Term Project

IE 6113
Quality Control and Improvements

Spring 2015

I.
In producing an alloy, the USL for the proportion of catalyst content is 2.2% and standard deviation is
0.5%. Any lot that contains 2% of its items below USL is considered acceptable with probability 0.95.
Any lot that has 10% or more of its items below USL is considered unacceptable with probability 0.90.
Requirements:

a.

Derive a mathematical variables sampling plan for this process

b.

Assuming unknown and using a batch size of 40, AQL of 1.4% and general inspection level of
III,
1. Find an appropriate set of sampling plans using ANSI/ASQC Z1.9, using Form 1 and Form
2 for Normal, Tightened and Reduced Inspection.
2. Compare the sample sizes and the protection that both the producer and consumer obtain
from this plan with the plan derived in (a.)
3. If a random sample of 10 items yields the following catalyst content (in %): 1.2, 1.6, 0.8,
1.9, 1.8, 1.4, 0.6, 0.9, 1.5 and 0.7. What is your decision using Form1 and Form2?

c.

1.
2.
3.
4.
5.
6.

Derive an attributes sampling plan that has the same OC curve as the one derived in (a.).
Compare the sample sizes required for the equivalent protection. Under what
circumstances would variables sampling be more economically efficient?
Construct the OC curve and ASN curve for the Sampling plan.
Consider chain sampling plans with same n, c=0, and i=3, 5, 7, construct the OC curves
for these chain sampling plans.
Derive an item-by-item Sequential Sampling plan. Construct the OC curve and ASN
curve for this plan.
Compare between (1), (4), and (5) from above.

d.

Using AQL of 1.4%, find an appropriate set of an attribute sampling plans using MIL STD
105E, for Normal, Tightened and Reduced Inspection. Compare the sample sizes and the
protection obtained from this plan with the plans derived in parts (a.), (b.1.) and (c.1.).

e.

A LSL of 1% with an AQL of 6.5% is imposed in addition to the given USL and AQL, what is
your decision?

[Note: The tables from ANSI/ASQC Z1.9 required to complete this part of the exercise are
available on the Montgomery SQC website: www.wiley.com/college/montgomery]

Term Project

IE 6113
Quality Control and Improvements

Spring 2015

II.
1. A life testing sampling plan of 6 items is to be terminated after the third failure. The lot is
accepted with a mean life of 600hr. with a probability of 0.99. The failures are observed at the
following times: 120, 140 and 160 hr. Using Handbook H-108, construct the OC curve for the
plan and write you recommendation on the decision about the lot in the following cases:
a. Failed items are not replaced
b. Failed items are immediately replaced during the test.
2. A life testing plan should accept the lot with a mean life of 1500 hr with a probability 0.95 and
reject lots with unacceptable mean life of 300 hr. with a probability of 0.90.
i. If the sample size is to be 5 times the rejection number, determine a time-terminated
life testing plan using (H-108) and construct the OC curve for the plan in the following
cases:
a. Failed items are not replaced
b. Failed items are immediately replaced during the test.
ii. Derive a Sequential replacement procedure, when testing
a. With replacement
b. Without replacement

Term Project

IE 6113
Quality Control and Improvements

Spring 2015

III.
A screening experiment was conducted to identify critical process drivers and analyze the various
factors, which might affect the intended design to meet customer requirements. The factors in this
experiment were identified after a series of brainstorming session and involved prior experience in
manufacturing other grades of this filters, it was concluded there are five major factors that have an
obvious effects and were considered in this experiment. The experiment was conducted in a controlled
manufacturing environment to minimize the effects of uncontrollable or unknown factors and was
similar to routine manufacturing environment.
Each of the five (5) factors has two levels. The experiment was run as full factorial of the 2 5
design and four (4) replications. Output data was collected for four response variables these are;
Membrane retention properties, Membrane Solute passage, Membrane permeability, Membrane
Integrity Test.
Analyze the giving data and draw a conclusion for all the 4 responses. Include everything
you learn in DOE lecture, (e.g., main effects, interaction effects, regression module)
The potential design factors are summarized in Table 1 below; each of the mentioned factors has two
levels as follows (use coded design), table 2 lists the responses that were measured in this experiment,
and table 3 presents the design and the resulting responses.
Table 1

FACTORS

LOW LEVEL

HIGH LEVEL

Factor 1 (A)

Low

High

Factor 2 (B)

Low

High

Factor 3 (C)

Low

High

Factor 4 (D)

Low

High

Factor 5 (E)

Low

High

IE 6113
Quality Control and Improvements

Term Project

Spring 2015

THE RESPONSES VARIABLES

Table 2
Response 1
Response 2
Response 3
Response 4

Response
Retention Property
Passage Test
Permeability Property
Integrity Test

Measurement/ Unit
Kilo Delton
Percent (%)
ml/min/cm2 @ 20C
sccm2/ft2 @ 60psi

Table 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

A
-1
1
-1
1
-1
1
-1
1
1
-1
-1
1
-1
-1
-1
-1
-1
-1

B
1
1
-1
1
1
1
1
-1
-1
1
-1
-1
-1
-1
1
1
-1
-1
1

C
-1
-1
1
1
-1
1
-1
1
-1
-1
1
1
-1
1
1
1
-1
-1
-1

D
1
-1
1
-1
1
-1
1
1
1
-1
-1
-1
1
-1
-1
-1
1
1
-1

E
1
1
1
-1
-1
1
-1
-1
-1
-1
-1
-1
-1
-1
1
1
-1
1
-1

R1
45
44
27
51
33
50
22
29
30
30
38
40
35
36
50
47
39
35
48

R2
1
1
3.1
1.4
1
1.3
0.9
2.2
1
0.9
1.6
0.8
0.9
0.6
1.4
1.7
0.8
0.6
1

R3
0.694
0.73
0.497
0.665
0.449
0.656
0.298
0.68
0.681
0.456
1.013
0.917
0.799
0.986
0.673
0.61
1.039
0.884
0.808

R4
14.3
15.5
5.9
13.2
6.6
13.2
5.9
13.2
8.3
15.5
19.3
19.3
11.1
19.3
11.1
8.3
16.7
15.5
15.5

IE 6113
Quality Control and Improvements

Term Project
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

-1
1
-1
1
-1
-1
-1
1
-1
-1
1
-1
-1
-1
-1
-1
-1
1
-1
1
1
1
-1
1
1
-1
1
-1
1
-1
-1
-1
-1
-1
-1
-1
-1
1
1

1
-1
1
1
1
-1
-1
-1
-1
-1
1
-1
1
-1
-1
1
1
-1
1
1
-1
1
1
-1
-1
-1
-1
-1
-1
1
-1
1
-1
1
1
-1
-1
1
1

-1
-1
1
-1
-1
1
1
-1
-1
-1
-1
-1
-1
1
1
-1
-1
-1
-1
-1
-1
1
-1
-1
1
-1
1
-1
1
-1
-1
1
-1
1
1
-1
-1
1
1

-1
-1
1
-1
-1
1
1
1
1
-1
1
1
1
1
1
1
-1
-1
1
-1
-1
-1
-1
-1
-1
-1
1
1
-1
1
1
-1
-1
-1
1
-1
-1
-1
1

1
-1
-1
-1
1
-1
-1
1
-1
1
1
-1
-1
1
-1
1
-1
-1
-1
1
1
1
-1
1
1
-1
-1
1
1
1
1
-1
-1
-1
1
1
-1
-1
-1

53
39
28
39
45
31
27
30
39
46
36
40
46
26
29
45
40
30
44
39
39
40
46
36
38
42
22
37
44
48
38
54
40
49
36
40
37
29
29

Spring 2015
1.2
1.5
3.6
1.4
1
2
1.8
1
1.1
0.6
1.4
0.8
0.6
1.8
2.2
1
0.8
1.1
0.8
1.2
0.8
1.5
0.7
1.1
1.4
0.9
2.5
1
1.4
1.2
1.2
1.2
1.2
1.2
2.6
0.9
0.8
2.6
2.6

0.791
0.89
0.342
0.508
0.723
0.711
0.617
0.763
1.039
0.997
0.425
0.995
0.707
0.576
0.66
0.656
0.666
0.715
0.758
0.502
0.891
0.439
0.789
0.878
0.653
0.986
0.417
0.902
0.723
0.661
1.006
0.6
0.978
0.613
0.428
0.902
0.899
0.339
0.339

20.7
15.5
8.3
14.3
19.3
12.1
12.1
5.9
19.3
20.7
4.5
16.7
14.3
14.3
13.2
14.3
13.2
19.3
16.7
11.1
11.1
10.1
23.5
22.1
11.1
15.5
22.1
18
14.3
12.1
20.7
10.1
20.7
13.2
8.3
15.5
14.3
14.3
14.3

IE 6113
Quality Control and Improvements

Term Project
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97

1
-1
1
1
-1
1
-1
1
-1
1
-1
1
-1
1
1
1
1
1
-1
-1
-1
-1
-1
1
1
1
-1
1
1
-1
-1
-1
1
1
1
1
1
-1
-1

-1
-1
1
-1
-1
1
-1
1
-1
1
-1
-1
1
-1
1
1
-1
1
-1
1
1
-1
-1
-1
1
-1
1
-1
1
-1
1
1
-1
-1
1
-1
1
-1
1

1
1
1
1
1
1
-1
1
1
-1
-1
-1
-1
1
1
1
-1
-1
1
1
-1
-1
1
-1
-1
-1
-1
1
-1
1
-1
1
1
-1
1
1
1
-1
-1

1
-1
-1
-1
-1
1
-1
1
1
-1
1
1
1
1
-1
-1
-1
-1
-1
1
-1
-1
-1
1
1
1
1
1
1
1
1
1
-1
1
1
-1
-1
-1
-1

-1
1
1
1
1
1
1
1
1
1
-1
1
-1
1
-1
-1
-1
1
1
1
-1
-1
-1
-1
-1
-1
1
-1
1
1
-1
-1
-1
1
1
-1
-1
1
1

23
43
37
37
40
19
41
25
29
42
39
32
35
24
33
40
35
40
44
33
37
40
36
33
35
38
40
18
38
27
36
33
33
31
25
40
40
43
50

Spring 2015
3
3.5
2
1.8
1.5
4.2
1.3
3.9
1.9
1.8
1
0.9
0.6
1.8
2.6
2
1.1
1.5
2.1
4.9
0.7
1.4
1
1
1.2
0.7
0.9
2.2
1.3
2.5
0.6
3.4
1.6
0.9
4.7
1
2.4
0.9
1.2

0.459
0.91
0.422
0.651
0.843
0.248
0.902
0.3
0.595
0.504
1.013
0.781
0.573
0.426
0.37
0.434
0.807
0.51
0.808
0.423
0.709
0.969
0.873
0.709
0.446
0.782
0.62
0.387
0.414
0.531
0.56
0.429
0.628
0.795
0.285
0.75
0.438
0.988
0.743

8.3
22.1
11.1
12.1
14.3
2.9
18
3.4
9.2
15.5
19.3
10.1
15.5
5.9
8.3
13.2
16.7
15.5
14.3
10.1
18
23.5
19.3
11.1
6.6
9.2
13.2
11.1
3.4
12.1
12.1
9.2
15.5
8.3
2.9
16.7
14.3
25
16.7

IE 6113
Quality Control and Improvements

Term Project
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128

-1
1
1
1
1
1
-1
-1
1
-1
-1
1
1
1
1
1
-1
1
-1
-1
1
1
1
1
1
1
1
1
1
-1
1

-1
1
-1
-1
-1
-1
1
1
1
1
1
-1
1
1
-1
1
1
1
1
-1
1
1
1
-1
1
-1
1
-1
-1
-1
1

-1
1
1
1
1
-1
1
1
-1
1
1
1
1
1
-1
1
1
-1
1
1
-1
-1
-1
-1
-1
1
1
1
-1
1
1

1
1
-1
1
1
-1
1
1
1
1
1
1
-1
1
1
1
-1
-1
-1
1
1
-1
-1
-1
1
-1
-1
-1
-1
-1
1

1
-1
-1
1
-1
1
1
1
-1
-1
-1
1
1
-1
1
-1
1
-1
-1
1
1
-1
1
1
1
1
1
-1
-1
1
1

38
15
42
25
23
36
37
33
29
29
38
29
40
21
29
15
53
33
51
27
33
36
40
37
32
45
38
40
40
49
21

Spring 2015
0.2
3.9
1
2
3.2
1.1
1.9
3.6
1
3.8
3.8
3
1.8
5.4
0.8
4.3
1.5
1.3
1.3
2.8
1.3
1
1.5
0.6
1.2
1.4
2.7
1
0.6
1.6
4.3

0.919
0.16
0.717
0.501
0.449
0.858
0.45
0.411
0.371
0.383
0.423
0.512
0.418
0.036
0.748
0.187
0.622
0.467
0.665
0.555
0.437
0.518
0.508
0.854
0.407
0.764
0.385
0.704
0.906
0.833
0.269

20.7
4.5
15.5
5.9
10.1
12.1
10.1
6.6
6.6
8.3
10.1
6.6
12.1
4.5
12.1
5.2
11.1
11.1
15.5
8.3
3.4
13.2
11.1
14.3
3.4
16.7
11.1
16.7
16.7
14.3
3.4