02413 Statistical Quality Control

EXAM II

Please return your exam to Flavia Dalia Frumosu in Room 250 in

Building 324 by 15:00 o’clock on December 8, 2017. Only the hard
(paper) copy of the exam will be accepted. Use this cover page as the first
page.

“I will not give or receive any assistance to or from anyone

during this exam. I acknowledge that any violation of this will be
considered cheating and will be punished accordingly.”

Signature:___________________________________

Name:

Student Number:

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Question 1: (20/100) The temperature readings from a blast furnace are taken every 5
minutes and given in the excel spreadsheet “E2DATA (2017).xls” in worksheet “Question
1”. Using appropriate statistical process control tools, determine whether the process is in
control or not.

Since all the points are within the control limits and there are no patterns, then process is
in statistical control.

Question 2: (15/100) A dairy plant is producing butter that is supposed to weigh 200 gr
each. The specification limits on the weight are given as 192 gr and 208 gr. 50 randomly
selected butter packages are weighed. The data is given in “E2DATA (2017).xls” in
worksheet “Question 2”. Given these specification limits, determine whether the process
is capable using the appropriate capability ratio(s).

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A capable process is a process whose spread on the bell-shaped curve is narrower than
the tolerance range or specification limits. USL is the upper specification limit and LSL is
the lower specification limit. From the figure, the bell shaped curve is narrow than the
specification limits. The process is capable

Question 3. (25/100) In a baked goods manufacturing plant, pastries go through a baking

process for 20 minutes at three different trays of the baking furnace. At the end of each
baking period a pastry is collected randomly from each of the three trays. 100 pastries for
each tray are collected and their weights are recorded to construct a T2 control chart.
The data is given in the excel spreadsheet “E2DATA (2017).xls” in worksheet “Question
3a”.

(a) (5/25) Construct the appropriate T2 control chart. Is the process in control (use
  0.01 )?

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From the charts, the process is in controll since no limit has been exceeded.

(b) (10/25) (Assume that Phase I data is in control) New process data (Phase II data)
collected from the same process is given in the excel spreadsheet “E2DATA (2017).xls”
in worksheet “Question 3b”. Using an appropriate T2 control chart determine whether the
process is in control. Provide T2 statistics you calculate in a table.
If the process is out-of-control, find out what caused the out-of-control signal. (use
  0.01 )?

Tray Tray Tray

1 2 3 V1 V2 T12 T22 UCL1 UCL2 Covar
102.3 105.5 103.9 1.1 1.3 3.7 5.2 8.4 13.3 0.267789
103 106.6 105.2 -0.8 -0.8 0.1 0.9 8.4 13.3 0.364105 1.058184
102.6 105.8 104.4 0.6 -0.4 2.0 2.0 8.4 13.3
102.7 106.4 104 -0.2 -0.2 1.0 6.7 8.4 13.3 0.215526
102.9 106.2 103.8 0.5 0 1.1 8.2 8.4 13.3 0.143947 0.19
102 106.7 103.8 -0.6 0 3.5 15.5 8.4 13.3
102.3 106.1 103.8 0.1 0 1.0 7.3 8.4 13.3 Average
102.8 106.2 103.8 0.3 0.3 1.1 8.2 8.4 13.3 106.46 104.835

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 102.5 106.5 104.1 0.6 1 1.1 6.2 8.4 13.3 0.1 0.136842
103.6 107.1 105.1 -1.2 -0.9 2.2 2.2 8.4 13.3
102.6 105.9 104.2 0.7 0.5 1.2 2.2 8.4 13.3 alpha 0.01
102.7 106.6 104.7 -1 -0.7 0.3 0.6 8.4 13.3 p 2
102.3 105.6 104 0.9 0.7 3.0 4.2 8.4 13.3 m 20
102.4 106.5 104.7 0.2 0.7 0.1 0.3 8.4 13.3 n 1
103.5 106.7 105.4 0.5 0.7 0.3 2.0 8.4 13.3
103.8 107.2 106.1 -0.4 0.4 2.2 8.9 8.4 13.3
103.8 106.8 106.5 -0.4 0.1 3.0 22.6 8.4 13.3
102.4 106.4 106.6 0.6 -0.5 6.1 34.7 8.4 13.3
103.1 107 106.1 0.4 0.4 1.6 10.1 8.4 13.3
103.1 107.4 106.5 3.6 15.6 8.4 13.3

The process is out of controll

(c) (10/25) As in part (b), new process data collected from the same process is given in
the excel spreadsheet “E2DATA (2017).xls” in worksheet “Question 3c”. Once again
assume that this is Phase II data for the control chart constructed in part (a). Using an
appropriate T2 control chart determine whether the process is in control.
Provide T2 statistics you calculate in a table. If the process is out-of-control, find out what
caused the out-of-control signal. (use   0.01 )?

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 Tray Tray Tray
1 2 3 V1 V2 T12 T22 UCL1 UCL2 Covar
103.5 105.7 105.8 1.5 -2 5.3 5.2 9.7 10.6 0.444833
103 107.2 103.8 -0.2 0.1 1.7 1.6 9.7 10.6 -0.0081 0.527384
103.1 107 103.9 -0.3 0.4 1.0 0.9 9.7 10.6
103.2 106.7 104.3 -0.5 0.1 0.1 0.1 9.7 10.6 0.506939
102.8 106.2 104.4 0.3 0.4 0.2 0.2 9.7 10.6 0.007755 0.537347
103.3 106.5 104.8 1.2 0.3 0.4 0.4 9.7 10.6
104.1 107.7 105.1 -2.5 -1 4.4 3.9 9.7 10.6 Average
101.9 105.2 104.1 2.5 0.4 3.9 3.4 9.7 10.6 106.492 104.358
104 107.7 104.5 -1.4 -1.2 3.3 2.9 9.7 10.6 0 -0.02857
102 106.3 103.3 -0.1 1.3 2.2 2.1 9.7 10.6
102.8 106.2 104.6 0 -0.1 0.3 0.3 9.7 10.6 alpha 0.01
102.6 106.2 104.5 0.4 -0.3 0.2 0.2 9.7 10.6 p 2
102.8 106.6 104.2 0 0.5 0.1 0.1 9.7 10.6 m 50
103.2 106.6 104.7 -0.5 -0.3 0.3 0.2 9.7 10.6 n 1
102.6 106.1 104.4 0.3 -0.2 0.3 0.3 9.7 10.6
102.7 106.4 104.2 -1.2 -0.7 0.1 0.1 9.7 10.6
101.4 105.2 103.5 0.7 1.6 5.2 4.6 9.7 10.6
103 105.9 105.1 0.6 0.1 1.8 1.7 9.7 10.6
103.7 106.5 105.2 0.7 -1.3 1.3 1.3 9.7 10.6
103 107.2 103.9 -1.3 -0.2 1.5 1.4 9.7 10.6
102.2 105.9 103.7 0.7 -0.1 1.6 1.5 9.7 10.6
102.5 106.6 103.6 0.8 1.1 1.1 1.1 9.7 10.6
104 107.4 104.7 -1.5 -0.6 2.1 1.8 9.7 10.6
102.5 105.9 104.1 0.1 0.8 0.9 0.8 9.7 10.6
103 106 104.9 -1.1 -0.8 1.1 1.0 9.7 10.6
101.6 104.9 104.1 2.5 0.3 5.9 5.1 9.7 10.6
103.6 107.4 104.4 -0.4 -0.5 1.9 1.6 9.7 10.6
102.8 107 103.9 -0.1 0.9 1.0 0.9 9.7 10.6
103.5 106.9 104.8 0.3 -1.5 0.8 0.7 9.7 10.6
102.5 107.2 103.3 -0.7 1.1 3.2 3.1 9.7 10.6
103 106.5 104.4 -0.5 -1.6 0.0 0.0 9.7 10.6
101.6 106 102.8 1.2 1.7 5.2 5.0 9.7 10.6
103.4 107.2 104.5 -0.9 1.1 1.2 1.0 9.7 10.6
103.5 106.3 105.6 -0.2 -0.8 3.0 3.0 9.7 10.6
103.2 106.1 104.8 1.2 1 0.7 0.7 9.7 10.6
104.5 107.3 105.8 -1.2 -0.1 5.5 5.1 9.7 10.6
103.5 106.1 105.7 0.6 -1.4 3.7 3.7 9.7 10.6
103.2 106.7 104.3 -1.2 0.1 0.1 0.1 9.7 10.6
102.4 105.5 104.4 0 -0.5 2.2 1.9 9.7 10.6
102 105.5 103.9 1.7 -0.9 2.6 2.3 9.7 10.6
102.4 107.2 103 -0.8 1.9 4.6 4.5 9.7 10.6

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 103.3 106.4 104.9 1 -2.3 0.6 0.6 9.7 10.6
103.1 107.4 102.6 -1.1 1.9 7.6 7.5 9.7 10.6
103.1 106.3 104.5 0.9 -0.1 0.1 0.1 9.7 10.6
103.5 107.2 104.4 -0.3 0.9 1.1 1.0 9.7 10.6
103.8 106.9 105.3 0 -1.5 2.1 2.0 9.7 10.6
102.8 106.9 103.8 -0.1 1.4 0.9 0.9 9.7 10.6
103.6 106.8 105.2 -0.5 -1.4 1.6 1.5 9.7 10.6
102.5 106.3 103.8 -0.6 0.6 0.7 0.6 9.7 10.6
102.4 105.7 104.4 1.4 1.2 9.7 10.6

The process is in controll

(If you need to make any assumptions, state them very clearly)

Question 4: (25/100) Consider the 11 process variables given in the excel spreadsheet
“E2DATA (2017).xls” in worksheet “Question 4a”.

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 (a) (4/25) What is the least number of principal components (scores) that explain
at least 85% of the variation?

Principal Component Analysis:

Eigenvalues:

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11
Eigenvalue 4.620 3.774 0.999 0.225 0.218 0.210 0.208 0.200 0.188 0.181 0.178
Variability (%) 42.001 34.306 9.086 2.046 1.978 1.911 1.888 1.819 1.706 1.643 1.616
Cumulative % 42.001 76.307 85.393 87.439 89.417 91.328 93.216 95.035 96.741 98.384 100.000

The least number of principal components is three that gives a percentage of 85.393%
(b) (4/25) Construct univariate control charts for the principal components
(scores) in (a). Is the process in control?

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The process is in controll since none of the ontrol limits has been exceeded.

(b) (8/25) Assume that the process in control (i.e. if there are any, the out of
control points in (b) can be overlooked). Consider the new data (Phase II data)
from the same process given in the excel spreadsheet “E2DATA (2017).xls” in
worksheet “Question 4b”. Construct univariate control charts for the principal
components (scores). Is the process in control now? If not which principal
component(s) indicates out of control?

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For the data, the process is in control since it is within the control limits.

(d) (9/25) Discuss which variable(s) you would consider to investigate the out-of-
control signal. Construct an appropriate univariate chart for the variable(s) you identified
and comment on the results.
I would consider investigating variable x2 and x8
X2

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X8

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Question 5: (15/100) Temperature readings from a chemical process are given in the
excel spreadsheet “E2DATA (2017).xls” in worksheet “Question 5”.
(a) (5/15) Plot EWMA of this series for =0, 0.1, 0.2, 0.4, 0.6, 0.8, 0.9, 1.
Comment on the effect of  on the EWMA.

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As the value of lambda increases, the variation in EWMA decreases

(b) (10/15) An EWMA control chart is to be constructed to catch a 0.75 shift

from the mean. If the shift has to be caught in 16 observations or less after the shift, use
Table 9-11 in your book (p. 437) to determine the appropriate  and L. Determine
whether the process is in control using the EWMA control chart (Use sample mean and
variances to construct the chart).

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The process is in control since none of the limits has been exceeded.

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