Faculty of Engineering

Undergraduate Modular Scheme

Session 2007/2008
Semester 1

Level 6

SUBJECT: MN3153: Quality

DATE: 7 January 2008

TIME: 09.30 – 12.30

Instructions to Candidates

This paper contains SIX questions

Answer FOUR questions only
All questions carry equal marks

Provided: Statistical Tables by J. Murdoch and J.A. Barnes, 4th Edition

CANDIDATES ARE PERMITTED TO BRING ONE APPROVED

CALCULATOR INTO THIS EXAMINATION
Candidates are reminded that the major steps in all arithmetical calculations
are to be set out clearly

Number of Pages: 1 – 3
1. (a) Squark Boxes plc, a speaker manufacturer, has a process that is to be
controlled using SPC by variables. The process gave the following
sample means and sample ranges for eight samples of sample size 5
taken at intervals of 1 hour.

Sample 1 2 3 4 5 6 7 8
Mean 72.4 66.2 67.5 70.7 69.8 68.4 72.8 71.6
Range 6.3 8.1 7.6 7.5 5.2 7.9 6.8 6.6

(i) Construct mean and range charts, plot the eight samples and
comment on the state of control of the process.
(10 marks)

(ii) What is the inherent process capability?

(3 marks)

(iii) The next sample gave a mean of 67.5 and a range of 2.0. Plot
this on the charts and comment.
(2 marks)

(b) Squark Boxes plc has another process that is to be controlled using
SPC by attributes. The process gave the following numbers of
defectives over ten samples of sample size 100 taken at intervals of 8
hours.

Sample 1 2 3 4 5 6 7 8 9 10
Defectives 3 3 2 1 2 3 3 2 4 4

(i) Construct an np-chart, plot the ten samples and comment on the
state of control of the process.
(8 marks)

(ii) The next two samples contained 7 and 9 defectives respectively.

Plot these on the np-chart and comment.
(2 marks)

2. (a) Define the term ‘reliability’.

(3 marks)

(b) A large number of items are put on test until all fail. Sketch the resulting
failure rate curve (bath-tub curve). Explain the three phases of the
curve.
(6 marks)

(c) An item has a reliability of 0.97 for 100 hours of normal operation. What
is the failure rate and what is the reliability function?
(4 marks)

2
 Question 2 continued on page 2…
Continuation of Question 2:

(d) The system shown in Figure Q2 has six components A, B, C, D, E and

F with reliability values of 0.98, 0.70, 0.90, 0.70, 0.92 and 0.94
respectively:

A C E F

Figure Q2

What is the system reliability?

(4 marks)

(e) What is Reliability Engineering? Briefly describe two of the techniques

of Reliability Engineering, explaining their role in reliability
enhancement.
(8 marks)

3. Write brief notes on three of the following:

(a) The Quality Awards (Business Excellence Awards)

(a) Quality Function Deployment (QFD)
(b) The ISO9000 Series of Standards
(c) Benchmarking
(25 marks)

4. Imagine you work for a company which is involved with the design and
manufacture of kitchen appliances. The Managing Director has read of a
recent product liability case in which a competitor was found to be at fault and
was forced to pay substantial damages to a customer injured by one of its
products.

The Managing Director has asked you to prepare a report discussing product
liability, the relevant legislation and what the company can do to minimise the
danger of loosing a similar case.

Prepare such a report.

(25 marks)

3
 Continued…
5. Engineers concerned with the short life of an acid resistant lining decided to
conduct a Taguchi style designed experiment aimed at increasing the acid
resistance time. The engineers identified six control factors (A, B, C, D, E and
F) and one interaction (AxC). The L8(27) orthogonal array was selected and
the experiment conducted in accordance with the experimental layout shown
below:

Factors/Interactions Resistance
Time
Trial A B F C AxC E D (hours x103)

1 1 1 1 1 1 1 1 2.23
2 1 1 1 2 2 2 2 3.25
3 1 2 2 1 1 2 2 2.10
4 1 2 2 2 2 1 1 1.93
5 2 1 2 1 2 1 2 3.28
6 2 1 2 2 1 2 1 2.60
7 2 2 1 1 2 2 1 3.18
8 2 2 1 2 1 1 2 4.10

(a) Calculate the level averages and plot the response graphs.
(9 marks)
ii
(b) What would be the optimum combination of control factors to maximise
the resistance time and what would be the resulting resistance time?
(5 marks)

(c) Explain why it is necessary to conduct a confirmation run.

(3 marks)

(d) What are the eight steps involved in conducting a Taguchi style
designed experiment?
(8 marks)

6. (a) Briefly describe each of the four common configurations of 3-D

Coordinate Measuring Machines (CMMs).
(20 marks)

(b) When should the use of non-contact probing be considered?

(2 marks)

(c) Use a sketch to illustrate the difference between roundness and

cylindricity.
(3 marks)

END OF EXAMINATION PAPER

4
5