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of Pages: 4

7619

Register Number:
Name of the Candidate:

DIPLOMA EXAMINATION - 2012

(PRODUCTION MANAGEMENT)
(PAPER III)

130. MANAGEMENT OF QUALITY AND RELIABILITY

Dec.)

(Time: 3 Hours
Maximum: 100 Marks
Answer any FIVE questions.
All questions carry equal marks.

(5 20 = 100)

1. (a) Define inspection and describe its importance.

(4)

(b) Describe the characteristics of quality control.

(6)

(c) A manufacturer purchases small bolts in cartons that usually contain several
thousands of bolts. Each shipment consists of a number of cartons. As a part of the
acceptance procedure for these bolts, 400 bolts are selected at random from each
carton and are subjected to visual inspection for certain defects. In a shipment of 10
cartons, the respective percentages of defectives found in the samples from the each
carton are 0, 0, 0.5, 0.75, 0, 2.0, 0.25, 0.25, 0, 0.25 and 1.25. Does this shipment of
bolts appear to exhibit statistical control with respect to the quality characteristics
examined in the inspection?
(10)
2. (a) Under what conditions np chart is preferred to p chart?

(4)

(b) List the steps to be followed to construct u chart?

(6)

(c) An item is made in lots of 200 each. The lots are given 100% inspection. The record
sheet for the first 25 lots inspected showed that a total of 75 items were defective.
(a) Determine the trial control limits for np chart showing numbers of defectives in
each lot.
(b) Assume that all points fall within the control limits. What is your estimate of the
process average fraction defective p?
(c) If this p remains unchanged, what is the probability that the 26th lot will contain
(i) exactly 7 defectives and (ii) 7 or more defectives?

(10)

3. (a) What are the objectives of developing control charts for variables?

(4)

(b) The following are the X and R values of 4 subgroups of readings.

(6)

2
X = 10.2, 12.1, 10.8, and 10.9

R = 1.1, 1.3, 0.9, and 0.8

The specification limits for the components are 10.7 0.2. Establish the control
limits for X and R chart. Will the product be able to meet its specification?
Take A2 (factor for X chart) = 0.58; D4(factor for R chart) = 2.11; D3 (Factor
for R Chart) = 0.00.
(c) Control charts of X and R, are to be maintained on drawings from a bowl of chips,
the distribution of which is approximately normal. The subgroup size is 5; X is 60
and standard deviation is 8. Assume that 3 control limits are to be based on X and
. Compute the values of the upper control limit, the centre line and the lower control
limit for the X , R and charts respectively.

(10)

4. (a) Write short notes on the maintenance of control charts.

(5)

(b) The results of inspection of 10 samples each containing 4 units are tabulated below
Sub groups size

Sample
Number

47

32

33

Sub groups size

Sample
Number

44

35

19

37

31

27

33

34

34

23

45

26

37

34

34

31

34

33

12

29

43

12

21

24

47

25

22

37

33

35

23

38

40

10

29

32

40

13

Construct the mid range chart for the above data.

(15)

5. (a) A fair percentage of certain product requires costly rework operation to change a
quality characteristic after the product has been rejected by the manufacturers 100%
final inspection. Rework is possible whenever the value of this quality characteristic
falls above the upper specification limit. If the value falls below the lower speciation
limit, the product must be scraped. X and R control charts have been initiated and
maintained for 50 subgroups of 5 each with samples taken from production every two
hours. The specification requirements for the measured quality are 119 10 and
standard deviation of 5. On the assumption that the quality characteristic is normally
distributed approximately, what percentage of defective product is being produced?
How much of this can be reworked?
(10)
(b) Control charts for X and R are maintained on the tensile strength in m Kg of certain
yarn. The subgroup size is 5. The values of X and R computed for the each
subgroup. After 25 subgroups, the summation of X = 5.685 and summation of R =
122. Compute the values of 3 sigma limits for X and R charts. Also determine
process capability. (For n=5, A2 = 0.58, D2 = 2326, B4 = 2.11 and D3 = 0).
(10)
6. Plot a group control chart for the following record of measurement of the diameters of a
part produced in each of the 6 spindles of an automatic screw machine. The figures given

are dimension in units of 0.01 mm in excess of 15 mm.

Diameter

Subgroup
number

Spindle
number

Part A

Diameter

Part B

Subgroup
number

Spindle
number

Part A

Part B

16

20

15

17

13

17

19

15

16

14

14

14

14

12

13

11

16

12

16

12

16

16

15

13

17

17

17

15

15

15

12

18

14

18

19

17

17

15

17

15

15

17

13

17

18

16

15

11

15

15

17

15

16

18

19

15

15

19

20

18

(20)
7. (a) In single sampling plan, a sample of size 45 is taken from a lot, which is in average
25% defective. Assuming that the system follows normal distribution, determine the
probability that a sample will contain.
(i) from 10 to 15 defectives; (ii) 13 or more defectives.

(6)

(b) A double sampling follows the procedure shown below:

Select a sample of 2 from a lot of 25. If both articles inspected are good, accept the
lot. If both are defective, reject the lot. If 1 is good and 1 defective, take a second
sample of one article.
If the article in the second sample is good, accept the lot. If it is defective reject the lot.
If a lot 20% defective is submitted, what is the probability of acceptance?

(14)

8. (a) Explain the terms producers risk, consumers risk, AQL and LTPD with reference
to the construction of operating characteristics curves.
(8)
(b) Construct the operating characteristics curve for the following attributes of single
sampling plan: n = 100, c = 4.
(12)
9. (a) Determine the values of P0.95 and P0.10 for the following two single sampling plans
Single sampling plan 1: N = 1000, n = 100, c=2.
Single sampling plan 2: N = 100, n = 100, c=4
By referring to the calculated values of P 0.95 and 0.10 in the above two single
sampling plans, discuss the impact of changing the acceptance number in single

sampling plans.

(6)

(b) Design a sequential sampling plan for the following specifications:

= 0.05, P1 = 0.10
= 0.20 P2 = 0.30
Also compute:
(a) Average outgoing quality when P! = p1
(b) Minimum number of items inspected for accepting the lot
(c) Minimum number of defectives for rejecting the lot.
(d) Average number of items inspected when the quality of t he lot is p1.

(14)

10. (a) What are the four sets of tables contained in the Dodge-Roming system.

(4)

(b) Discuss the relationship between reliability and quality control.

(6)

(c) A hydraulic subsystem consists of two sub-systems in parallel, each having the
following components and characteristics.
(10)
Component

Failure rate per hour Number of Components

Pump

22.4 10-6

Quick Disconnect

4.4 10-6

Check Valve

3.1 10-6

Shut off Valve

59 10-6

4.13 10-6

Lines and fittings

The components within each subsystem are all necessary for the sub-system
success. Two parallel sub-systems operate simultaneously and either can perform
the mission. What is the mission reliability if the mission time is 300 hours?
(Assume an exponential distribution).
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