1. What are the basic tools of SPC and their main application areas?

2. Construct a static model or map of a process of your choice, which you

know well. Make sure you identify the customers and outputs, suppliers
and inputs, how you listen to the voice of the customer and hear the
voice of the process.
Chng 5
5.1. A bottle filling machine is being used to fill 150ml bottles of a
shampoo. The actual bottles will hold 156ml. The machine has
been set to discharge an average of 152ml. It is known that the
actual amounts discharged follow a normal distribution with a
standard deviation of 2ml. a. What proportion of the bottles
overflow?
b. The overflow of bottles causes considerable problems and it
has therefore been suggested that the average discharge should
be reduced to 151ml. In order to meet the weights and measures
regulations, however, not more than 1 in 40 bottles, on
average,must contain less than 146ml. Will the weights and
measures regulations be contravened by the proposed changes?
5.2 To: International Chemicals Supplier
From: Senior Buyer, Perplexed Plastics Ltd
SUBJECT: MFR Values of Polyglyptalene
As promised, I have now completed the examination of our delivery
records and have verified that the values we discussed were not in fact in
chronological order. They were simply recorded from a bundle of
certificates of analysis held in our quality records file. I have checked,
however, that the bundle did represent all the daily deliveries made by
ICS since you started to supply in October last year. Using your own lot
identification system I have put them into sequence as manufactured:
1
2
3
4
5
6
7
8
9
10
11
12

4.1
4.0
4.2
4.2
4.4
4.2
4.3
4.2
4.2
4.1
4.3
4.1

13
14
15
16
17
18
19
20
21
22
23
24

3.2
3.5
3.0
3.2
3.3
3.2
3.3
2.7
3.3
3.6
3.2
2.9

25
26
27
28
29
30
31
32
33
34
35
36

3.3
3.0
3.4
3.1
3.5
3.1
3.2
3.5
2.4
3.5
3.3
3.6

37
38
39
40
41
42
43
44
45
46
47
48

3.2
3.4
3.5
3.0
3.4
3.5
3.6
3.0
3.1
3.4
3.1
3.6

49
50
51
52
53
54
55
56
57
58
59
60

3.3
3.3
3.4
3.4
3.3
3.2
3.4
3.3
3.6
3.1
3.4
3.5

61
62
63
64

3.2
3.7
3.3
3.1

I hope you can make use of this information. Analyse the above data and
report on the meaning of this information.
5.3 In manufacturing it is frequently necessary to estimate the proportion
of product produced outside the tolerance limits, when a process is not
capable of meeting the requirements. The method to be used is illustrated
in the following example: 100 units were taken from a margarine
packaging unit which was in statistical control or stable. The packets of
margarine were weighed and the mean weight, X mean =255g, the
estimated standard deviation, s = 4.73g. If the product specification
demanded a weight of 250 10g, how much of the output of the
packaging process would lie outside the tolerance zone?
5.4 A bagging line fills plastic bags with polyethylene pellets which are
automatically heat sealed and packed in layers on a pallet. SPC charting
of the bag weights by packaging personnel has shown an estimated
standard deviation of 20g. Assume the weights vary according to a normal
distribution. If the stated minimum quantity in one bag is 25kg what must
be average quantity of resin put in a bag be if the risk for underfilling is to
be about one chance in 250?
Chng 6
6.1 (a) Explain the principles of Shewhart control charts for sample mean
and sample range. (b) State the Central Limit Theorem and explain its
importance in SPC.
6.2 The following are measures of the impurity, iron, in a fine chemical
which is to be used in pharmaceutical products. The data is given in parts
per million (ppm).
Sample

X1

X2

X3

X4

X5

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

15
14
13
15
9
11
13
10
8
10
13
7
11
11
13

11
16
6
15
12
14
12
15
12
10
16
10
7
7
9

8
11
9
9
9
11
9
12
14
9
12
9
16
10
12

15
14
5
15
8
12
6
4
9
14
15
11
10
10
13

6
7
10
7
8
5
10
6
10
14
18
16
14
7
17

16
17
18
19
20

17
4
8
9
15

10
14
9
10
10

11
5
6
7
10

9
11
13
10
12

8
11
9
13
16

Set up mean and range charts and comment on the possibility of using
them for future control of the iron content.
6.3 You are responsible for a small plant which manufacturers and packs
jollytots, a childrens sweet. The average contents of each packet should
be 35 sugar-coated balls of candy which melt in your mouth. Every halfhour a random sample of five packets is taken and the contents counted.
These figures are shown below:
Sample

Packet contents
1
2
1
33
36
2
35
35
3
31
38
4
37
35
5
34
35
6
34
33
7
34
36
8
36
37
9
34
34
10
34
35
11
34
34
12
35
35
13
36
36
14
35
35
15
35
35
16
33
33
17
34
40
18
33
35
19
34
33
20
37
32
Use the data to set up mean
usage.

3
37
32
35
36
36
38
37
35
32
37
35
41
37
32
34
35
36
33
37
34
and range

4
5
38
36
37
35
36
38
36
34
36
37
35
38
35
34
32
31
34
36
34
32
36
32
38
35
31
34
32
39
34
34
35
34
32
37
34
40
34
34
35
34
charts, and briefly outline their

6.4 You are a Sales Representative of International Chemicals. Your

Manager has received the following letter of complaint from Perplexed
Plastics, now one of your largest customers.
To: Sales Manager, International Chemicals From: Senior Buyer, Perplexed
Plastics
Subject: MFR Values of Polymax

We have been experiencing line feed problems recently which we suspect

are due to high MFR values on your Polymax. We believe about 30 per
cent of your product is out of specification. As agreed in our telephone
conversation, I have extracted from our records some MFR values on
approximately 60 recent lots. As you can see, the values are generally on
the high side. It is vital that you take urgent action to reduce the MFR so
that we can get out lines back to correct operating speed.
MFR Values
4,
3,
3,
3,
4
3
2
5
2,
3,
3,
3,
4
0
2
3
3,
3,
3,
3,
3
2
3
6
4,
3,
3,
3,
2
4
2
1
3,
3,
3,
2,
4
4
2
7
Specification 3.0 to

3,
4,
3,
3,
3
3
2
6
4,
2,
3,
3,
1
9
5
1
3,
3,
4,
3,
1
6
3
0
3,
3,
4,
3,
5
3
1
3
3,
4,
3,
4,
1
2
4
2
3.8g/10 minute.

3,
5
3,
4
3,
2
4,
1

3,
6
3,
1
3,
6
3,
0

4,
2
3,
0
3,
1
3,
3

3,
7
4,
2
3,
3
3,
5

3,
5
3,
3
3,
4
4,
0

3,2
3,4
3,4
3,5

Subsequent to the letter, you have received a telephone call advising you
that they are now approaching a stock-out position. They are threatening
to terminate the contract and seek alternative supplies unless the
problem is solve quickly.
Do you agree that their complaint is justified?
Discuss what action you are going to take.
6.5 The following data were obtained when measurements of the zinc
concentration (measured as percentage of zinc sulphate on sodium
sulphate) were made in a viscose rayon spin-bath. The mean and range
values of 20 samples of size 5 are given in the table.
Sample
Range
1
2
3
4
5
6
7
8
9
10

Zn conc.
6,97
6,93
7,02
6,93
6,94
7,04
7,03
7,04
7,01
6,99

Range
0,38
0,20
0,36
0,31
0,28
0,20
0,38
0,25
0,18
0,29

Sample
11
12
13
14
15
16
17
18
19
20

7,05
6,92
7,00
6,99
7,08
7,04
6,97
7,00
7,07
6,96

Znconc.
0,23
0,21
0,28
0,20
0,16
0,17
0,25
0,23
0,19
0,25

If the data are to be used to initiate mean and range charts for controlling
the process, determine the action and warning lines for the charts. What
would your reaction be to the development chemist setting a tolerance of
7.00 0.25 per cent on the zinc concentration in the spin-bath?
6.6 Conventional control charts are to be used on a process manufacturing
small components with a specified length of 60 1.5mm. Two identical
machines are involved in making the
Sample
Machine I
Machine II
Mean
Range
Mean
Range
number
1
60.10
2.5
60.86
0.5
2
59.92
2.2
59.10
0.4
3
60.37
3.0
60.32
0.6
4
59.91
2.2
60.05
0.2
5
60.01
2.4
58.95
0.3
6
60.18
2.7
59.12
0.7
7
59.67
1.7
58.80
0.5
8
60.57
3.4
59.68
0.4
9
59.68
1.7
60.14
0.6
10
59.55
1.5
60.96
0.3
11
59.98
2.3
61.05
0.2
12
60.22
2.7
60.84
0.2
13
60.54
3.3
61.01
0.5
14
60.68
3.6
60.82
0.4
15
59.24
0.9
59.14
0.6
16
59.48
1.4
59.01
0.5
17
60.20
2.7
59.08
0.1
18
60.27
2.8
59.25
0.2
19
59.57
1.5
61.50
0.3
20
60.49
3.2
61.42
0.4
Calculate the control limits to be used on a mean and range chart for each
machine and give the reasons for any differences between them. Compare
the results from each machine with the appropriate control chart limits
and the specification tolerances.
6.7 Control of dissolved iron in a dyestuff
Mean and range charts are to be used to maintain control on dissolved
iron content of a dyestuff formulation in parts per million (ppm). After 25
subgroups of 5 measurements have been obtained.
n=25

i=0

n=25

X i =390

Ri
i=0

=84

(a) Design the appropriate control charts. (b) The specification on the
process requires that no more than 18ppm dissolved iron be present in the
formulation. Assuming a normal distribution and that the process
continues to be in statistical control with no change in average or

dispersion, what proportion of the individual measurements may be

expected to exceed this specification?
6.8 Pin manufacture_______________________________
Samples are being taken from a pin manufacturing process every 1520
minutes. The production rate is 350400 per hour, and the specification
limits on length are 0.820 and 0.840cm. After 20 samples of 5 pins, the
following information is available:
n=20

X i
i=0

n=20

Ri

=16.68

i=0

=0.14

(a) Set up mean and range charts to control the lengths of pins produced
in the future. (b) On the assumption that the pin lengths are normally
distributed, what percentage of the pins would you estimate to have
lengths outside the specification limits when the process is under control
at the levels indicated by the data given? (c) What would happen to the
percentage defective pins if the process average should change to
0.837cm? (d) What is the probability that you could observe the change in
(c) on your control chart on the first sample following the change?
Chng 7
7.1 The data in the table opposite shows the levels of contaminant in a
chemical product: (a) Plot a histogram. (b) Plot an individuals or run chart.
(c) Plot moving mean and moving range charts for grouped sample size n
4. Interpret the results of these plots.
Levels of contamination in a chemical product
Sample
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Result(ppm)
404.9
402.3
402.3
403.2
406.2
406.2
402.2
401.5
401.8
402.6
402.6
414.2
416.5
418.5
422.7
422.7
404.8

Sample
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

Result(ppm)
409.6
409.6
409.7
409.9
409.9
410.8
410.8
406.1
401.3
401.3
404.5
404.5
404.9
405.3
405.3
415.0
415.0

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

401.2
404.8
412.0
412.0
405.9
404.7
403.3
400.3
400.3
400.5
400.5
400.5
402.3
404.1
404.1
403.4
403.4
402.3
401.1
401.1
406.0
406.0
406.0

58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80

407.3
399.5
399.5
405.4
405.4
397.9
390.4
390.4
395.5
395.5
395.5
398.5
400.0
400.2
401.5
401.5
401.3
401.2
401.3
401.9
401.9
404.4
405.7

7.2 Evan and Hamble manufacture shampoo which sells as an own-label

brand in the Askway chain of supermarkets. The shampoo is made in two
stages: a batch mixing process is followed by a bottling process. Each
batch of shampoo mix has a value of 10,000, only one batch is mixed per
day, and this is sufficient to fill 50,000 bottles.
Askway specify that the active ingredient content should lie between 1.2
per cent and 1.4 per cent. After mixing, a sample is taken from the batch
and analysed for active ingredient content. Askway also insist that the net
content of each bottle should exceed 248ml. This is monitored by taking 5
bottles every half-hour from the end of the bottling line and measuring the
content.
(a) Describe how you would demonstrate to the customer, Askway, that
the bottling process was stable. (b) Describe how you would demonstrate
to the customer that the bottling process was capable of meeting the
specification.
(c) If you were asked to demonstrate the stability and capability of the
mixing process how would your analysis differ from that described in parts
(a) and (b).
7.3 Middshire Water Company discharges effluent, from a sewage
treatment works, into the River Midd. Each day a sample of discharge is

taken and analysed to determine the ammonia content. Results from the
daily samples, over a 40 day period, are given below:
Ammonia content
Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Ammonia(pp
m)
24.1
26.0
20.9
26.2
25.3
20.9
23.5
21.2
23.8
21.5
23.0
27.2
22.5
24.0
27.5
19.1
27.4
26.9
28.8
29.9
27.0
26.7
25.1
29.6
28.2
26.7
29.0
22.1
23.3
20.2
23.5
18.6
21.2
23.4
16.2
21.5
18.6
20.7
18.2
20.5

Temperature(
C)
10
16
11
13
17
12
12
14
16
13
10
12
10
9
8
11
10
8
7
10
11
9
7
8
10
12
15
12
13
11
17
11
12
19
13
17
13
16
11
12

Operator
A
A
B
A
B
C
A
A
B
B
C
A
C
C
B
B
A
C
B
A
A
C
C
B
B
A
A
B
B
C
B
C
C
B
C
A
C
C
C
C

Use suitable techniques to detect and demonstrate changes in ammonia

concentration?
Chng 8
8.1 Explain the difference between an: np-chart, p-chart, c-chart.
8.2 A factory finds that on average 20 per cent of the bolts produced by a
machine are defective. Determine the probability that out of 4 bolts
chosen at random: (a) 1, (b) 0, (c) at most 2 bolts will be defective.
8.3 The following record shows the number of defective items found in a
sample of 100 taken twice per day.
Sample
Number
of
Number
defectives
1
4
2
2
3
4
4
3
5
2
6
6
7
3
8
1
9
1
10
5
21
2
22
1
23
0
24
3
25
2
26
2
27
0
28
1
29
3
30
0
Set up a Shewhart np-chart,
results.

Sample
Number
of
number
defectives
11
4
12
4
13
1
14
2
15
1
16
4
17
1
18
0
19
3
20
4
31
0
32
2
33
1
34
1
35
4
36
0
37
2
38
3
39
2
40
1
plot the above data and comment on the

8.4 Twenty samples of 50 polyurethane foam products are selected. The

sample results are:
SampleNo.
1
2
3
Numberdefec 2
3
1
tive
SampleNo.
11 12 13
Numberdefec 2
2
3
tive
Design an appropriate control
interpret the results.

4
4

5
0

6
1

7
2

8
2

9
3

10
2

14
4

15
5

16
1

17
0

18
0

19
1

20
2

chart. Plot these values on the chart and

8.5 A control chart for a new kind of plastic is to be initiated. Twenty-five

samples of 100 plastic sheets from the assembly line were inspected for
flaws during a pilot run. The results are given below. Set up an appropriate
control chart.
Sample No.
Number
flaws/sheet
Sample No.
Number
flaws/sheet
Sample No.
Number
flaws/sheet

1
of 2

2
3

3
0

4
2

5
4

6
2

7
8

8
4

9
of 5

10
8

11
3

12
5

13
2

14
3

15
1

16
2

18
of 4

19
1

20
0

21
3

22
2

23
4

24
2

25
1

17
3

8.6 In an effort to improve safety in their plant, a company decided to

chart the number of injuries that required first aid, each month.
Approximately the same amount of hours were worked each month. The
table below contains the data collected over a 2-year period.
Year1Month Numberofinjuri Year2Month Numberofinjuri
es(c)
es(c)
January
6
January
10
February
2
February
5
March
4
March
9
April
8
April
4
May
5
May
3
June
4
June
2
July
23
July
2
August
7
August
1
September 3
September 3
October
5
October
4
November
12
November
3
December
7
December
1
Use an appropriate charting method to analyse the data.
Chng 9
9.1 (a) Explain the principles of Shewhart control charts for sample mean
and sample range, and cumulative sum control charts for sample mean
and sample range. Compare the performance of these charts.
(b) A chocolate manufacturer takes a sample of six boxes at the end of
each hour in order to verify the weight of the chocolates con- tained within
each box. The individual chocolates are also examined visually during the
check-weighing and the various types of major and minor faults are
counted. The manufacturer equates 1 major fault to 4 minor faults and
accepts a maximum equivalent to 2 minor physical faults/chocolate, in

any box. Each box contains 24 chocolates. Discuss how the cusum chart
techniques can be used to monitor the physical defects. Illustrate how the
chart would be set up and used.
9.2 The following record shows the number of defective items found in a
sample of 100 taken twice per day.
Sample
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Number
defectives
4
2
4
3
2
6
3
1
1
5
4
4
1
2
1
4
1
0
3
4

of Sample
number
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Number
defectives
2
1
0
3
2
0
1
3
0
3
0
2
1
1
4
0
2
3
2
1

of

Set up and plot a cusum chart. Interpret your findings. (Assume a target
value of 2 defectives.)
9.3 Small plastic bottles are made from preforms supplied by Britanic
Polymers. It is possible that the variability in the bottles is due in part to
the variation in the preforms. Thirty preforms are sampled from the
extruder at Britanic Polymers, one preform every 5 minutes for two and a
half hours. The weights of the preforms age (g).
32.9 33.7 33.4 33.4 33.6 32.8 33.3 33.1 32.9 33.0
33.2 32.8 32.9 33.3 33.1 33.0 33.7 33.4 33.5 33.6
33.2 33.8 33.5 33.9 33.7 33.4 33.5 33.6 33.2 33.6
Carry out a cusum analysis of the preform weights and comment on the
stability of the process.

9.4 (a) Using process capability studies, processes may be classified as

being in statistical control and capable. Explain the basis and meaning of
this classification.
(b) Define the process capability indices Cp and Cpk and describe how
they may be used to monitor the capability of a process, its actual
performance and its performance as perceived by a customer.
9.5 Discuss in detail the applications of Pareto analysis and cause and
effect analysis as aids in solving operations management problems. Give
at least two illustrations. You are responsible for a biscuit production plant,
and are concerned about the output from the lines which make chocolate
wholemeal biscuits. Output is consistently significantly below target. You
suspect that this is because the lines are frequently stopped, so you
initiate an in-depth investigation over a typical 2-week period. The table
below shows the causes of the stoppages, number of occasions on which
each occurred, and the average amount of output lost on each occasion:
Cause

No.
of Lost
production
occurrences
(00s biscuits)

Wrapping
cellophanewrapbre 1031
3
akage
cartonerfailure
85
100
Enrober
chocolatetoothin
102
1
chocolatetoothick
92
3
Preparation
underweightbiscuit 70
25
s
overweightbiscuits 21
25
biscuits misshapen 58
1
Ovens
biscuitsovercooked 87
2
biscuitsundercook 513
1
ed
Use this data and the appropriate techniques to indicate where to
concentrate remedial action.
How could stratification aid the analysis in this particular case?
9.6 A company manufactures a range of domestic electrical appliances.
Particular concern is being expressed about the warranty claims on one
particular product. The customer service department provides the
following data relating the claims to the unit/component part of the
product which caused the claim:
Unit/component part

Number of claims

Average
warranty

cost
work

of
(per

claim)
Drum
110
48.1
Casing
12842
1.2
Work-top
142
2.7
Pump
246
8.9
Electric motor
798
48.9
Heater unit
621
15.6
Door lock mechanism
18442
0.8
Stabilizer
692
2.9
Power additive unit
7562
1.2
Electric control unit
652
51.9
Switching mechanism
4120
10.2
Discuss what criteria are of importance in identifying those unit/component parts to examine initially. Carry out a full analysis of the data to
identify such unit/component parts.