Chapter 8 Exercise Solutions

Chapter 8 Exercise Solutions

8.3.
2
10.375; 6.25; 6.25 2.059 3.04
USL [(350 5) 350] 10 50; LSL [(350 5) 350] 10 50
(obs 350) 10
x x
x x
i i
x R R d
x
o = = = = = =
= + = = =
=

USL LSL 50 ( 50)

5.48
6 6(3.04)
x x
p
x
C
o

= = =
The process produces product that uses approximately 18% of the total specification
band.

USL 50 10.375

4.34
3 3(3.04)
LSL 10.375 ( 50)

6.62
3 3(3.04)

min( , ) 4.34
x
pu
x
x
pl
x
pk pu pl
C
C
C C C

o

= = =

= = =
= =

This is an extremely capable process, with an estimated percent defective much less than
1 ppb. Note that the C
pk
is less than C
p
, indicating that the process is not centered and is
not achieving potential capability. However, this PCR does not tell where the mean is
located within the specification band.

8.6.
2
4; 199; 3.5; 3.5 2.059 1.70
x
n x R R d o = = = = = = =
USL =200 +8 =208; LSL =200 8 =192

(a)
Potential:
USL LSL 208 192

1.57
6 6(1.70)
p
C
o

= = =
The process produces product that uses approximately 64% of the total specification
band.

(b)
Actual:
USL 208 199

1.76
3 3(1.70)
LSL 199 192

1.37
3 3(1.70)

min( , ) 1.37
pu
pl
pk pl pu
C
C
C C C

o

= = =

= = =
= =


(c)
The current fraction nonconforming is:
Chapter 8 Exercise Solutions
| |
| |
| |
Actual
Pr{ LSL} Pr{ USL}
Pr{ LSL} 1 Pr{ USL}
LSL USL
Pr 1 Pr

192 199 208 199
Pr 1 Pr
1.70 1.70
( 4.1176) 1 (5.2941)
0.0000191 1 1
0.0000191
p x x
x x
z z
z z

o o
= < + >
= < + s
(
= < + s
` `
(
) )
(
= < + s
` `
(
) )

= u + u
= +
=

If the process mean could be centered at the specification target, the fraction
nonconforming would be:
Potential
192 200
2 Pr
1.70
2 0.0000013
0.0000026
p z

= <
`
)
=
=

8.25.
MTB > Stat > Control Charts > Variables Charts for Subgroups > X-bar R


Test Results for Xbar Chart of Ex8.25All
TEST 1. One poi nt mor e t han 3. 00 st andar d devi at i ons f r omcent er l i ne.
Test Fai l ed at poi nt s: 2, 3

Chapter 8 Exercise Solutions
The x chart has a couple out-of-control points, and the R chart is in control. This
indicates that the operator is not having difficulty making consistent measurements.

(b)
Gauge 2
2
Total
2 2 2 2
Product Total Gauge
Product
98.2; 2.3; 2.31.693 1.359
4.717
4.717 1.359 2.872
1.695
x R R d o
o
o o o
o
= = = = =
=
= = =
=


(c)
Gauge
Total

1.359
100 100 62.5%

4.717
o
o
= =

(d)
USL =100 +15 =115; LSL =100 15 =85
Gauge
6
6(1.359)
0.272
USL LSL 115 85
P
T
o
= = =



Chapter 8 Exercise Solutions
8.28.
MTB > Stat > ANOVA > Balanced ANOVA
In Results, select Display expected mean squares and variance components
ANOVA: Ex8.28Reading versus Ex8.28Part, Ex8.28Op
Fact or Type Level s
Ex8. 28Par t r andom 20
Ex8. 28Op r andom 3

Fact or Val ues
Ex8. 28Par t 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20
Ex8. 28Op 1, 2, 3

Anal ysi s of Var i ance f or Ex8. 28Readi ng
Sour ce DF SS MS F P
Ex8. 28Par t 19 1185. 425 62. 391 87. 65 0. 000
Ex8. 28Op 2 2. 617 1. 308 1. 84 0. 173
Ex8. 28Par t *Ex8. 28Op 38 27. 050 0. 712 0. 72 0. 861
Er r or 60 59. 500 0. 992
Tot al 119 1274. 592

S = 0. 995825 R- Sq = 95. 33% R- Sq( adj ) = 90. 74%

Expect ed Mean Squar e
Var i ance Er r or f or Each Ter m( usi ng
Sour ce component t er m unr est r i ct ed model )
1 Ex8. 28Par t 10. 2798 3 ( 4) + 2 ( 3) + 6 ( 1)
2 Ex8. 28Op 0. 0149 3 ( 4) + 2 ( 3) + 40 ( 2)
3 Ex8. 28Par t *Ex8. 28Op - 0. 1399 4 ( 4) + 2 ( 3)
4 Er r or 0. 9917 ( 4)

2
Repeatability Error
0.992 MS o = =
2 P?O E
Part?Operator
0.712 0.992
0.1400 0
2
MS MS
n
o

= = =
2 O P?O
Operator
1.308 0.712
= 0.0149
20(2)
MS MS
pn
o

= =
2 P P?O
Part
62.391 0.712
= 10.2798
3(2)
MS MS
on
o

= =

The manual calculations match the MINITAB results. Note the Part Operator variance
component is negative. Since the Part Operator term is not significant (o =0.10), we
can fit a reduced model without that term. For the reduced model:

ANOVA: Ex8.28Reading versus Ex8.28Part, Ex8.28Op

Expect ed
Mean Squar e
f or Each
Ter m( usi ng
Var i ance Er r or unr est r i ct ed
Sour ce component t er m model )
1 Ex8. 28Par t 10. 2513 3 ( 3) + 6 ( 1)
2 Ex8. 28Op 0. 0106 3 ( 3) + 40 ( 2)
3 Er r or 0. 8832 ( 3)
Chapter 8 Exercise Solutions
(a)
2 2
Reproducibility Operator
2 2
Repeatability Error
0.0106
0.8832
o o
o o
= =
= =


(b)
2 2 2
Gauge Reproducibility Repeatability
Gauge
0.0106 0.8832 0.8938
0.9454
o o o
o
= + = + =
=


(c)

Gauge
6
6 0.9454
/ 0.1050
USL-LSL 60 6
P T
o

= = =

This gauge is borderline capable since the estimate of P/T ratio just exceeds 0.10.

Estimates of variance components, reproducibility, repeatability, and total gauge
variability may also be found using:

MTB > Stat > Quality Tools > Gage Study > Gage R&R Study (Crossed)
Gage R&R Study - ANOVA Method
Two-Way ANOVA Table With Interaction
Sour ce DF SS MS F P
Ex8. 28Par t 19 1185. 43 62. 3908 87. 6470 0. 000
Ex8. 28Op 2 2. 62 1. 3083 1. 8380 0. 173
Ex8. 28Par t * Ex8. 28Op 38 27. 05 0. 7118 0. 7178 0. 861
Repeat abi l i t y 60 59. 50 0. 9917
Tot al 119 1274. 59

Two-Way ANOVA Table Without Interaction
Sour ce DF SS MS F P
Ex8. 28Par t 19 1185. 43 62. 3908 70. 6447 0. 000
Ex8. 28Op 2 2. 62 1. 3083 1. 4814 0. 232
Repeat abi l i t y 98 86. 55 0. 8832
Tot al 119 1274. 59

Gage R&R
%Cont r i but i on
Sour ce Var Comp ( of Var Comp)
Tot al Gage R&R 0. 8938 8. 02
Repeat abi l i t y 0. 8832 7. 92
Repr oduci bi l i t y 0. 0106 0. 10
Ex8. 28Op 0. 0106 0. 10
Par t - To- Par t 10. 2513 91. 98
Tot al Var i at i on 11. 1451 100. 00

St udy Var %St udy Var
Sour ce St dDev ( SD) ( 6 * SD) ( %SV)
Tot al Gage R&R 0. 94541 5. 6724 28. 32
Repeat abi l i t y 0. 93977 5. 6386 28. 15
Repr oduci bi l i t y 0. 10310 0. 6186 3. 09
Ex8. 28Op 0. 10310 0. 6186 3. 09
Par t - To- Par t 3. 20176 19. 2106 95. 91
Tot al Var i at i on 3. 33842 20. 0305 100. 00
Number of Di st i nct Cat egor i es = 4
Chapter 8 Exercise Solutions
8.28 continued

Visual representations of variability and stability are also provided: