IN6331 Assignment 5 Solution

8-4.
n 5; x 0.00109; R 0.00635; x 0.00273 ; tolerances: 0 0.01
USL LSL 0.01 0.01
C p 1.22
6 6(0.00273)
The process produces product that uses approximately 82% of the total specification band.

USL 0.01 0.00109

C pu 1.09
3 3(0.00273)
LSL 0.00109 (0.01)
C pl 1.35
3 3(0.00273)
C min(C , C ) 1.09
pk pl pu

This process is not considered capable, failing to meet the minimally acceptable definition of capable
Cpk 1.33

T x 0 0.00109
V 0.399
S 0.00273
C
p 1.22
C pm
1.13
1V 2 1 (0.399) 2
Since Cpm is greater than 1, the mean lies within approximately the middle third of the specification
band.

T 0.00109 0
0.399
0.00273
C
pk 1.09
C pkm 1.01
1 2
1 0.399 2

8-5.
x 100; s 1.05; x s c4 1.05 0.9400 1.117

(a)
USL LSL (95 10) (95 10)
Potential: C p 2.98
6 6(1.117)

(b)

1
 LSL x 100 (95 10)
C pl 4.48
3 x 3(1.117)
USL x (95 10) 100
Actual: C pu 1.49
3 x 3(1.117)
C pk min(C pl , C pu ) 1.49
(c)
p Actual Pr{x LSL} Pr{x USL}
Pr{x LSL} 1 Pr{x USL}
LSL USL
Pr z 1 Pr z

85 100 105 100
Pr z 1 Pr z
1.117 1.117
(13.429) 1 (4.476)
0.0000 1 0.999996
0.000004
85 95 105 95
p Potential Pr z 1 Pr z
1.117 1.117
(8.953) 1 (8.953)
0.000000 1 1.000000
0.000000

8-7.
n 2; x 39.7; R 2.5; x R d 2 2.5 1.128 2.216
USL = 40 + 5 = 45; LSL = 40 5 = 35

(a)
USL LSL 45 35
Potential: C p 0.75
6 6(2.216)

(b)
USL 45 39.7
C pu 0.80
3 3(2.216)
LSL 39.7 35
Actual: C pl 0.71
3 3(2.216)
C min(C , C ) 0.71
pk pl pu

2
(c)
x T 39.7 40
V 0.135
s 2.216
C p 0.75
C pm 0.74
1V 2 1 (0.135) 2
C pk 0.71
C pkm 0.70
1V 2 1 (0.135) 2
The closeness of estimates for Cp, Cpk, Cpm, and Cpkm indicate that the process mean is very close to the
specification target.
(d)
The current fraction nonconforming is:
p Actual Pr{x LSL} Pr{x USL}
Pr{x LSL} 1 Pr{x USL}
LSL USL
Pr z 1 Pr z

35 39.7 45 39.7
Pr z 1 Pr z
2.216 2.216
(2.12094) 1 (2.39170)
0.0169634 1 0.991615
0.025348
If the process mean could be centered at the specification target, the fraction nonconforming would be:
35 40
p Potential 2 Pr z
2.216
2 Pr{z 2.26}
2 0.01191
0.02382

8-14
MTB > Stat > Basic Statistics > Normality Test
(Add percentile lines at Y values 50 and 84 to estimate and .)

P r o b a b i l i t y P l o t o f C y c l e T i m e ( E x 7 -1 4 C T )
Norm a l
99
M ean 1 3.2
S tD e v 4.09 7
95 N 30
AD 0.40 1
90
P - V a lu e 0.34 0
84
80
70
Percent

60
50 50
40
30
20

10

5
17.27
13.2

1
5 10 15 20 25
R e im b u r s e m e n t C y c le Tim e , D a y s

3
A normal probability plot of reimbursement cycle times shows the distribution is close to normal.
x p50 13.2
p84 17.27
p84 p50 17.27 13.2 4.07
6 6(4.07) 24.42

8-24
(a)
n 2; x 21.8; R 2.8; Gauge 2.482
MTB > Stat > Control Charts > Variables Charts for Subgroups > X-bar R
Xbar-R Chart of Part Measurements (Ex7-24All)
30 1

U C L=27.07
Sample M ean

25
_
_
X=21.8
20

LC L=16.53
1
15 1
1
2 4 6 8 10 12 14 16 18 20
Sample

U C L=9.15
8
Sample Range

4
_
R=2.8
2

0 LC L=0

2 4 6 8 10 12 14 16 18 20
Sample

Test Results for Xbar Chart of Ex7-24All

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 8, 12, 15, 20

The R chart is in control, and the x chart has a few out-of-control parts. The new gauge is more
repeatable than the old one.

(b) specs: 25 15
P 6 Gauge 6(2.482)
100 100 49.6%
T USL LSL 2(15)

4
8-25
MTB > Stat > Control Charts > Variables Charts for Subgroups > X-bar R
Xbar-R Chart of Part Mesaurements (Ex7 -2 5 All)
102.0 1

100.5 U C L= 100.553

Sample M ean
99.0 _
_
X= 98.2
97.5

96.0 LC L= 95.847

1
1 2 3 4 5 6 7 8 9 10
S a m p le

6.0 U C L= 5.921

4.5
Sample Range

3.0 _
R = 2.3
1.5

0.0 LC L= 0
1 2 3 4 5 6 7 8 9 10
S a m p le

Test Results for Xbar Chart of Ex8-25All

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 2, 3
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)
x 98.2; R 2.3; Gauge R d 2 2.3 1.693 1.359
Total
2
4.717
Product
2
Total
2
Gauge
2
4.717 1.3592 2.872
Product 1.695
(c)
Gauge 1.359
100 100 62.5%
Total 4.717
(d)
USL = 100 + 15 = 115; LSL = 100 15 = 85
P 6 Gauge 6(1.359)
0.272
T USL LSL 115 85

8-26
(a)
Excel : workbook Chap07.xls : worksheet Ex8-26
x1 50.03; R1 1.70; x2 49.87; R2 2.30
R 2.00
n 3 repeat measurements
d 2 1.693
Repeatability R d 2 2.00 1.693 1.181

5
Rx 0.17
n 2 operators
d 2 1.128
Reproducibility Rx d 2 0.17 1.128 0.151

(b)
Measurement
2
Error Repeatability Reproducibility 1.181 0.151 1.418
2 2 2 2

Measurement Error 1.191

(c) specs: 50 10
P 6 Gauge 6(1.191)
100 100 35.7%
T USL LSL 60 40

9-1.0 = 1050; = 25; = 1; K = (/2) = (1/2)25 = 12.5; H = 5 = 5(25) = 125

(a)
MTB > Stat > Control Charts > Time-Weighted Charts > CUSUM
CUSUM Chart of Molecular Weight (Ex8-1mole)
target = 1050, std dev = 25, k = 0.5, h = 5
1250

1000
Cumulative Sum

750

500

250
UCL=125
0 0
LCL=-125

2 4 6 8 10 12 14 16 18 20
Sample

The process signals out of control at observation 10. The point at which the assignable cause occurred
can be determined by counting the number of increasing plot points. The assignable cause occurred
after observation 10 3 = 7.
(b) MR2 d 2 38.8421/1.128 34.4345
No. The estimate used for is much smaller than that from the data.

9-17
= 0.1, L = 2.7, = 25, CL = 0 = 1050, UCL = 1065.49, LCL = 1034.51
MTB > Stat > Control Charts > Time-Weighted Charts > EWMA

6
 EWMA Chart of Molecular Weight (Ex8-1mole)
lambda = 0.1, L = 2.7
1140

1120

1100
EWMA

1080

+2.7SL=1065.4
1060
_
_
X=1050
1040
-2.7SL=1034.6

2 4 6 8 10 12 14 16 18 20
Sample

Process exceeds upper control limit at sample 10; the same as the CUSUM chart.

10-1.
A 2.530, nA 15, A 101.40
B 2.297, nB 9, B 60.444
C 1.815, nC 18, C 75.333
D 1.875, nD 18, D 50.111
Standard deviations are approximately the same, so the DNOM chart can be used.

R 3.8, 2.245, n 3
x chart: CL = 0.55, UCL = 4.44, LCL = 3.34
R chart: CL = 3.8, UCL = D4 R = 2.574 (3.8) = 9.78, LCL = 0

Stat > Control Charts > Variables Charts for Subgroups > Xbar-R Chart
Xbar-R Chart of Measurements (Ex9-1Xi)
U C L=4.438
4
Sample M ean

2
_
_
X=0.55
0

-2

LC L=-3.338
-4
2 4 6 8 10 12 14 16 18 20
Sample

10.0 U C L=9.78

7.5
Sample Range

5.0
_
R=3.8
2.5

0.0 LC L=0

2 4 6 8 10 12 14 16 18 20
Sample

7
Process is in control, with no samples beyond the control limits or unusual plot patterns.

10-2.
Since the standard deviations are not the same, use a standardized x and R charts. Calculations for
standardized values are in:
n 4, D3 0, D4 2.282, A2 0.729; RA 19.3, RB 44.8, RC 278.2
Graph > Time Series Plot > Simple
Control Chart of Standardized Xbar (Ex9-2Xsi)
1.5

1.0

+A2 = 0.729
0.5
Ex9-2Xsi

0.0 0

-0.5
-A2 = -0.729

-1.0
Ex9-2Samp 2 4 6 8 10 12 14 16 18 20
Ex9-2Part A A A B B C C C C C

Control Chart of Standardized R (Ex9-2Rsi)

2.5
D4 = 2.282

2.0

1.5
Ex9-2Rsi

1.0 1.006

0.5

0.0 D3 = 0

Ex9-2Samp 2 4 6 8 10 12 14 16 18 20
Ex9-2Part A A A B B C C C C C

Process is out of control at Sample 16 on the x chart.

10-30.
= 0.01/hr or 1/ = 100hr; = 2.0
a1 = $0.50/sample; a2 = $0.10/unit; a'3 = $5.00; a3 = $2.50; a4 = $100/hr
g = 0.05hr/sample; D = 2hr

(a) n = 5, k = 3, h = 1, = 0.0027
( 0 k n ) ( 0 2 ) ( 0 k n ) ( 0 2 )

n n h h2
0.4992

3 2 5 3 2 5 2 12
(1.472) (7.472) eh
0.27
0.0705 0.0000
0.0705
1 e h
h
E(L) = $3.79/hr

8
(b)n = 3, kopt = 2.210, hopt = 1.231, = 0.027, 1 = 0.895
E(L) = $3.6098/hr

10-31. = 0.01/hr or 1/ = 100hr; = 2.0

a1 = $0.50/sample; a2 = $0.10/unit; a'3 = $50; a3 = $25; a4 = $100/hr
g = 0.05hr/sample; D = 2hr
(a)
n = 5, k = 3, h = 1, = 0.0027
( k n ) ( ) ( k n ) ( )
0 0 0 0
n n


k n k n
3 2 5 3 2 5
(1.472) (7.472)
0.0705 0.0000
0.0705
h h 2 1 0.01(12 )
0.4992
2 12 2 12
eh 0.0027
0.27
1 e
h
h 0.01(1)
E(L) = $4.12/hr

(b)n = 5, k = 3, h = 0.5, = 0.0027, = 0.0705

h h 2 0.5 0.01(0.52 )
0.2498
2 12 2 12
eh 0.0027
0.54
1 e h 0.01(0.5)
h

E(L) = $4.98/hr

(c)
n = 5, kopt = 3.080, hopt = 1.368, = 0.00207, 1 = 0.918
E(L) = $4.01392/hr