wage eae wy ae ete Problem 2. In a capability study of a lathe used in tuming a shalt to a diameter of 23.75 + 0.1 mm a sample of 6 consecutive pieces was taken each day for 8 days. The diameters of these shafts are as given below : dst day 2ndday 3rdday 4thday Sthday 6thday 7thday 8th day 23.77 23.80 23.77 23.79 23.75 23.78 23.76 23.76 23.80 23.78 23.78 23.76 23.78 23.76 23.78 23.79 23.78 23.76 23.77 23.79 23.78 23.73 23.75 23.77 23.73 23.70 23.77 23.74 23.77 23.76 23.76 23.72 23.76 23.81 23.80 23.82 23.76 23.74 23.81 23.78 23.75 23.77 23.74 23.76 23.79 23.78 23.80 23.78 Scanned with CamScannerCONTROL CHARTS FOR VARIABLES 191 Construct the X and R chart and find out the process capability for the machine. Sol. Average diameter for the first day X1 +.Xp4 Xy + X44 X5 + Xo ee ae ee Baan (23.77 + 23.80 + 23.78 + 23,73 + 23.76 + 23.75 6 = 23.765. Similarly, the averages for each day are calculated and the results are tabulated as below : RB. Bin’ X Xs % % % 23765 23.77 23.7716 23.7767 23.7717 23.7583 23.7767 23. 1667 x Now, 24 low, 4 = OUST «93.7696, | Ranges : | Ri Ry R3 Ry Rs Re Ry Rg 0.07 O11 0.06 0.08 0.04 0.05 0.06 0.07 poke R=) = 00675. For X chart : 2 UCLy= X+ AR f = 23.1696 + 0.48 x 0.0675 [Ap = 0.48 for subgroup of from Table Appendix] = 23,7696 + 0.0324 = 23.802. LCLz= X- AR | = 23.7696 - 0.0324 = 23.7322. | For R chant : # UCL = Dak = 2 x 0,0675 = 0.1350. CLp= DsR pein al wh [Dy = 0 for subgroup of © oF less} Process capability : " R Go’ = 0x7 = £%0.0675 _ 9.15982 25: {for subgroup of 6, dy = 2.534 from ‘Table Appendix] Scanned with CamScanner0.2 mm from data. Xmax — Xmin ‘Therefore, (Xmax — Xmin) > 60°. Conclusion. All manufactured products will meet specifications as long as the process stays in control, | Problem 3. The following table shows the averages and ranges of the spindle diameters in millimetres for 30 subgroups of 5 items each. xX R x R x R 45,020 0375 45.600 0.215 45.26 0.150 44.950 0.450 45,020 0.175 45.650 0.200 45.480 0.450 45.320 0.200 45.620 0.400 45.320 0.150 45.560 0.425 45.480 0.225 45.280 0.200 45.140 0.250 45,380 0.125 45.820 0.250 45.620 0375 45.660 0.350 45.580 0.275 45.800 0.475 45.460 0.225 45.400 0.475 45.500 0.200 45.640 0.375 45.660 0.475 45.780 0.275 45.390 0.650 45.680 0.275 45.640 0.225 45.290 0.350 For the first 20 samples set up an X chart and an R chart. Plot the next 10 samples on these charts to see if the process continues ‘‘under control’” both as to average and range. Also find the process capability. Sol. =e 13435, OF = == X= T= 5 = 0.06009 UCR = X + 30% UCL = 45,4585 + 3 x 0.06009 11x 0.3125 = 45.4585 + 0.1803 = 06594 5.6388 LCLp = D3R= 0 X~3 oy 45,4585 ~ 0,1803 = 45,2782. 60° = 6 x 0.13425 0.80550 LCL Process capability scanned with CamScannerProblem 8. Control charts for Xand o are maintained on the weight in kg. of the contents of a certain container. The subgroup size is 10. The values of X¥ and 6 are computed for each subgroup. After 18 subgroups, ZX = 595.8 and Xo = 8.24. Compute the values of 0’ on the assumption the process is in statistical control. Solution. For Xchart UCLY= X + Ayg = 33.10 + 1.03 x 0.4577 = 33.5714 LCL = X ~ Ayg= 33.10 - 1.03 x 0.4577 = 32.6286. For 6 chart UCL¢ = Byo = 1.72 x 0.4577 = 0.7872 LCLo = B3.5 = 0.28 x 0.4577 = 0.12815 For calculating poe: ns pO Siill =04! a 62 ~ :0,9227 Problem 9. A fair percentage of a certain product requires costly rework Operations to change a certain quality characteristic after the product has been rejected by the manufacturer’s 100 percent final inspection. Rework is Possible whenever the value of this quality characteristic falls above the upper specification limit. If the value falls below the lower specification limit, the product must be scrapped. Xand R control charts have been initiated and maintained for 50 subgroups of 5 each with samples taken from production every 2 hours. The specification requirements for the measured quality are 119 + 10 and a’ of 5, On the assumption that the quality characteristic is normally distributed, approximately what percentage of defective product is being produced ? How much of this can be reworked ? Solution. Process capability = 60’ =6x5 = 30 Scanned with CamScannerCONTROL CHARTS FOR VARIABLES 199 Specified tolerance = 129 - 109 = 20. ‘ Since, 60° > specified tolerance some non-conforming products will be always made. : Percent defective will correspond to the area above the line for dimension 129 (Upper specification limit) and also below the line for dimension 109 (Lower specification limit). es 129 (Xmax) ——¥ (124) | 108 (min) | Fig. 6.17. X,-x - Now, Zio ae 1h o 5 Area corresponding to this figure from table = 0.8413 Therefore, the defective parts produced above the upper specification limit = (1 - 0.8413) = 0.1587 = 15.87% Similarly oh Area = 0.00135 = 0.135%. | Therefore, total percentage of defective parts = 15.87 + 0.135 = 16,005. And the percent defective which can be reworked = 15.87% (above USL). Problem 10. A certain product has been statistically controlled at a process average of 36.0 and a standard deviation of 1.00. The product is presently being sold to two users who have different specification requirements. User A has established a specification of 38.0 + 4.0 for the product, and user B has specification of 36.0 + 4.0. (a) Based on the present process set up, what percent of the product produced Will not meet the specifications set up by user A ? (b) What percent of the product will not meet the specifications of user B? (©) Assuming that the two users’ needs are equal, a suggestion is made to Scanned with CamScannerScanned with CamScannerOL CONTROL CHARTS FOR VARIABLES 2 (rar ~ Xmin) > 60°, and also the process is centred mid way, therefore, all products will meet the specifications for the user B. ia (© When the process average is shifted to 37. For the user A the situation i follows : will be represented as fol Xmaxe 42 Xmin=34 Fig. 6.18. (c) The defective products will correspond to the area below the lower specification limit of 34. z -3 Corresponding area from Table A = 0.00135. Therefore, 0.135% of the products will not meet the specifications. (@) For the user B. a5 387 3 =Soe Xmax= 40 Xmin = 32 Fig. 6.18. (d) The defective products will correspond to the area above the upper Specification limit. Zz 40 - 37 —F =3 Therefore, the defective parts produced above the upper specification limit s = (1 - 0,99865) = 0.00135. | And the percent of the products which will not meet the Specifications = 0.135%. | Corresponding area from Table A = 0.99865, Scanned with CamScanner202 STATISTICAL QUALIry comp, (e) The shift to a process average of 37 will be desirable, SINCE the toy percent defectives = 0.135 + 0.135 = 0.27% instead of 2.28%, when the process average was 36. (As far as the user A ang user B is concerned the % of Products not meeting the Specifications will j. negligible when the process average is 37). Problem 11. The design specifications for a component are 100 + 0.5 mm whereas the process report shows that process average is 99,9 mM. and standard Geviation is 0.18. Do these figures call for any action by any one ? What action is necessary and by whom ? Solution. Upper Specification limit = 100 + 0.5 = 100.5 mm Lower specification limit = 100-05 = 995 mm. X= 999 9 =0.18 (given) max - Xmin) = 1.0 oma Sie oS Capability = 60" = 6 x 0.18 = 1.08, re neem = Xnin) < 60, Defective Products will always be there. !t is There gk actin to Teduce the number of Fieatives produced a ‘ween the specification limits and process capabilit): hence it is Suggested that the tolerances shoul me without affecting the functioning of the Product, The aan pe pate puanly i, modify the specifications, At the same time it ig een engineer is authorised | ie centring of the Process, solutely Necessary to main ———{marraases] ces of ariation giving suitable Ga Chance causes and Assignable cau (b) What is a and eS ‘ant by natural tole, lain the rance of Oe i to be considered = Re Process g (a) Sample size. in Scanned with CamScanner