IE2130

Quality Engineering I
(Semester 2, AY2015-16)

Tutorial Problems
__________________________________________________________________________________________

Guidelines and Recommendations

1.

Solve the problems yourself and try to understand the underlying concepts.

2.

Use Microsoft Excel or any other software if needed.

3.

There is no need to submit the solutions for grading except for Question 4 of Topic 3.

4.

Assignment 1 deals with Question 4 of Topic 3 (in red font). You may include comments on
the contribution of each group member if you so wish. Otherwise all team members will receive
the same marks.

5.

The problems will be discussed in tutorial classes. Standard hard or soft copy solutions
will not be provided. For similar problems with solutions, refer to the relevant examples
in the textbook. Study these examples will help you to better understand the topic
covered.

Topic 2

Product/process characterization

(Comments: Read Chapter 3 of the textbook, especially some of the examples. You should
have no problem with these questions. The main issue here is how they are linked to quality
control.)

1.

Yield strengths of a component are measured. The first yields (in kN) are as follows:
108, 96, 102, 104, 156, 126, 128 and 150.
Find the median and the range. Calculate the sample average, sample variance and
sample standard deviation by hand. Then use Microsoft Excel (or any other software) to
generate these "summary statistics". Which of these five sample statistics does not have
the same unit of measurement as all the other?
What can you infer from the results obtained?
Answers: 117, 60, 121.25, 511.93, 22.63.

2.

The output voltage of a power supply is normally distributed with mean 5 V and
standard deviation 0.02 V. If the lower and upper specifications for voltage are 4.95 V
and 5.05 V respectively, what is the probability that a power supply selected at random
will conform to the specifications on voltage?
Answer: 98.8%.

3.

The life of a car battery is normally distributed with mean 900 days and standard
deviation 35 days. What fraction of the batteries would be expected to survive beyond
1000 days?
Answer: 0.21%.

4.

A light bulb has a normally distributed light output with mean 5000 end foot-candles and
standard deviation of 50 end foot-candles. Find a lower specification limit such that only
0.5% of the bulbs will not exceed this limit.
Answer: 4871.

5.

Problem 2 to 4 illustrate how the normal distribution can be used to model the quality
characteristic of a process and to determine key quality parameters based on sample
information. What if the distributions of the quality characteristics are not normal?

6.

Give below are the data in Slide 14 of Topic 2:

Mon
Tue
Wed
Thu
Fri
Sat
Sun

226.8
362.8
155.4
258.0
276.5
406.3
327.8

382.7
243.2
177.7
392.9
501.2
341.3
333.7

347.1
332.2
224.6
144.8
395.2
308.6
161.7

271.1
329.5
423.6
257.6
316.8
405.0
509.5

417.6
304.2
352.1
508.2
250.1
236.1
307.8

(a) Use Microsoft Excel (or any other software) to generate the summary statistics in
Slide 19, plot the histogram and NPP as shown in Slide 44, and obtain the results for
the three exercises in Slide 48.
(b) How do you see the process? Is it good enough? What are the possible actions to
improve it if this is needed?
(c) Refer to Slide 53 and try to appreciate the steps in A Systematic Problem-Solving
Process.

Topic 3

Control charts for variables

(Comments: Some of the questions are taken from Chapter 6 of the textbook. Question 4 is
based on the data given in the lecture notes - see slide 28 of Topic 4.)
1.

The data as shown are X and R values for 24 samples of size n = 5 taken from a process
producing a certain component. The measurements are made on the inside diameter of
the component, with only the last three decimals recorded, i.e. 34.5 should be 0.50345.
Sample no.
1
2
3
4
5
6
7
8
9
10
11
12

R
3
4
4
4
5
6
4
3
7
8
3
9

34.5
34.2
31.6
31.5
35.0
34.1
32.6
33.8
34.8
33.6
31.9
38.6

Sample no.
13
14
15
16
17
18
19
20
21
22
23
24

35.4
34.0
37.1
34.9
33.5
31.7
34.0
35.1
33.7
32.8
33.5
34.2

R
8
6
5
7
4
3
8
4
2
1
3
2

(a) Set up X and R charts on this process. Is the process in statistical control? If
necessary, revise the trial control limits.
(b) If specifications on this diameter are 0.5030 0.0010, find the percentage of
nonconforming components produced by the process. Assume that diameter is
normally distributed.
Answers: (a) Not in control, exclude sample no. 12 and 15. Replot and final control
charts - 36.25, 33.65, 31.06; 9.52, 4.5, 0. (b) 0.05%.
2.

Samples of size n = 6 items each are taken from a process at regular intervals. A quality
characteristic is measured, and X and R values are calculated for each sample. After 50
samples, we have
50

50

i 1

i 1

X i 2000 and Ri 200

Assume the quality characteristic is normally distributed and the process is in control.
(a) Compute control limits for the X and R control charts.
(b) The specification limits are 41 5. Assume 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 percent scrap and rework is the process producing?

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

Answers: (a) 41.932 and 38.068, 8.016 and 0; (b) 0.57% and 72 ppm.
3.

An X chart is used to control the mean of a normally distributed quality characteristic. It

is known that = 6.0 and n = 4. The centre line = 200, UCL = 209, and LCL = 191. If
the process mean shifts to 188, find the probability that this shift is detected on the first
subsequent sample.
Answer: 84.1%.

4.

The data set refers to the ball shear strengths (X) of a product at a bonding temperature of
240C:
Mon S1
S1
S2
S2
Tue S1
S1
S2
S2
Wed S1
S1
S2
S2
Thu S1
S1
S2
S2
Fri S1
S1
S2
S2
Sat S1
S1
S2
S2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

87.5
80.1
77.6
75.8
88.7
74.8
83.7
79.8
88.8
76.9
82.6
85.7
66.9
83.4
76.9
64.1
80.1
73.3
75.3
82.1
73.7
73.5
73.5
87.0

86.5
68.0
84.0
75.7
56.4
62.9
71.9
66.2
63.1
73.7
60.8
51.6
69.9
52.6
74.5
63.4
68.5
67.0
77.5
71.8
74.2
67.1
71.5
63.1

66.3
67.5
68.1
69.2
62.7
61.1
58.9
56.3
58.3
65.5
65.5
71.4
54.1
69.4
63.8
66.5
67.1
84.2
66.4
69.2
76.4
64.0
74.6
69.2

73.1
84.2
60.0
67.8
67.6
70.1
77.6
54.5
74.6
59.4
78.4
57.3
71.4
74.9
70.6
59.0
65.3
62.5
79.0
75.6
63.6
54.0
78.1
57.3

69.4
87.5
68.1
65.4
63.8
58.4
70.1
52.0
75.6
70.1
67.6
60.0
64.0
55.1
74.8
60.7
65.5
62.8
61.8
69.5
70.0
59.2
69.3
80.6

(a) Taking all the 120 observations together, find Xmin, Xmax, R, and the mean and standard
deviation.
Answers: 51.6, 88.8, 37.2, 69.72, 8.90.
(b) Plot the histogram for X. How does a change in the number of intervals affect the plot?
Plot the normal probability plot (NPP).
(c) Given that LSL = 40, compute the expected FNC.
5

Answer: 419 ppm.

(d) Plot the X and R charts. Apply the synthesizing rules. Is the process in control?
Answers: 81.42, 69.72, 58.02; 42.91, 20.29, 0.
(e) Based on the 24 X 's in (d), plot the histogram and the NPP. Compare the distributions
of X and X. Find the mean and standard deviation of X .
Answer: Central Limit Theorem applies; 69.72, 4.13.
(f) From the data/results in (a), (d) and (e), show empirically whether the following
relationships hold:
x x / n

x R / d2

What is the practical significance of the relationships in SPC?

(g) Assume that the process mean shifts to 78. For the X chart in (d), what is the probability
of not detecting the shift in the first sample plotted after the shift? What is the ARL in
this case? Use only sensitizing rule 1.
Answers: To be provided after submission of Assignment 1.
(h) For the same set of data, construct the X and S charts. Compare the plotted charts with
the X and R charts obtained in (d). Is there any difference in the conclusion reached for
the process?
Answers: 81.54, 69.72, 57.91; 17.30, 8.28, 0.
(i) With n = 1 and 24 samples, construct the X and MR charts. Use the larst column of the
data set (leave out the first four columns). In general, what are the differences between
these charts and those in (d)?
Answers: 91.21, 66.72, 42.23, 30.09, 9.21, 0.
(j) Use the first three columns of the original data set, i.e. n = 3 with 24 samples and leave
out the last two columns, construct the X and R charts. For this set of control charts,
answer the same questions in part (d) and part (g). In general and from the SPC
viewpoint, explain the differences between the two sets of control charts and their
performances, i.e. one with n = 5 and the other with n = 3.
Answers: To be provided after submission of Assignment 1.

Topic 4

Process capability analysis

(Comments: Some of the questions are taken from Chapter 8 of the textbook.)
1.

Perform a process capability analysis using the revised X and R charts for Question 1
in Topic 3.
Answers: Cp = 1.73 , Cpk = 1.10.

2.

A process is in statistical control with X(=) = 199 and R = 3.5. The control chart uses a
sample size of n = 4. Specifications are at 200 8. The quality characteristic is normally
distributed.
(a) Estimate the Cp and Cpk.
(b) How much improvement could be made in process performance if the mean could
be centered at the nominal value?
Answers: (a) 1.57 and 1.37; (b) From 19 ppm to 2.6 ppm.

3.

A process is in statistical control with X(=) = 75 and S = 2. The control chart uses a
sample size of n = 5. Specifications are at 80 8. The quality characteristic is normally
distributed.
(a) Estimate the Cp and Cpk.
(b) How much could process fallout be reduced by shifting the mean to the nominal
dimension?
Answers: (a) 1.25 and 0.47; (b) From 7.9% to 172 ppm.

4.

Consider the following two processes which produce the same product. The sample size
is n = 5 and the processes are in statistical control.
Process A

Process B

Centre line of the X chart

100

105

Centre line of the S chart

Specifications are at 100 10. Calculate the Cp and Cpk and interpret the values. Which
process would you prefer to use. The quality characteristic is normally distributed.
Answers: Process A, Cp = Cpk = 1.045; Process B, Cp = 3.133, Cpk = 1.566.

Topic 5

Measurement systems analysis

(Comments: Use the technique described in the lecture notes to solve the problems.)
1.

Given the following data for readings by 3 appraisals on 6 parts with 2 trials.
Part
number
1
2
3
4
5
6

Appraiser A
Trial 1
Trial 2
10.65
10.60
11.00
11.00
10.85
10.80
10.85
10.95
10.55
10.45
11.00
11.00

Appraiser B
Trial 1
Trial 2
10.55
10.55
11.05
10.95
10.80
10.75
10.80
10.75
10.40
10.40
11.00
11.05

Appraiser C
Trial 1
Trail 2
10.50
10.55
11.05
11.00
10.80
10.80
10.80
10.80
10.45
10.50
11.00
11.05

(a) Using GRR Method 1, calculate gauge repeatability and reproducibility. If the
specifications are at 10 1.40, calculate the P/T ratio (use the default 6-sigma
formula). Calculate the P/T ratio if the 5.15-sigma formula is used. Comment on the
gauge capability.
(b) Using GRR Method 2, estimate the R&R (% of total variation). Comment on the
gauge capability.
Answers: (a) 0.0369, 0.0320, 10.45%, 8.97%; (b) 21.14%.
2.

In a GRR study, 2 operators use the same gauge to measure 10 parts 3 times each:
Part
number
1
2
3
4
5
6
7
8
9
10

Operator A Measurements
1
2
3
50
49
50
52
52
51
53
50
50
49
51
50
48
49
48
52
50
50
51
51
51
52
50
49
50
51
50
47
46
49

Operator B Measurements
1
2
3
50
48
51
51
51
51
54
52
51
48
50
51
48
49
48
52
50
50
51
50
50
53
48
50
51
48
49
46
47
48

(a) Using GRR Method 1, estimate gauge repeatability and reproducibility. If the
specifications are at 50 10, calculate the P/T ratio (use the default 6-sigma
formula). Calculate the P/T ratio if the 5.15-sigma formula is used. Comment on the
gauge capability.
(b) Using GRR Method 2, estimate the R&R (% of total variation). Comment on the
gauge capability.
Answers: (a) 1.181, 0.151, 35.7%, 30.7%; (b) 64.18%.
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Topic 6
1.

Control charts for attributes (Refer to Chapter 7 of the textbook.)

The number of nonconforming items in samples of size 150 are as shown. Construct a p
chart. Is the process in control? If not, assume that assignable causes can be found for all
points outside the control limits and calculate the revised control limits.
Sample no.
1
2
3
4
5
6
7
8
9
10

No. of nonconforming
items
8
1
3
0
2
4
0
1
10
6

Sample no.
11
12
13
14
15
16
17
18
19
20

No. of nonconforming
items
6
0
4
0
3
1
15
2
3
0

Answers: Final revised chart gives CL = 0.0141, UCL = 0.0430, LCL = 0.

2.

In designing a p chart, with centre line at 0.20 and 3-sigma control limits, what is the
sample size required to yield a positive lower control limit? What is the sample size
necessary to give a probability of 0.50 of detecting a shift in the process to 0.26 in the
first sample plotted after the shift?
Answers: >36 and 400.

3.

The number of nonconformities found on final inspection of a device is as shown. Is the

process is in statistical control? What centre line and control limits would you
recommend for controlling future production?
Sample no.
1
2
3
4
5
6
7
8
9

No. of
nonconformities
0
1
1
0
2
1
1
3
2

Sample no.
10
11
12
13
14
15
16
16
18

No. of
nonconformities
1
0
3
2
5
1
2
1
1

Answers: CL = 1.5, UCL = 5.17 and LCL = 0. Process in control.

4.

Find the 3-sigma control limits for (a) a c chart with process average equal to 9
nonconformities; (b) a u chart with c = 16 and n = 4.
Answers: (a) CL = 9, UCL = 18 and LCL = 0; (b) CL = 4, UCL = 7 and LCL = 1.
9

Topic 7
1.

Acceptance sampling (Comments: Refer to Chapter 15 of the textbook.)

Suppose that a single-sampling plan with n = 150 and c = 2 is being used for receiving
inspection where the supplier ships the product in lots of size N = 3000.
(a) Draw the OC curve for this plan.
(b) Draw the AOQ curve and find the AOQL
(c) Draw the ATI curve for this plan
Answers: (b) About 0.0087.

2.

Suppose that a supplier ships components in lots of size 5000. A single-sampling plan
with n = 50 and c = 2 is being used for receiving inspection. Rejected lots are screened
and all defective items are reworked and returned to the lots.
(a) Draw the OC curve for this plan.
(b) Find the level of lot quality that will be rejected 90% of the time.
(c) Management has objected to the use of the above sampling procedure and want to
use a plan with c = 0, arguing that this is more consistent with their zero-defects
program. What do you think of this?
(d) Design a single-sampling plan with c = 0 that will give a 0.90 probability of
rejection of lots having the quality level found in (b). The two plans are now
matched at the LTPD point. Draw the OC curve for this plan and compare it to the
one for n = 50, c = 2 in (a).
(e) Suppose that incoming lots are 0.5% nonconforming. What is the probability of
rejecting these lots under both plans? Calculate the ATI at this point for both plans.
Which plan to you prefer? Why?
Answers: (b) p = 0.1030; (c) The plan will be extremely hard on the vendor; (d) n = 21,
the OC curve is much steeper; (e) 0.0021, 0.09991, 60, 518.

3.

Using ANSI/ASQ Z1.4, determine the single sampling plans for the following
information:

(a)
(b)
(c)
(d)

Inspection level
II
I
III
III

Inspection
Tightened
Normal
Reduced
Normal

AQL
1.5%
65
0.40%
2.5%

Lot size
1,400
115
160,000
27

Answers: (a) n = 125, c = 3, r = 4; (b) n = 8, c = 10, r = 11; (c) n =500, c = 5, r = 8;

(d) n =20, c =1, r = 2.

10

4.

Explain the meaning of the sampling plan in Question 3(c) if for a sample taken (i) d = 6,
(ii) d = 8, and (iii) d = 4.
Answers: (i) Lot accepted, NI reinstated; (ii) Lot rejected, NI reinstated; (iii) Lot
accepted, RI continues.

5.

A product is supplied in lots of size N = 10,000. The AQL has been specified at 0.10%.
Find the normal, tightened and reduced single-sampling plan from ANSI/ASQ Z1.4..
Use general inspection level II.
Answers: n = 125, c = 0, r = 1; n = 200, c = 0, r = 1; n = 50, c = 0, r = 1.

11