SECTION-1

Basic Statistics

1.Exercises on Manual Computation of Mean & Standard Deviation

1.1 Data on 5 samples for % carbon in as follows.

3.15 3.25 3.29 3.18 3.12

Calculate the Mean & Standard Deviation

Answer:

Mean = (3.15+3.25+3.29+3.18+3.12)/5 = 3.198

Standard Deviation = sqrt((1/(n-1))(∑power(x-xbar,2))) = 0.070498

1.2 Permeability data for 10 samples of Green Sand is given below:

120, 180 160 155 125 175 110 145 175 150

Calculate the Mean and SD

Interpret these summary figures specifications are 110-200

Answer:

Mean = (120+180+160+155+125+175+110+145+175+150)/10 = 149.5

Standard Deviation = sqrt((1/(n-1))(∑power(x-xbar,2))) = 24.54588

As per the given data , the permeability is within the specification but in order to reduce
the rejection a better sigma rating has to be achieved.

1.3 (a) Calculate the average for the following two data sets A&B

A: 11, 15, 12, 13, 14

B: 11, 15 12, 130, 14

What did you learn from this exercise

Answer:

Average(A)=(11+15+12+13+14)/5= 13
Average(A)=(11+15+12+130+14)/5= 36.4
When the data set is small and there is drastic variation in one of the rating then average is
greatly affected. In order to reduce this larger sample size has to be taken in order to reflect
upon the real average.

1.4 Calculate the Mean and Standard Deviation for the following two data sets A&B

1.4.1 A: 1.125, 1.785, 1.913, 1.675, 1.807, 1.325

B: 1001.125, 1001.325, 1001.675, 1001.785, 1001.807, 1001.913

1.4.2 A: 11.125, 11.785, 11.913, 11.675, 11.807, 11.325

B: 1.1125, 1.1325, 1.1675, 1.1785, 1.1807, 1.1913

1.4.3 A: 116, 120, 118, 119, 117

B: 2.0, 1.9, 1.8, 1.7, 1.6

What did you learn from these three exercises 1.4.1 through 1.4.3

Answer:

1.4.1 Mean(A)= 1.605

S.D(A) = 0.310409
Mean(B) = 1001.605
S.D(B) = 0.310409

Increasing or decreasing a data set with a constant increases or decreases the mean by that
same value but the standard deviation remains the same.

1.4.2 Mean(A)= 11.605

S.D(A) = 0.310409
Mean(B) = 1.1605
S.D(B) = 0.031041

Multiplying or diving a data set with a constant , results in the mean and standard deviation
multiplied or divided with that same value as well.

1.4.3 Mean(A)= 118

S.D(A) = 1.581139
Mean(B) = 1.8
S.D(B) = 0.158114
After finding out the mean and standard deviation of A we will be able to find out the mean
and standard deviation of B by using the inferences from the 1.4.1 and 1.4.2.

SECTION-2

Normal Distribution
 1. The breaking strength of cable is known to be normally distributes with a mean of 4000 kg
and a standard deviation of 25 kg. The manufacturer prefers that at least 95% of his
product meet a strength requirement of 4050 kg. Is this requirement being met? if not, by
changing the process parameter, what should the process mean target value be?

Answer:

If we attain 6 sigma rating then we will be able to achieve 99.73 % success rate.

So the mean should be (4050 + (6*25)) = 4200 and if the same standard deviation is
maintained then 99.73% of the cable will be above strength requirement.

But if we reduce the standard deviation to 10 then mean should be (4050 + (6*10)) =
4110 in order to achieve 99.73% success rate.

2. A company has been able to restrict the use of electrical power through energy conservation
measures. The monthly use is known to be normal with a mean of 6000KWh and a standard
deviation of 400 Kwh

A. What is the probability that the monthly consumption will be less than 5910Kwh

B. What is the probability that the monthly consumption will between

5900and 6030 Kwh

C. The capacity of the utility that supplies this company is 6100Kwh. What is the probability
that demand will not exceed supply by more than 100 Kwh.

Answer:

A. Since 5910 is (90/400)S.D away from the mean. Using the areas under the standard
normal curve table we will be able to find out the probability.
So 90/400 = 0.225 S.D
So 0.41 is the probability of monthly consumption will be less than 5910kwh.

B. So between 100/400 = 0.25 S.D

And 30/400 = 0.075 S.D
(0.5-0.4013) + (0.5 – 0.46) = 0.1387
0.1387 is the probability that the monthly consumption will between
5900and 6030 Kwh

C. So 100/400 = 0.25S.D
(1-0.4013)=0.5987
D. 0.5987 is the probability that demand will not exceed supply by more than 100 Kwh.
 SECTION-3

Six Sigma Rating

1. In the year 2004 -2005, the number of melts meeting the specifications with respect to
chemical and metallurgical characteristics was 2000 out of 6000 melts. Obtain the sigma
rating.

Answer:

33.33% success rate

1.1 sigma rating.

2. In a bearings unit the full time yields are as follows in each section

Parting : 98%
Turning : 97%
Heat Treatment : 95%
Graining and super finishing : 96%
Final inspection and testing : 98 %
Obtain the sigma rating for the unit

Answer:

98%(96%(95%(97%(98%)))) = 84.96%
84.96% success rate so
2.5 sigma rating

3. In a Bank, out of 9,85,000 credit card accounts, 1500 accounts were found to be
defaulting at the end of the year, in spite of careful scrutiny at the time of account
opening. Obtain six sigma rating of the credit card scheme.

Answer:

983500 accounts out of 985000 did not default.

99.847% success rate so
4.4 sigma rating.

4. In a share registry, in the data entry department 9885 forms were found to be okay out
of 10,000 application forms for which data was typed in. in the rest of forms, there were
some keying in errors and rework was found to be necessary There were 20 CTQ’s in
all. Calculate the six sigma rating of the data entry department

Answer:
9885 forms out of 10000 were found to be without error.
98.85% success rate so 3.7 sigma rating

5. In a medical diagnostics unit the quality assurance department found that only 98%of
the tests done were found to be okay and the rest were marginally differing. Obtain the
six sigma Rating for the unit.
 Answer:

98% success rate so

3.5 sigma rating.

6. a) In a machine shop there are 20 machines and in all 1200, aspects are checked on all
the machines as CTQ’s for preventive machine each time. In 2004-05, 12 monthly
preventive maintenance actions were implemented as a rating practice. However 100
machines breakdowns occurred which were attributable to poor preventive maintenance
either by design/ conformance. Obtain the sigma rating for the department.

b) Out of 500 problems reported for quality problems. Operators reported to be happy
only in 475 cases after the maintenance. Obtain the sigma rating for the maintenance
quality.

Answer:
a)Preventive maintanence quality
1100 out of 1200 success.
91.66 success rate
2.9 sigma rating.

b)Maintance quality
475 out of 500 success
95% success rate so
3.1 sigma rating.

7. A software company reported that only in one case out of six projects during the last one
year, they could meet the promised target on delivery. Obtain the sigma rating for the
delivery process.

Answer:
Success rate is (1/6)= 16.66% so
0.5 sigma rating.

8. A small-scale printing press is specialized in printing wedding cards. During the year
2004-05, 3000 orders were executed and in all, the orders contained 6,00,000 alphabets.
The proprietor reported that there were 150 spelling mistakes in the cards, while even
though customers were responsible for final approval. Thus even customer overlooked
such fine mistakes. Obtain the sigma rating for the press.

Answer:
Since we are not given with any other information, lets assume that 150 spelling
mistake corresponds to 150 alphabets being wrong.

So 599850 out of 600000 are correct

So 99.975% is the success rate.
So 5 sigma rating.

09. In the hardware stores of a company:

a) Out of 25,000 types of different items, under/ over stock was found in 150 items during the
annual audit carried out by the firm. Obtain sigma rating for the stock issuing process.
 b) Under stock/ overstock was reported to the tune of Rs.1.28 Lakhs out of Rs. 980.457 crores
worth of transactions. Obtain the sigma rating for the stores.
c) Which rating should the stores use-comment.

Answer:
a)24850 success out of 25000
99.4% success rate so
4 sigma rating.

B)1.28 lakh defect out of 980.457 crores.

.013% is defect so
3.7 sigma rating.

c) use the rating in a) because that helps us reduce the stocking problem in exact item. It is a
better indicator and bettering that will automatically result in the bettering of the sigma
rating of b) as well.

10. The production department of a company was found to be on target for only 860 shifts out of
900 shifts in a year. Obtain the sigma rating for the Production delivery process

Answer:
95.55% success rate so
3.2 sigma rating.

11. In a training institution, out of 285 courses conducted in a year, only for 190 courses the
participants reported meeting these expectations. Obtain sigma rating for the customer
satisfaction rating process.

Answer:
190 out of 285 courses are success.
66.66% success rate so
1.9 sigma rating.

12. A Govt. department was found to initiate only 87% of the approval budget in a year. Obtain the
sigma rating for the funding utilization process.

Answer:
2.6 sigma rating

13. An R&D department developed 15 new types of innovations out of which only 10 were found
to be commercially viable. Obtain six sigma rating for the departments R&D planning process.

Answer:
10 success out of 15.
66.66% success rate so
1.9 sigma rating.

14. In a big unit, out of 350 quality circles, only 25 were found to be doing active work. Obtain six
sigma rating for the steering committee of the company.

Answer:
25 success out of 350.
7.14% success rate.
0 sigma rating.

15. The security department is supposed to carry out in all 2 types of checks per employee during
their exit out of the factory each day. There are 2000 employee during their exit out of the
selling each day. There are 2000 employees and 300 working days in a year. In all 15
employees were caught stealing some items or other in a year. Obtain sigma rating for the
checking process.

Answer:
Sigma rating here cannot be determined because it does not give us information on how many
people had actually stolen things and out of which how many had been caught. Because
the sigma rating for the checking process depends on these two values only and not the
total number of checks performed.

SECTION-4

Analysis & Control

1. A Quality characteristic follows normal distribution with mean µ=65 Standard

Deviatioon=2. Find the probability that it takes a value a) less than 63 b) greater than 68 c)
between 70 & 60 d) between 61 &69

Answer:
a)0.1587
b).0668
c)between 2.5sd and -2.5sd
0.9876
d)between 2sd and -2sd
0.9544.

2. Width of the coil, used in electrical machines is one of the important quality characteristics.
It was observed that coils were getting rejected due to non-conformance. Data were
collected on 20 coils. Observations were taken at three different positions. Data is shown
in table. Analyze the data using control chart and answer the following
 a) Is process under statistical control?
Xbar-R Chart of C1, ..., C3
22.2
UCL=22.1224
22.0
Sample Mean

21.8 _
_
X=21.7267

21.6

21.4
LCL=21.3310
1 3 5 7 9 11 13 15 17 19
Sample

1.00 UCL=0.996

0.75
Sample Range

0.50 _
R=0.387
0.25

0.00 LCL=0
1 3 5 7 9 11 13 15 17 19
Sample

Ans : No the process is not under statistical control

b) Is process capable of meeting the specifications(21.76+.13mm)
Ans: No , the process is not capable of meeting the specification.

S.No. 1 2 3 X- R
1 21.50 21.60 21.80 21.63333 0.3
2 21.45 21.50 21.75 21.56667 0.3
3 21.45 21.70 21.85 21.66667 0.4
4 21.75 21.60 22.00 21.78333 0.4
5 21.80 21.50 21.60 21.63333 0.3
6 21.45 21.60 21.80 21.61667 0.35
7 21.85 21.50 21.80 21.71667 0.35
8 21.85 21.50 21.85 21.73333 0.35
9 21.80 21.75 21.80 21.78333 0.05
10 22.00 21.60 22.00 21.86667 0.4
11 21.85 21.75 21.85 21.81667 0.1
12 21.75 21.90 21.50 21.71667 0.4
13 22.10 21.50 21.85 21.81667 0.6
14 22.00 21.50 22.10 21.86667 0.6
15 22.10 21.45 21.80 21.78333 0.65
16 21.80 21.40 21.45 21.55 0.4
17 22.00 21.30 21.45 21.58333 0.7
18 22.00 21.30 21.90 21.73333 0.7
19 22.00 21.60 21.90 21.83333 0.4
20 21.80 21.85 21.85 21.83333 0.05
 3. Several tube sheets for coil cooler of centrifugal compressors were rejected due to oversize
holes and leakage at expand joint. Data were collected on hole size after reaming of drilled
holes as shown in the table. Analyze the data and offer your comment about the behavior of
the process. Design suitable control charts for the reaming process.

PROCESS DATA FOR REMAING OPERATION

Subgroup 1 2 3 4 Xbar R
No
1 19.340 19.340 19.340 19.340 19.34 0
2 19.340 19.340 19.340 19.340 19.34 0
3 19.345 19.335 19.340 19.345 19.34125 0.01
4 19.340 19.340 19.340 19.345 19.34125 0.005
5 19.340 19.335 19.340 19.340 19.33875 0.005
6 19.330 19.340 19.335 19.335 19.335 0.01
7 19.340 19.340 19.345 19.340 19.34125 0.005
8 19.345 19.340 19.340 19.340 19.34125 0.005
9 19.340 19.335 19.340 19.340 19.33875 0.005
10 19.340 19.340 19.345 19.340 19.34125 0.005
11 19.335 19.335 19.330 19.330 19.3325 0.005
12 19.340 19.340 19.340 19.345 19.34125 0.005
13 19.340 19.330 19.335 19.340 19.33625 0.01
14 19.330 19.330 19.335 19.330 19.33125 0.005
15 19.330 19.330 19.330 19.330 19.33 0
16 19.330 19.330 19.330 19.335 19.33125 0.005
17 19.335 19.330 19.335 19.330 19.3325 0.005
18 19.340 19.330 19.330 19.335 19.33375 0.01
19 19.335 19.335 19.335 19.340 19.33625 0.005
20 19.335 19.330 19.330 19.345 19.335 0.015
21 19.330 19.335 19.335 19.340 19.335 0.01
22 19.340 19.330 19.340 19.340 19.3375 0.01

Ans :
 Xbar-R Chart of C1, ..., C4
5 6 5 5 5 UCL=19.34201

19.340
6 6
Sample Mean

_
_
X=19.33687

19.335
6 2
6
8 5 LCL=19.33174
1 1
19.330
1
1 3 5 7 9 11 13 15 17 19 21
Sample

0.016 UCL=0.01609
Sample Range

0.012

0.008 _
R=0.00705

0.004

0.000 LCL=0
1 3 5 7 9 11 13 15 17 19 21
Sample

The process is not under statistical control

4 In order to control the air gap between stator and rotor of Electric motor, it was proposed to make
use control chart for machining of rotor diameter. Data were collected on 23 rotors by taking
measurement at three different positions on each rotor. Variability between positions was found to
be insignificant and hence three observations from one rotor were treated as a sample. Analyze the
data and answer the following questions

1 Is process stable?
2.if tolerance provided is + 0.075, is the process capable?
3. Design suitable control chart for this process.

ROTOR DIA

S.No D.E M.E N.D.E X R

1 634.00 633.85 634.10 633.983
3 0.25
2 633.80 633.83 633.90 633.843
3 0.1
3 633.90 633.91 633.95 633.92 0.05
4 633.92 633.97 634.00 633.963
3 0.08
5 633.85 633.85 633.96 633.886
7 0.11
6 633.93 633.78 633.83 633.846
7 0.15
7 633.96 633.94 634.08 633.993
3 0.14
8 634.20 634.38 634.28 634.286 0.18
 7
9 633.95 634.00 633.92 633.956
7 0.08
10 634.00 634.20 634.19 634.13 0.2
11 634.03 633.81 633.80 633.88 0.23
12 633.08 633.08 633.85 633.336
7 0.77
13 634.05 633.88 633.05 633.66 1
14 634.15 634.18 634.09 634.14 0.09
15 634.24 633.96 633.96 634.053
3 0.28
16 634.04 634.05 633.95 634.013
3 0.1
17 633.85 633.93 634.00 633.926
7 0.15
18 633.95 634.15 634.15 634.083
3 0.2
19 633.60 633.70 633.67 633.656
7 0.1
20 634.42 634.43 634.42 634.423
3 0.01
21 633.97 633.99 634.01 633.99 0.04
22 633.94 634.75 634.72 634.47 0.81
23 633.88 633.90 634.06 633.946
7 0.18

Xbar-R Chart of D.E, ..., N.D.E

634.50 1
1

UCL=634.305
634.25
Sample Mean

_
_
634.00 X=633.973

633.75
5
LCL=633.642
633.50

1
1 3 5 7 9 11 13 15 17 19 21 23
Sample

1
1.00

UCL=0.834
Sample Range

0.75

0.50
_
R=0.324
0.25
2 2

2
0.00 LCL=0
1 3 5 7 9 11 13 15 17 19 21 23
Sample

Answer:
a)No
b)No

5. Pareto analysis
 Consider the rework of Watch in Watch Assembly in a certain
period, the rework was as under

S.No. Defect Code Quantity

1 Dirty A 63
2 Waveness on upper Lugs B 1140
3 Burr at bottom of lugs C 529
4 Thread in case pipe D 225
5 Milling/filling defect E 1178
6 Tips polishing F 609
7 Scratches in level G 556
8 Shining at OSR H 28
9 Black spots in between lugs I 199
10 Black spots in at OSR J 548
11 Turning lines on upper of lugs K 45
Total 5120

Pareto Chart of Code

5000 100

4000 80
Quantity

60 Percent
3000

2000 40

1000 20

0 0
Code E B F G J C D I A K H
Quantity 1178 1140 609 556 548 529 225 199 63 45 28
Percent 23.0 22.3 11.9 10.9 10.7 10.3 4.4 3.9 1.2 0.9 0.5
Cum % 23.0 45.3 57.2 68.0 78.7 89.1 93.5 97.3 98.6 99.5 100.0