MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY JAIPUR DEPARTMENT OF MECHANICAL ENGINEERING B.Tech.

(Open Elective) Open book END-TERM EXAMINATION, DECEMBER 2013 Six Sigma (ME340) Part B Max. Marks 30 TIME: 90 Minutes Date: 25/11/13
Read carefully all the questions and be as concise as possible.

Q1. A Six sigma team member, after measuring process capability of a fiber producing machine realizes that even though Cp is 1.78, the process is still producing defective strands of fiber. Give any four reasons that possibly might be causing this problem. [4M] Q2. The following data were obtained over a 10 days period to initiate and R control chart for a quality characteristic of a certain manufactured product that had required a substantial amount of rework. All the figures apply to a product made on a single machine by single operator. The size of each sample is 5. Two samples are taken each day. (Take A2 = 0.58; D4=2.11; D3=0; d2=2.326) [8 M] Sample no. 1 2 3 4 5 6 7 8 9 10 177.6 176.6 178.4 176.6 177 179.4 178.6 179.6 178.8 178.2 R Sample no. 23 11 8 12 22 13 12 14 7 15 8 16 15 17 6 18 7 19 12 20 R 179.8 9 176.4 8 178.4 7 178.2 4 180.6 6 179.6 6 177.8 10 178.4 9 181.6 7 177.6 10

(a) Determine trial control limits for the and R control charts. (b) What preliminary conclusions can you draw about the statistical control from your observations and analysis of the data and of the control charts? (c) The specified requirements for the quality characteristic are given as 17111. If a product falls below lower specification limit of 160, it must be scrapped, whereas if it falls above the upper specification limit of 182, it may be reworked. Because scrapping an article is much more costly than rework, it is desired to hold scrap to low figure without causing excessive rework. The process averages can be shifted by a relatively simple machine adjustment. What would you suggest as the aimed at value for process centering in the immediate future? Why? (d) The and R control charts are to be continued. What would you recommend as the new limits on these charts?

Q3. A certain product has been statistically controlled at a process average of 36 and a standard deviation of 1. The product is presently being sold to two consumers who have different specification requirements. Consumer A has established a specification of 384 for the product, and consumer B has specification of 364. [7 M] (a) Based on the present process set up, what percentage of the product produced will not meet specifications set up by consumer A? (b) What percent of the product will not meet the specifications of consumer B? (c) Assuming that the two consumers needs are equal, a suggestion is made to shift the process target value to 37. At this suggested value, what percentage of the product will not meet the specifications of user A? (d) At the suggested process target, what percentage of the product will not meet the specification of consumer B? (e) Do you think that this shift to a process target of 37 would be desirable? Explain your answer. Q4. Nonconformities in automobiles fall into three categories-serious, major, and minor. Five samples of 5 automobiles are chosen, and the total number of non-conformities in each category is reported. The table shows the results. Assuming a weighing system of 50, 10 and 1 for serious, major, and minor nonconformities, respectively, construct a demerits per unit control chart. Also make a number of non conformities chart treating each non-conformity equally. Can it be concluded that if demerit per unit control chart shows out of control process then same observation will be exhibited by c-chart as well? [6M] Sample no. Serious defects Major defects Minor defects 1 0 5 8 2 0 3 2 3 1 0 6 4 1 2 1 5 0 6 8 Q5.A Six Sigma team member has performed tasks of process given as follows. He has committed several mistakes. Find out the mistakes (point wise) giving suitable justification for the same. He takes samples over a period of 30 days from the process. These samples are taken daily in morning at 8 AM and size of each sample is five units. From the samples collected he first performs process capability analysis of the quality parameter. He finds that process is capable and well centered on the basis of Cp. In order to investigate the causes leading to poor sigma level, he performs C&E analysis. After finding a major cause, he makes FMEA to increase RPN of the cause. But in this process, he could only get reduced RPN. Eventually, the project is left incomplete to conclude that the sigma level cannot be improved. [5M]