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The first thing that must be done is to develop quality control limits for the
sample means. This can be done as follows. Because the process appears to
x
be unstable, we can use the desired mean as the nominal line. Desired
=
50.0,
=
1.2
(from
past
results
of
Wet-Land
Drilling),
x / n 1.2 6 1.2 / 2.45 0.489.
Tim Av
e
e
6:0 49.
0
6
7:0 50.
0
2
8:0 50.
0
6
9:0 50.
0
8
10:0 49.
0
9
11:0 50.
0
3
12:0 48.
0
6
1:0 49.
0
0
Day Shift*
Lo Hig Av Lo Hig Av Lo Hig
w h e w h e w h
48. 50. 48. 47. 52. 48. 45. 49.
7 7 6 4 0 4 0 0
49. 51. 50. 49. 52. 48. 44. 49.
1 2 0 2 2 8 8 7
49. 51. 49. 49. 52. 49. 48. 51.
6 4 8 0 4 6 0 8
50. 51. 50. 49. 51. 50. 48. 52.
2 8 3 4 7 0 1 7
49. 52. 50. 49. 51. 51. 48. 55.
2 3 2 6 8 0 1 2
48. 51. 50. 49. 52. 50. 49. 54.
6 7 0 0 3 4 5 1
46. 50. 50. 48. 52. 50. 48. 50.
2 4 0 8 4 0 7 9
46. 50. 50. 49. 53. 48. 47. 51.
4 0 1 4 6 9 6 2
Evening Shift
Ti
me
2:0
0
3:0
0
4:0
0
5:0
0
Av
e
49.
0
49.
8
50.
3
51.
4
Lo Hig
w h
48. 51.
4 0
48. 50.
8 8
49. 50.
1 6
45. 51.
2 2
6:0
0
7:0
0
8:0
0
9:0
0
51.
6
51.
8
51.
0
50.
5
49.
2
50.
0
48.
6
49.
4
54.
7
55.
6
53.
2
52.
4
46. 41.
8 0
50. 46.
0 2
47. 44.
4 0
47. 44.
0 2
51. 46.
2 4
51. 46.
7 5
48. 47.
7 2
48. 48.
9 4
44.
0
44.
4
46.
6
47.
2
49.
7
50.
0
48.
9
49.
5
Night Shift
Tim Av Lo Hig Av Lo Hig Av Lo Hig
e
e w h e w h e w h
10:0 49. 46. 50. 47. 46. 50. 49. 48. 50.
0
2 1 7 2 6 2 2 1 7
11:0 49. 46. 50. 48. 47. 50. 48. 47. 50.
0
0 3 8 6 0 0 4 0 8
12:0 48. 45. 50. 49. 48. 50. 47. 46. 49.
0
4 4 2 8 2 4 2 4 2
1:0 47. 44. 49. 49. 48. 51. 47. 46. 49.
0
6 3 7 6 4 7 4 8 0
2:0 47. 44. 49. 50. 49. 52. 48. 47. 51.
0
4 1 6 0 0 2 8 2 4
3:0 48. 45. 49. 50. 49. 50. 49. 49. 50.
0
2 2 0 0 2 0 6 0 6
4:0 48. 45. 49. 47. 46. 50. 51. 50. 51.
0
0 5 1 2 3 5 0 5 5
5:0 48. 47. 49. 47. 44. 49. 50. 50. 51.
0
4 1 6 0 1 7 5 0 9
* Boldfaced type indicates a sample outside the quality control limits.
(a) Day shift (6:00
AM2:00 PM):
Numberofmeanswithincontrollimits 23
96%
Totalnumberofmeans
24
(b) Evening shift (2:00
PM10:00 PM):
Numberofmeanswithincontrollimits 12
50%
Totalnumberofmeans
24
PM6:00 AM):
Numberofmeanswithincontrollimits 12
50%
Totalnumberofmeans
24
(1)
As is now evident, none of the shifts meet the control specifi-cations. Bag
weight monitoring needs improvement on all shifts. The problem is much
more acute on the evening and night shifts staffed by the more recent hires.
Note also, that the number of samples indicating a short weight is much
greater than the number indicating excess weight.
With regard to the range, 99.73% of the individual bag weights should lie
within 3 of the mean. This would represent a range of 6, or 7.2. Only one
of the ranges defined by the differ-ence between the highest and lowest bag
weights in each sample exceeds this range. Alternatively: D4 Sample
Range UCLR and D2 Sample Range LCLR.
This is dangerous if the process is out of control, but the mean range for
the first shift is 3.14 (the lowest of any shift) and D4 3.14 6.28 and D3
3.14 0. A range of 0 to 6.28 compares favorably with 7.2, with only two
values exceeding the range limit. It would appear, then, that the problem is
not due to abnormal deviations between the highest and lowest bag weights,
but rather to poor adjustments of the bag weight-feeder causing assignable
variations in average bag weights.
The proper procedure is to establish mean and range charts to guide the
bag packers. The foreman would then be alerted when sample weights
deviate from mean and range control limits. The immediate problem,
however, must be corrected by additional training and bag weight monitoring
and weight-feeder adjustments. Short-run declines in bag output may be
necessary to achieve acceptable bag weights.
The result from the statistics shows that there was a statistical control on the
day shift for the first 2 days. That is, the weight of the bag fell within the
operational limits. The assumption is that because the problem exists across
all the shifts then there may be a problem with the machine, possibly a
malfunction or gradual deterioration of quality due to machine wear.
This is so because statistics has shown that the machine has been
performing to standards before the problem arise. Because the machine
operates acceptable within the control limit for shift 1 and shift 2.
For all shifts statistics show that production was indeed out of control.
In concluding, there was a small change in the average of the bag weights.
The average weight of the bag fell within the average limit except for one
shift, this shows that machine is operating at a consistent level but not within
the acceptable control limits.
(2)
RECOMMENDATION
CONTROL
FOR
PROPER
QUALITY