Assignment 7

(Solution)
Control Charts, Process capability and QFD

Dr. Jitesh J. Thakkar

Department of Industrial and Systems Engineering

Indian Institute of Technology Kharagpur
 Instruction
• Total No. of Questions: 15. Each
question carries one point.
• All questions are objective type. In
some of the questions, more than one
answers are correct.
• This assignment includes true/false
statement questions.
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Question 1
What are the control limits of p-chart for the following data of 20
samples of 100 pairs of jeans?
Sample Number of defectives Proportion Defectives
1 6 0.06
2 4 0.04
3 1 0.02
. . .
. . .
20 12 0.17
Total 180

a) UCL = 0.1286 and LCL = 0.0624

b) UCL = 0.1186 and LCL = 0.0614
c) UCL = 0.0911 and LCL = 0.0866
d) UCL = 0.1126 and LCL = 0.0756
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Solution 1
Answer: b (UCL = 0.1186 and LCL = 0.0614)
𝑇𝑜𝑡𝑎𝑙 𝐷𝑒𝑓𝑒𝑐𝑡𝑖𝑣𝑒𝑠 180
𝑝= = = 0.09
𝑇𝑜𝑡𝑎𝑙 𝑆𝑎𝑚𝑝𝑙𝑒 𝑜𝑏𝑠𝑒𝑟𝑣𝑎𝑡𝑖𝑜𝑛 20 × 100
𝑝(1 − 𝑝) 0.09(1 − 0.09)
𝑈𝐶𝐿 = 𝑝 + 𝑧 = 0.09 + 3 = 0.1186
𝑛 100

𝑝 1−𝑝 0.09(1 − 0.09)

𝐿𝐶𝐿 = 𝑝 − 𝑧 = 0.09 − 3 = 0.0614
𝑛 100

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 2
A hospital manager receives a certain number of
complaints each day about the hospitals service.
Complaints for 15 days are given in the table shown.
What are the control limits when one will construct a
control chart using three sigma limits?
a) UCL and LCL are 5±3 5
b) UCL = 0 and LCL = -1.708
c) UCL = 11.708 and LCL = 0
d) None of these
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Table of Question 2
Days Number of D3ays Number of
complaints complaints
1 4 9 5
2 6 10 3
3 4 11 5
4 5 12 4
5 4 13 4
6 8 14 6
7 6 15 4
8 7 Total 75
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Solution 2
Answer: c (UCL = 11.708 and LCL = 0)
𝑇𝑜𝑡𝑎𝑙 𝑑𝑒𝑓𝑒𝑐𝑡𝑠 75
𝑐= = =5
𝑆𝑎𝑚𝑝𝑙𝑒𝑠 15
𝑈𝐶𝐿 = 𝑐 + 𝑧 𝑐 = 5 + 3 5 = 11.708
𝐿𝐶𝐿 = 𝑐 − 𝑧 𝑐 = 5 − 3 5 = −1.708
If LCL is negative then it is taken as zero.

Dr. Jitesh J. Thakkar, IIT Kharagpur

Common Data Question
(Question 3 & 4)

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Common data Question
The following data is a common data given for x-bar and
range chart calculations in Question Number 3 and 4.
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

17.5 16.3 13.8 16.7 14.1

15.3 18.4 17.2 11.3 12.5

12.7 14.9 15.6 14.4 18.8

x-bar 15.16 16.53 15.53 14.13 15.13

R 4.8 3.5 3.4 5.4 6.3
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Data

Sample
Size = m
A2 A3 d2 D3 D4 B3 B4
2 1.880 2.659 1.128 0 3.267 0 3.267
3 1.023 1.954 1.693 0 2.574 0 2.568
4 0.729 1.625 2.059 0 2.282 0 2.266
5 0.577 1.427 2.326 0 2.114 0 2.089
6 0.483 1.287 2.534 0 2.004 0.030 1.970

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 3

What is the value of central line and UCL

for Range chart?

a) Central Line = 3.25 and UCL = 4.68

b) Central Line = 5.24 and UCL = 12.756
c) Central Line = 4.71 and UCL = 12.667
d) Central Line = 4.68 and UCL = 12.046

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 3
Answer: d (Central Line = 4.68 and UCL = 12.046)

• Central Line =
5
𝑖=1 𝑅𝑖 4.8+3.5+3.4+5.4+6.3
𝑅= = = 4.68
𝑛 5
• UCL = 𝐷4 × 𝑅 = 2.574 × 4.68 = 12.046
• Here sample size is 3 so value of 𝐷4 from chart
is 2.574.

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 4
What will be the lower control limit for x-bar chart for
the previous problem?

a) 10.51
b) 20.084
c) 15.296
d) None of these

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 4
Answer: a (10.51)
𝑛
𝑖=1 𝑋𝑖
𝑥= , where n is the number of observations
𝑛
𝑘
𝑖=1 𝑥𝑖
𝑥= , where k is the number of subgroups
𝑘
𝑈𝐶𝐿 = 𝑥 + 𝐴2 × 𝑅
𝐿𝐶𝐿 = 𝑥 − 𝐴2 × 𝑅
By putting the values we will get LCL = 10.51 approximately.

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 5
p Charts calculate the percent defective in a
sample whereas c Charts counts number of
defects in item.

a) True
b) False

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 5
Answer: a (True)

Described in the video lecture

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 6
A ___________ is an attributes control chart used with
data collected in sub groups of varying size. Fill in the
blank with appropriate option.

a) C chart
b) P chart
c) U chart
d) NP chart
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Solution 6
Answer: c (U chart)

A u-chart is an attributes control chart used with

data collected in subgroups of varying sizes. U-
charts show how the process, measured by the
number of nonconformities per item or group of
items, changes over time. Nonconformities are
defects or occurrences found in the sampled
subgroup.

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 7
What is the importance of the capability analysis?

a) Capability analysis determines whether the inherent variability

of the process output fails within the acceptable range of the
variability allowed by the design specifications for the process
output.
b) Capability analysis determines whether the invariability of the
process output fails within the acceptable range of the
variability allowed by the design specifications for the process
output.
c) Both of the above
d) None of the above

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 7
Answer: a
Capability analysis determines whether the
inherent variability of the process output fails
within the acceptable range of the variability
allowed by the design specifications for the
process output.

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 8
Process Capability Analysis differs fundamentally from
control charting because

a) It focuses on improvement not control

b) It focuses on variable not attribute, data involved
c) Capability study address range of individual
outputs
d) All of the above

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 8
Answer: d (All of the above)
Process Capability Analysis differs fundamentally from
control charting because
It focuses on improvement not control
It focuses on variable not attribute, data involved
Capability study address range of individual outputs
Control charting addresses ranges of sample measures

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 9
For a process the upper specification limit is 18.5
and the lower specification limit is 12.5 with a
standard deviation of 0.85. What will be the
process capability ratio of the process for six
sigma process?

a) 1.658
b) 1.724
c) 1.754
d) 1.828

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 9
Answer: b (1.724)
𝑈𝑆𝐿−𝐿𝑆𝐿
Process capability ratio = 𝐶𝑝 = =
6𝜎
18.5−12.5
= 1.724
6×0.85
Here USL = Upper Specification Limit
LSL = Lower Specification Limit

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 10
We are studying two processes for machining a part.
Process A produces parts which have a mean length of
150 and a standard deviation of 3. Process B produces
parts which have a mean length of 155 and standard
deviation of 1. The design specifications for the part are
150±10. Data given is for Z = -3.333 area under the
standard normal curve to the left of Z will be 0.00043.
What will be the value of process capability ratio for
process B and 𝐶𝑝𝑘 for process A?
a) 1.111 and 3.333 respectively
b) 3.333 and 1.111 respectively
c) 3.333 and 1.667 respectively
d) None of these
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Solution 10
Answer: b (3.333 and 1.111 respectively)
𝑈𝑆𝐿−𝐿𝑆𝐿
Process capability ratio for B = 𝐶𝑝 = =
6𝜎
160−140
= 3.333
6×1
𝑈𝑆𝐿 − 𝜇 𝜇 − 𝐿𝑆𝐿
𝐶𝑝𝑘 𝑓𝑜𝑟 𝐴 = min ,
3𝜎 3𝜎
160 − 150 150 − 140
= min , = 1.111
3∗3 3∗3

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 11
Which of the following statements are wrong?
I. Natural variation exceeds design specifications:
process is not capable of meeting specification all
the time.
II. Design specification and natural variations are
same: process is capable of meeting specification
most of the time.

a) Only I
b) Only II
c) Both I and II
d) None of these
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Solution 11
Answer: d (None of these)
Both the statements are correct statements

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 12
What QFD (Quality Function Deployment) do?

a) QFD develop and manufacture towards

measured goals.
b) QFD gives passive reaction to customer
goals.
c) QFD optimises products and processes.
d) None of these

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 12
Answer: a and c
QFD (Quality Function Deployment)
- Listens to e the customer.
- develop and manufacture towards measured
goals.
- optimises products and processes.

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 13
Twenty samples of size 4 are taken from a stable
process. The average means of the sample means
is 42.5, and the average range of the samples is
1.5. What is the UCL for the R-chart?

a) 0.00
b) 3.1725
c) 3.423
d) 43.37

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 13
Answer: c (3.423)
• Average of Ranges of 20 samples =
20
𝑖=1 𝑅
𝑅= = 1.5 ( Central Line for R
20
chart)
• Upper Control Limit of R Chart =
𝐷4 × 𝑅 = 2.282 × 1.5 = 3.423
• (𝐷4 = 2.282 for sample size 4)
Dr. Jitesh J. Thakkar, IIT Kharagpur
 Question 14
What causes design to fail?

a) Not enough basic knowledge at hand when a design

project starts
b) Too little activity in the beginning of the project
c) Bad and/or non existing demand specifications
d) All of these

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 14
Answer: d (All of these)
The following are the causes of designs to fail:
- Not enough basic knowledge at hand when a design
project start
- Corporate Management view is to simplistic
- Too little activity in the beginning of the project
- Unspecified demands and constraints
- Bad and/or non existing demand specifications
- Time is not enough to be thorough
- Unrealistic time frames
- Bad co-operation between marketing/customer design,
engineering and manufacturing

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Question 15
What is the roof of the house of quality in
QFD indicates?

a) Relationship Matrix
b) Co-relationship Matrix
c) Conflict Matrix
d) Target Specification

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Solution 15
Answer: b and c ( Co-relationship Matrix
and Conflict Matrix)

Dr. Jitesh J. Thakkar, IIT Kharagpur

 Dr. Jitesh J. Thakkar, IIT Kharagpur
Thank you