60 0.308 3 = 59.076 UCLR = D4 R = 1.777 3 = 5.331 LCLR = D3 R = 0.223 3 = 0.669

Chapter 6 Supplement: Statistical Process Control

S6.7

Sample 1 2 3 4 5 6 7 8 9

X 63.5 63.6 63.7 63.9 63.4 63.0 63.2 63.3 63.7

R 2.0 1.0 1.7 0.9 1.2 1.6 1.8 1.3 1.6

Sample 10 11 12 13 14 15 16 17 18

X 63.5 63.3 63.2 63.6 63.3 63.4 63.4 63.5 63.6

R 1.3 1.8 1.0 1.8 1.5 1.7 1.4 1.1 1.8

Sample 19 20 21 22 23 24 25

X 63.8 63.5 63.9 63.2 63.3 64.0 63.4

R 1.3 1.6 1.0 1.8 1.7 2.0 1.5

X = 63.49 , R = 1.5 , n = 4 . From Table S6.1, A2 = 0.729 , D4 = 2.282 , D3 = 0.0 . UCLX = X + A2 R = 63.49 + 0.729 1.5 = 64.58 LCLX = X A2 R = 63.49 0.729 15 = 62.40 . UCLR = D4 R = 2.282 1.5 = 3.423 LCLR = D3 R = 0 1.5 = 0 The process is in control. 65.00 64.00 63.00 62.00 61.00 60.00 0 4.00 3.00 2.00 1.00 0.00 0 LCL UCL Control Chart X

LCL UCL

10

15 Sample Control Chart R

20

25

30

10

15 Sample

20

25

30

Instructors Solutions Manual t/a Operations Management

S6.8

Time 9 AM 10 AM 11 AM 12 PM 1 PM

Box 1 9.8 10.1 9.9 9.7 9.7

Box 2 10.4 10.2 10.5 9.8 10.1

Box 3 9.9 9.9 10.3 10.3 9.9

Box 4 10.3 9.8 10.1 10.2 9.9 Average

Average 10.10 10.00 10.20 10.00 9.90 10.04

Range 0.60 0.40 0.60 0.60 0.40 0.52

n = 4 . From Table S6.1, A2 = 0.729 , D4 = 2.282 , D3 = 0.0 . UCLX = X + A2 R = 10.04 + 0.729 0.52 = 10.42 LCLX = X A2 R = 10.04 0.729 0.52 = 9.66 UCLR = D4 R = 2.282 0.52 = 1187 . LCLR = D3 R = 0 0.52 = 0 The smallest sample mean is 9.9, the largest 10.2. Both are well within the control limits. Similarly, the largest sample range is 0.6, also well within the control limits. Hence, we can conclude that the process is presently within control. One step the QC department might take would be to increase the sample size to provide a clearer indication as to both control limits and whether or not the process is in control. S6.9 X = 19.90 , R = 0.34 , n = 4 , A2 = 0.729 , D4 = 2.282 UCL = 19.90 + 0.729( 0.34 ) = 20.15 (a) LCL = 19.90 0.729( 0.34 ) = 19.65 UCL = 2.282( 0.34 ) = 0.78 (b) LCL = 0 (c) The ranges are ok; the means are not in control.

S6.10 X = 10 , R = 3.3 (a) standard deviation = 1.36, x = 136 .

5 = 0.61

Chapter 6 Supplement: Statistical Process Control

(b)

Using x UCL = 10 + 3( 0.61) = 1183 . LCL = 10 3( 0.61) = 817 .

Using A2 = 0.577 UCL = 10 + 3.3( 0.577) = 1190 . LCL = 10 3.3( 0.577) = 810 . (c) (d) UCL = 2115 (3.3) = 6.98 . LCL = 0 (3.3) = 0 Yes, both mean and range charts indicate process is in control.

S6.11 RDesired = 3.5 , XDesired = 50 , n = 6 UCLX = X + A2 R = 50 + 0.483 3.5 = 5169 . LCLX = X A2 R = 50 0.483 3.5 = 48.31 UCLR = D3 R = 2.004 3.5 = 7.014 LCLR = D4 R = 0 3.5 = 0 The smallest sample range is 1, the largest 6. Both are well within the control limits. The smallest average is 47, the largest 57. Both are outside the proper control limits. Therefore, although the range is within limits, the average is outside limits, and apparently increasing. Immediate action is needed to correct the problem and get the average within the control limits again.

Instructors Solutions Manual t/a Operations Management