Question one

(a)A control chart for X and Rare maintained on certain dimensions of manufactured part, measured in
mm. The sub group size is 4. The values of X and R are computed for each subgroup. After 20 subgroups
x =412.83 and R= 4.39. Compute the values of 3sigma Limits for the X and R charts and estimate the
value of standard deviation for the population () on the assumption that the process is in statistical
control

(b)It is your first day on the job as a chemical engineer in a plant and one of your responsibilities is to
monitor the pH of a particular process using pH meter for your first 8 days. The experimental data
generated in the 8 days is shown below.

1st day 2nd day 3rd day 4th day 5th day 6th day 7th day 8th day
23.77 23.81 23.77 23.80 23.74 23.79 23.75 23.75
23.90 23.77 23.79 23.75 23.79 23.75 23.79 23.80
23.79 23.75 23.76 23.80 23.79 23.72 23.74 23.78
23.73 23.71 23.76 23.73 23.76 23.75 23.76 23.71
23.75 23.81 23.81 23.83 23.75 23.73 23.80 23.79
23.74 23.78 23.73 23.75 23.80 23.79 23.82 23.77

(i) Construct X and R charts to report your results

(ii)Given the pH specifications of 23.750.1 find out the process capability

Question two

(a)Write short note about the following as they are applied in quality control

(i) Control charts

(ii) Control and warning limits
In quality control, control limits are lines on the control chart that indicate the threshold at which the
process is considered statistically unlikely and are drawn typically at three standard deviations from
the centre line.
Warning limits are drawn as separate lines, typically two standard deviations above and below the
centre line.
(iii) Process capability
This is a measurable property of a process to the specification expressed as a process capability
index or process performance index.
The output of this measurement is usually illustrated by a histogram and calculations that predict how
many parts will be produced out of specification.

The two parts of process capability are:

1. Measure the variability of the output of the process.
2. Compare that variability with a proposed specification or product tolerance.
(iv) Total quality management:
Total quality management (TQM) describes a management approach to long-term success
through customer satisfaction.
 In a total quality management effort, all members of an organization participate in improving
processes, products, services and the culture in which they work.

(b) Explain the objectives of quality control in production

To establish the desired quality standards which are acceptable to the customers

To discover flaws of variations in the raw materials and the manufacturing process in order to ensure
smooth and uninterrupted production.

To evaluate the methods and processes of production and suggest further improvements in their
functioning.

To study and determine the extent of quality deviation in a product during the manufacturing process.

To analyse in detail the causes responsible for such deviation.

To undertake such steps which are helpful in achieving the desired quality of the product.