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OPIM Quality & Statistical Process Control

This document discusses statistical process control and quality management concepts including: 1) Using control charts like p-charts, x-charts, and R-charts to monitor processes and identify if a process is in or out of control. 2) Calculating process capability indices to determine if a process meets design specifications. 3) Solving various statistical process control problems involving control limits, process capabilities, sampling distributions, and determining if a process is in or out of control based on sample data.

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Humphrey Osaigbe
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381 views

OPIM Quality & Statistical Process Control

This document discusses statistical process control and quality management concepts including: 1) Using control charts like p-charts, x-charts, and R-charts to monitor processes and identify if a process is in or out of control. 2) Calculating process capability indices to determine if a process meets design specifications. 3) Solving various statistical process control problems involving control limits, process capabilities, sampling distributions, and determining if a process is in or out of control based on sample data.

Uploaded by

Humphrey Osaigbe
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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PART 6: MANAGING QUALITY & STATISTICAL PROCESS CONTROL

Question 45
The Minnow County Highway Safety Department monitors accidents at the intersection of
Routes 123 and 14. Accidents at the intersection have averaged three per month.
a. Which type of control chart should be used? Construct a control chart with three-sigma
control limits.
b. Last month, seven accidents occurred at the intersection. Is this sufficient evidence to
justify a claim that something has changed at the intersection?

Question 46
Pioneer Chicken advertises “lite” chicken with 30 percent fewer calories. (The pieces are 33
percent smaller.) The process average distribution for “lite” chicken breasts is 420 calories,
with a standard deviation of the population of 25 calories. Pioneer randomly takes samples of
six chicken breasts to measure calorie content.
c. Design an x-chart using the process standard deviation. Use three-sigma limits.
d. The product design calls for the average chicken breast to contain 400 ± 100 calories.
Calculate the process capability index (target = 1.33) and the process capability ratio.
Interpret the results.

Question 47
The Watson Electric Company produces incandescent lightbulbs. The following data on the
number of lumens for 40-watt lightbulbs were collected when the process was in control.
OBSERVATION
Sample 1 2 3 4
1 604 612 588 600
2 597 601 607 603
3 581 570 585 592
4 620 605 595 588
5 590 614 608 604

a. Calculate control limits for an R-chart and an x-chart.


b. Since these data were collected, some new employees were hired. A new sample obtained the
following readings: 570, 603, 623, and 583. Is the process still in control?

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Question 48
What are the control limits of p-chart for the following data of 20 samples of 100 pairs of jeans?

Sample Number of defectives Proportion Defectives

1 6 0.06

2 4 0.04

3 1 0.02

. . .

. . .

20 12 0.17

Total 180

Question 49
A hospital manager receives a certain number of complaints each day about the hospitals
service. Complaints for 15 days are given in the table shown. What are the control limits when
one will construct a control chart using three sigma limits?

Days Number of D3ays Number of


complaints complaints
1 4 9 5
2 6 10 3
3 4 11 5
4 5 12 4
5 4 13 4
6 8 14 6
7 6 15 4
8 7 Total 75

Question 50
The following data is a common data given for x-bar and range chart calculations in
Question’s (a) and (b).

Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

17.5 16.3 13.8 16.7 14.1


15.3 18.4 17.2 11.3 12.5
12.7 14.9 15.6 14.4 18.8
x-bar 15.16 16.53 15.53 14.13 15.13
R 4.8 3.5 3.4 5.4 6.3

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Sample A A d D D B B
Size = m 2 3 2 3 4 3 4
2 1.880 2.659 1.128 0 3.267 0 3.267
3 1.023 1.954 1.693 0 2.574 0 2.568
4 0.729 1.625 2.059 0 2.282 0 2.266
5 0.577 1.427 2.326 0 2.114 0 2.089
6 0.483 1.287 2.534 0 2.004 0.030 1.970

e. What is the value of central line and UCL for Range chart?
f. What will be the lower control limit for x-bar chart for the previous problem?

Question 51

For a process the upper specification limit is 18.5 and the lower specification limit is 12.5 with
a standard deviation of 0.85. What will be the process capability ratio of the process for six
sigma process?

Question 52

We are studying two processes for machining a part. Process A produces parts which have a
mean length of 150 and a standard deviation of 3. Process B produces parts which have a mean
length of 155 and standard deviation of 1. The design specifications for the part are 150±10.
Data given is for Z = -3.333 area under the standard normal curve to the left of Z will be
0.00043. What will be the value of process capability ratio for process B and 𝐶𝑝𝑘 for process
A?

Question 53

Twenty samples of size 4 are taken from a stable process. The average means of the sample
means is 42.5, and the average range of the samples is 1.5. What is the UCL for the R-chart?

Question 54

Control charts for X and R are kept on the manufacture of a drive shaft. After 30 subgroups
have been drawn and inspected, and the diameters recorded, ∑𝑋̅ = 624.30 mm and ∑𝑅 =
12.3mm. The subgroup size is 4. Assume that the diameters of the shafts are normally
distributed.

g. Assuming the process is in a state of control, compute the 𝑋̅ and R chart central line and
control limits for the next production period. (4 P)

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h. What is the probability that an item chosen at random will have a diameter smaller than
20.4 mm? (4 P)
i. Estimate the standard deviation 𝜎𝑋− of the sample mean. (2 P)

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