NOOR ASYIKIN BT.

NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS

Assignment

6.10 The thickness of a printed circuit board is an important quality parameter. Data on
board thickness (in inches) are given in Tablee 6E.5 for 25 samples of three boards
each.

a) Set up 𝑥̅ and R control charts. Is the process in statistical control?

Printed Circuit Board Thickness

Sample
x1 x2 x3 𝐱̅ R
Number
1 0.0624 0.0636 0.0645 0.063500 0.0021
2 0.0630 0.0631 0.0622 0.062767 0.0009
3 0.0628 0.0631 0.0633 0.063067 0.0005
4 0.0634 0.0630 0.0631 0.063167 0.0004
5 0.0614 0.0628 0.0635 0.062567 0.0021
6 0.0613 0.0629 0.0634 0.062533 0.0021
7 0.0630 0.0639 0.0625 0.063133 0.0014
8 0.0628 0.0627 0.0622 0.062567 0.0006
9 0.0623 0.0626 0.0633 0.062733 0.0010
10 0.0631 0.0631 0.0633 0.063167 0.0002
11 0.0630 0.0630 0.0643 0.063433 0.0013
12 0.0623 0.0630 0.0630 0.062767 0.0007
13 0.0630 0.0636 0.0630 0.063200 0.0006
14 0.0645 0.0640 0.0631 0.063867 0.0014
15 0.0614 0.0644 0.0637 0.063167 0.0030
16 0.0631 0.0627 0.0630 0.062933 0.0004
17 0.0616 0.0623 0.0631 0.062333 0.0015
18 0.0630 0.0635 0.0621 0.062867 0.0014
19 0.0631 0.0631 0.0634 0.063200 0.0003
20 0.0640 0.0635 0.0629 0.063467 0.0011
21 0.0628 0.0625 0.0616 0.062300 0.0012
22 0.0615 0.0625 0.0619 0.061967 0.0010
23 0.0630 0.0632 0.0630 0.063067 0.0002
24 0.0630 0.0629 0.0640 0.063300 0.0011
25 0.0623 0.0629 0.0630 0.062733 0.0007
1.573800 0.0272

∑25
𝑖=1 𝑅𝑖 0.0272
𝑅̅ = = = 0.001088
25 25
𝐿𝐶𝐿 = 𝑅̅ 𝐷3 = 0.001088(0) = 0
𝑈𝐶𝐿 = 𝑅̅ 𝐷4 = 0.001088(2.574) = 0.002801
 NOOR ASYIKIN BT. NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS

∑25
𝑖=1 𝑥̅ 𝑖 1.5738
𝑥̿ = = = 0.062952
25 25
𝐿𝐶𝐿 = 𝑥̿ − 𝐴2 𝑅̅ = 0.0062952 − (1.023)(0.001088) = 0.061839
𝑈𝐶𝐿 = 𝑥̿ + 𝐴2 𝑅̅ = 0.0062952 + (1.023)(0.001088) = 0.064065

0.0645

0.0640

0.0635
Sample Mean

0.0630

0.0625

0.0620

0.0615
1 3 5 7 9 11 13 15 17 19 21 23 25

Sample Mean LCL UCL CL

0.0035

0.0030

0.0025
Sample Range

0.0020

0.0015

0.0010

0.0005

0.0000
1 3 5 7 9 11 13 15 17 19 21 23 25
-0.0005

Sample Range CL LCL UCL

The process is not in statistical control; R is beyond the upper control limit for
Sample No. 15.
 NOOR ASYIKIN BT. NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS

b) Estimate the process standard deviation.

𝑅̅ 0.001088
𝜎̂ = = = 0.000643
𝑑2 1.693
c) What are the limits that you would expect to contain nearly all the process
measurements?
𝜇 ± 3𝜎 = [𝐿𝑆𝐿, 𝑈𝑆𝐿]
0.062952 ± 3(0.000643) = [0.061024,0.06488]
d) If the specifications are at 0.0630 in. ± 0.0015 in., what is the value of the PCR
Cp?
𝑈𝑆𝐿 − 𝐿𝑆𝐿
𝐶𝑝 =
6𝜎
(0.0630 + 0.0015) − (0.0630 − 0.0015)
𝐶𝑝 = = 0.77803
6(0.000643)

Cp < 1, means there are relatively few nonconforming units will be produced.

6.12 The net weight (in oz) of a fertilizer product is to be monitored by 𝑥̅ and R control
charts using a sample size n = 5. Data for 20 preliminary samples are shown in Table
6E.7.

a) Set up 𝑥̅ and R control charts using these data. Does the process exhibit
statistical control?

Sample x1 x2 x3 x4 x5 𝐱̅ R
Number
1 15.8 16.3 16.2 16.1 16.6 16.2 0.8
2 16.3 15.9 15.9 16.2 16.4 16.14 0.5
3 16.1 16.2 16.5 16.4 16.3 16.3 0.4
4 16.3 16.2 15.9 16.4 16.2 16.2 0.5
5 16.1 16.3 16.4 16.3 16.0 16.22 0.4
6 16.1 15.8 16.7 16.6 16.4 16.32 0.9
7 16.1 16.3 16.5 16.1 16.5 16.3 0.4
8 16.2 16.1 16.2 16.1 16.3 16.18 0.2
9 16.3 16.4 16.4 16.1 16.5 16.34 0.4
10 16.6 16.3 16.4 16.1 16.5 16.38 0.5
11 16.2 16.6 15.9 16.1 16.4 16.24 0.7
 NOOR ASYIKIN BT. NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS
12 15.9 16.8 16.7 16.0 16.5 16.38 0.9
13 16.4 16.3 16.6 16.2 16.1 16.32 0.5
14 16.5 16.5 16.2 16.1 16.4 16.34 0.4
15 16.4 16.3 16.3 16.0 16.2 16.24 0.4
16 16.0 16.4 16.3 16.1 16.2 16.2 0.4
17 16.4 16.0 16.4 16.1 16.2 16.22 0.4
18 16.0 16.2 16.4 16.5 16.1 16.24 0.5
19 16.4 16.2 16.3 16.2 16.4 16.3 0.2
20 16.4 16.4 16.5 16.0 15.8 16.22 0.7
325.28 10.1

∑20
𝑖=1 𝑅𝑖 10.1
𝑅̅ = = = 0.505
20 20
𝐿𝐶𝐿 = 𝑅̅ 𝐷3 = 0.505(0) = 0
𝑈𝐶𝐿 = 𝑅̅ 𝐷4 = 0.505(2.114) = 1.06757

∑20
𝑖=1 𝑥̅ 𝑖 325.28
𝑥̿ = = = 16.264
20 20
𝐿𝐶𝐿 = 𝑥̿ − 𝐴2 𝑅̅ = 16.264 − (0.577)(0.505) = 15.97262
𝑈𝐶𝐿 = 𝑥̿ + 𝐴2 𝑅̅ = 16.264 + (0.577)(0.505) = 16.55539

Xbar-R Chart of x1 , ..., x5

1 6.6
UCL=16.5553

1 6.4
Sample Mean

__
X=16.264
1 6.2

1 6.0
LCL=15.9727
1 3 5 7 9 11 13 15 17 19
Sample

UCL=1.068
1 .00
Sample Range

0.75
_
0.50 R=0.505

0.25

0.00 LCL=0
1 3 5 7 9 11 13 15 17 19
Sample
 NOOR ASYIKIN BT. NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS
The process is in statistical control, with no out-of-control signals, runs, trends, or
cycles.

b) Estimate the process mean and standard deviation.

𝜇 = 𝑥̿ = 16.264
̅
𝑅 0.505
𝜎̂ = = = 0.217111
𝑑2 2.326
c) Does fill weight seem to follow a normal distribution.

A normal probability plot of the fill weight shows the distribution is close to normal.

d) If the specifications are at 16.2 ± 0.5, what conclusions would you draw about
process capability?
𝑈𝑆𝐿 − 𝐿𝑆𝐿
𝐶𝑝 =
6𝜎
(16.2 + 0.5) − (16.2 − 0.5)
𝐶𝑝 = = 0.767657
6(0.217111)
Cp < 1, which can be conclude that there are relatively few nonconforming units
will be produced by this process.

e) What fraction of containers produced by the process is likely to be below the

lower specification limit of 15.7 oz?
 NOOR ASYIKIN BT. NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS
15.7 − 16.264
𝑝 = 𝑃{𝑥 < 15.7} = 𝜙 ( )
0.217111
𝑝 = 𝜙(−2.60) = 1 − 0.99534 = 0.00466
Based on the computed value, the fraction is 0.466% [4660 parts per million].

6.18 Samples of n = 4 items each are taken from a process at regular intervals. A quality
characteristic is measured, and 𝑥̅ and R values are calculated for each sample. After
50 samples, we have
50 50

∑ 𝑥̅𝑖 = 2100 𝑎𝑛𝑑 ∑ 𝑅𝑖 = 175

𝑖=1 𝑖=1
Assume that quality characteristic is normally distributed.

a) Compute control limits for the 𝑥̅ and R control charts.

∑50
𝑖=1 𝑅𝑖 175
𝑅̅ = = = 3.5
50 50
𝐿𝐶𝐿 = 𝑅̅ 𝐷3 = 3.5(0) = 0
𝑈𝐶𝐿 = 𝑅̅ 𝐷4 = 3.5(2.282) = 7.987

∑50
𝑖=1 𝑥̅ 𝑖 2100
𝑥̿ = = = 42
50 50
𝐿𝐶𝐿 = 𝑥̿ − 𝐴2 𝑅̅ = 42 − (0.729)(3.5) = 39.4485
𝑈𝐶𝐿 = 𝑥̿ + 𝐴2 𝑅̅ = 42 + (0.729)(3.5) = 44.5515

b) All points on both control charts fall between the control limits computed in part
(a). What are the natural tolerance limits of the process?
𝜇 = 𝑥̿ = 42
3.5 ̅
𝑅
𝜎̂ = =
= 1.6999
𝑑2 2.059
𝐿𝑁𝑇𝐿 = 𝜇 − 3𝜎 = 42 − 3(1.6999) = 36.9003
𝑈𝑁𝑇𝐿 = 𝜇 + 3𝜎 = 42 + 3(1.6999) = 47.0997
Natural process tolerance limits: [36.9, 47.1]

c) If the specification limits are 41 ± 4.5, what are your conclusions regarding the
ability of the process to produce items within these specifications?
𝑈𝑆𝐿 − 𝐿𝑆𝐿
𝐶𝑝 =
6𝜎
 NOOR ASYIKIN BT. NOOR HAZAM
2014252126
QMT752 QUALITY MANAGEMENT AND ANALYSIS
(41 + 4.5) − (41 − 4.5)
𝐶𝑝 = = 0.8824
6(1.6999)
Cp < 1, which can be conclude that there are relatively few nonconforming units
will be produced by this process.

d) Assuming that if an item exceeds the upper specification limit it can be reworked,
and if it is below the lower specification limit it must be scrapped, what
percentage scrap and rework is the process producing?
𝑝̂𝑟𝑒𝑤𝑜𝑟𝑘 = Pr{𝑥 > 𝑈𝑆𝐿} = 1 − Pr{𝑥 < 𝑈𝑆𝐿}
46.5−42
𝑝̂𝑟𝑒𝑤𝑜𝑟𝑘 = 1 − 𝜙 ( ) = 1 − 𝜙(2.65) = 0.00402, or
1.6999
0.402%

𝑝̂𝑠𝑐𝑟𝑎𝑝 = Pr{𝑥 < 𝐿𝑆𝐿} = Pr{𝑥 < 36.5}

36.5−42
𝑝̂𝑠𝑐𝑟𝑎𝑝 = 𝜙 ( ) = 𝜙(−3.24) = 0.0006, or 0.06%
1.6999

e) Make suggestions as to how the process performance could be improved.

First, center the process at 43, not 42, to reduce scrap and rework costs.
Second, reduce variability such that the natural process tolerance limits are
closer to.