Chapter 4

Statistical Process Control

TRUE/FALSE QUESTIONS

1. SPC involves monitoring the production process to prevent poor quality.

2. SPC is a statistical method for identifying defective items after the product is finished.
3. SPC looks for unusual and unwarranted variability.
4. Traditionally, inspectors at the beginning and end of the production process conducted
inspection.
5. The traditional role of inspection reflected complete confidence in the ability of the supplier to
deliver quality parts.
6. The traditional form of inspection separated the responsibility of detection of quality problems
from those individuals most likely to understand the cause of the problem.
7. With the advent of TQM principles and practices, the traditional role of inspection is even more
critical.
8. Under TQM specifications, inspections are performed at every workstation.
9. If a production process is in control, it will produce exactly identical items, one after another.
10. All production processes have some variability that is acceptable.
11. Random variability in the production process occurs as a result of natural common occurrences.
12. Random variability in the production process occurs from defective materials.
13. Random variability in the production process occurs from operator fatigue.
14. Nonrandom variability can be corrected.
15. SPC is a tool for operators to use for the purpose of making improvements in the production
process.
16. The main purpose of SPC is for a supervisor or manager’s evaluation of the work of a machine
operator.
17. In a TQM environment, a well-trained operator who monitors the production process will always
be able to correct the problem without group help.
18. The quality of a product can be evaluated using a discrete response.
19. The quality of a product can be evaluated using a continuous response.
20. An attribute is a product characteristic that can be evaluated with a discrete response.

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21. An example of an attribute used in quality measurement is length.

22. An example of an attribute used in quality measurement is weight.
23. A variable measure is a product characteristic that can be measured on a continuous scale.
24. An example of a variable measure in testing a light bulb is indicating whether it lights when turned
on.
25. A variable measure typically provides more information about the product than an attribute
measure.
26. R-charts are used for variable measures.
27. P-charts are used for variable measures.
28. Mean control charts are used for variable measures.
29. P-charts use attribute type data.
30. Control charts that measure attributes are visually different from control charts that measure
variables.
31. When a sample average is beyond the control limits on a process control chart, the cause is likely
to be random variation.
32. It is possible for sample observations to be within the control limits yet the process is out of
control.
33. A p-chart is appropriate when the proportion of defective items in a sample cannot be determined.
34. A c-chart uses the number of defective items in a sample.
35. In control limit formulas, z = 3.00 is frequently used.
36. In control limit formulas, z = 3.00 corresponds to a normal probability of 95%.
37. The smaller the value of z, the narrower the control limits.
38. The smaller the value of z, the more sensitive the chart is to changes in the production process.
39. Wider control limits make it easier to detect changes in the process that are not random.
40. A p-chart is based on the binomial distribution.
41. The c-chart is based on the Poisson distribution.
42. The normal distribution can be used to approximate these distributions for the c-chart if the
sample is large enough.
43. The normal distribution can be used to approximate these distributions for the p-chart if the
sample is large enough.
44. An X-bar chart uses the process average of a sample.
45. An R-chart reflects the amount of dispersion in a sample.
46. P-charts and c-charts are typically used together.
47. The X-bar chart and R-chart are typically used together.

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48. The size of samples taken for an X-bar chart tends to be small.
49. The size of samples taken for an X-bar chart is usually 4 or 5.
50. The X-bar chart and R-chart are frequently used together because both the process average and
variability must be in control.
51. When an R-chart exhibits a distinct downward trend in the range values, it means there is more
variation in the process.
52. In order to save time and effort, it is frequently suggested that the R-chart be developed first to
make sure it is in control before developing the X-bar chart.
53. Even though a control chart may indicate that a process is in control, it is possible that the sample
variations within the control limits are not random.
54. If sample values in a control chart "bounce around" above and below the centerline, they are
reflecting natural, random variations.
55. If sample values in a control chart stay considerably above the centerline, but within the control
limits, they are reflecting natural, random variation.
56. A run is a sequence of sample values that display the same characteristic.
57. A pattern test, or run test, calculates the number of observed runs in a control chart.
58. X-bar charts and R-charts require sample sizes in the hundreds.
59. P-charts and c-charts generally use a sample size of 4 or 5.
60. Large sample sizes are needed for attribute type control charts.
61. Variable charts require smaller samples.
62. Some Japanese companies use a sample size of 2 for their quality control charts.
63. The terms "control limits" and "tolerances" can be used interchangeably.
64. It is possible for a process to be in control according to control charts, yet not meet product
tolerances.
65. A process meets design specifications if the natural variability in a process exceeds tolerances.
66. The Cp ratio is a measure used to quantify the capability of the process.
67. The process capability ratio is the ratio of the range of the process variation to the range of the
design specification.
68. If the Cp ratio is less than 1.0, then the process is capable of producing within the design
specifications.
69. The process capability index indicates if the process mean has shifted away from the design
target.
70. When Cp equals Cpk, this indicates that the process mean is centered on the design target.
71. Product design qualifications that are twice as large as the natural are known as "6-sigma"

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quality.
72. TQM adherents believe "ppm" does not predict quality accurately enough and, therefore, prefer
the use of "% or probability" to measure quality.
73. A service defect is a failure to meet customer requirements.
74. Quality measurements for customer satisfaction can be determined only by inspection.
75. A process is considered to be in control if and only if the sample means are near the process
average.
76. With a p-chart, a sample is taken periodically from the production processes and the proportion of
defective items in the sample is determined to see if the proportion falls within the control limits.
77. The lower control limit for the p-chart is given by LCL = p + Zp.
78. An estimate of p-bar can be found by dividing the total number of defects by the total sample of
observations.
79. The process average c-bar in the c-chart is found by dividing the total number of defects by the
number of samples.
80. In order to perform the pattern test, we must identify the runs that exist in the sample data.
81. SPC is a tool for identifying problems.
82. SPC is a tool for making improvements.
83. An attribute is a product characteristic such as color.
84. Control charts cannot be applied to services.
85. Control charts are graphs that visually show if a sample is within statistical control limits.
86. If a process is out of control, the cause should be identified.
87. The X-bar and R-chart measure the process differently.
88. A pattern test determines if the observations within the limits of a control chart display a
nonrandom pattern.
89. Tolerances are design specifications reflecting product requirements.
90. Tolerances determine the natural capability of the process.
91. Design tolerances have a statistical link to the natural limits of the control chart.
92. Number of defective parts per million (PPM) has become the international measure of quality.
93. All processes have variability.
94. Eight consecutive points on one side of the centerline is one general guideline used for identifying
a pattern on a control chart.
95. Tolerances are product design specifications required by the customers.

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MULTIPLE CHOICE QUESTIONS

96. Which of the following statements concerning statistical process control is true?
a) SPC involves taking one random sample to determine if a lot is acceptable.
b) SPC is used extensively in the U.S., but acceptance has been slow in Japan.
c) SPC is an approach that directly conflicts with TQM.
d) SPC is a tool used to prevent poor quality.
(moderate)

97. Traditionally, the inspection process was used

a) to correct process flaws
b) only to identify defects in the finished products
c) to keep track of an employee's work
d) to provide continuous improvement in the product
(moderate)

98. Within the TQM philosophy, which of the following can cause the process to be declared "out-of-
control"?
a) operator fatigue
b) a faulty measuring process
c) malfunctioning machinery
d) all of the above
(moderate)

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99. Which of the following is identified as a random cause of poor quality?

a) errors due to lack of training
b) variability resulting from natural, common occurrences
c) equipment which is out of adjustment
d) defective raw materials
(moderate)

100. Fifteen samples, each of size 50, were randomly drawn from a production line to produce a p-
chart. The total number of defects found in these samples was 60. The estimate of the average
proportion defective is
a) .06
b) .08
c) 1.2
d) none of the above
(moderate)

101. From a p-chart where 20 samples were taken, each of size 50, the estimate of the average
proportion defective is .05. For this data, the estimate of the standard deviation for sample
proportion defective is
a) .001
b) .031
c) .049
d) none of the above
(moderate)

102. A p-chart has been prepared. Computations show that the average proportion defective is .032,
while the standard deviation is .0176. From this data, what are the 3-sigma control limits for this
chart?
a) LCL = .032 UCL = .085
b) LCL = .053 UCL = .032
c) LCL = 0 UCL = .085
d) not enough information to determine the control limits
(moderate)

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103. A p-chart has been prepared. Computations show that the average proportion defective is .051,
while the standard deviation is .022. From this data, what are the 3-sigma control limits for this
chart?
a) LCL = .051 UCL = .117
b) LCL = .066 UCL = .051
c) LCL = 0 UCL = .117
d) none of the above
(moderate)

104. On a p-chart, there is a definite trend upward (i.e., the p-values are increasing). Therefore, we
can conclude
a) the process is in control
b) the process shows a problem that should be investigated
c) the process is out of control
d) more data must be gathered to make a conclusion
(moderate)

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105. The measure used to produce a c-chart is

a) proportion of defective items in a sample
b) the number of defective units in a sample
c) the number of defects found in the sample
d) percentage of defects found in the population
(easy)

106. For a c-chart, a defect is

a) any scratch, nick, or other blemish that makes the item less desirable
b) only the defects that make the item unusable
c) only the defects that cannot be repaired
d) only the defects that can be repaired
(moderate)

107. C-chart statistics are based on

a) the binomial distribution
b) the exponential density function
c) the Poisson distribution
d) none of the above
(easy)

108. Typically, the control limits of a c-chart represent sigma limits

a) 2
b) 3
c) 4
d) 6
(easy)

Table 15.1
The data represented below are the results of inspections of 10 batches of lamps (4 lamps per batch).
The inspections identified the number of nicks, scratches, and other blemishes within a batch.

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 Sample 1 2 3 4 5 6 7 8 9 10
#
c-value 8 12 6 3 10 12 8 15 5 8

109. Using the data in Table 15.1, what is the average number of defects per 4 lamps that the process
is experiencing?
a) 8.7
b) 87
c) 21.75
d) none of the above
(easy)

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110. Using the data in Table 15.1, what is the standard deviation for the number of defects per 4 lamps
that the process is experiencing?
a) 2.95
b) 9.32
c) 87
d) none of the above
(easy)

111. Using the data in Table 15.1, what is the upper control limit for the 3-sigma control limits for the
number of defects per 4 lamps that the process is experiencing?
a) 11.65
b) 17.55
c) 25.00
d none of the above
(moderate)

112. Using the data in Table 15.1, what is the lower control limit for the 3-sigma control limits for the
number of defects per 4 lamps that the process is experiencing?
a) -0.15
b) 0.00
c) 2.95
d) none of the above
(moderate)

113. The X-bar chart is based on which distribution?

a) normal density function
b) binomial distribution
c) the Poisson distribution
d) none of the above
(moderate)

114. Typically, the control limits of an X-bar chart represent _____ sigma limits.
a) 2
b) 3

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 c) 4
d) 6
(easy)

115. When developing an X-bar chart, the value plotted is

a) the average of the sample
b) all the sample observations
c) the difference between the largest and smallest value in the sample
d) the largest value in each sample
(easy)

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116. When developing a range-chart, the value plotted is

a) the average of all the observations in the sample
b) the largest value in the sample
c) the difference between the largest and smallest values in the sample
d) the average of the largest and smallest values in the sample
(easy)

Table 15.2

Factors for Determining Control

Limits

Sample A2 D3 D4
size
2 1.88 0 3.27
3 1.02 0 2.57
4 0.73 0 2.28
5 0.58 0 2.11
6 0.48 0 2.00
7 0.42 0.88 1.92
8 0.37 0.14 1.86
9 0.34 0.18 1.82
10 0.31 0.22 1.78

117. A manufacturing company uses a production process that mills components to an average
thickness of .005 inch, with an average range of .0015 inch. Using samples of size 3, what is the
upper control limit on the X-bar chart?
a) .0015
b) .005
c) .007
d) none of the above
(moderate)

118. A manufacturing company uses a production process that mills components to an average
thickness of .005 inch, with an average range of .0015 inch. Using samples of size 3, what is the
lower control limit on the X-bar chart?

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 a) .003
b) .005
c) .006
d) none of the above
(moderate)

119. Four samples of size 5 were taken from a process. The average range value was .1625. What is
the upper control limit on the R-chart?
a) .343
b) .371
c) .650
d) none of the above
(moderate)

120. Four samples of size 5 were taken from a process. The average range value was .1625. What is
the lower control limit on the R-chart?
a) -0.180
b) 0.00
c) .1625
d) none of the above
(moderate)

121. Five samples of size 4 were taken from a process. The average range value was 2.3520. What is
the upper control limit on the R-chart?
a) 3.740
b) 4.963
c) 5.363
d) none of the above
(moderate)

122. Five samples of size 4 were taken from a process. The average range value was 2.3520. What is
the lower control limit on the R-chart?
a) 0.000
b) 0.964

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c) 9.336
d) none of the above
(moderate)

123. Five samples of size 4 were taken from a process. The average of the range value was 2.352.
The average of the sample means was 19.64. Using the X-bar chart together with an R-chart,
what is the upper control limit of the X-bar chart?
a) 21.004
b) 21.357
c) 33.721
d) none of the above
(moderate)

124. Five samples of size 4 were taken from a process. The average of the range value was 2.352.
The average of the sample means was 19.64. Using the X-bar chart together with an R-chart,
what is the lower control limit of the X-bar chart?
a) 17.923
b) 18.276
c) 21.004
d) none of the above
(moderate)

125. Which of the following would not indicate an out-of-control process?

a) values consistently above the center line
b) values that move in an upward trend
c) values that "bounce around" above and below the center line
d) values that move in a downward trend
(moderate)

126. Given 24 samples with the total number of nonconformities being 472, compute the mean number
of nonconformities:
a) c-bar = 24
b) c-bar = 19.67
c) c-bar = 472

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 d) none of the above
(easy)

127. Given 24 samples with the number of nonconformities being 472, compute the upper control limit
for the c-chart.
a) 24
b) 32.97
c) 472
d) none of the above
(moderate)

128. Given 24 samples with the total number of nonconformities being 472, compute the center line of
the c chart.
a) 19.67
b) 24
c) 472
d) none of the above
(easy)

129. Given 24 samples with the total number of nonconformities being 472, compute the lower control
limit for the c-chart.
a) 6.36
b) 24
c) 472
d) none of the above
(moderate)

130. Given a sample size of 50 for thirty groups with the total number of nonconformities being 347,
compute the fraction nonconforming.
a) .315
b) 9.44
c) 15.73
d) none of the above
(easy)

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131. Given a sample size of 50 for thirty groups with the total number of nonconformities being 347,
compute the standard deviation of the sample proportion defective.
a) .003
b) .004
c) .060
d) none of the above
(moderate)

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132. Given a sample size of 50 for thirty groups with the total number of nonconformities being 347, for
a p-bar chart, compute the upper control limit at 3-sigma limits.
a) .24
b) .25
c) .41
d) none of the above
(moderate)

133. Given a sample size of 50 for thirty groups with the total number of nonconformities being 347,
for a p-bar chart, compute the lower upper control limit at 3-sigma limits.
a) .05
b) .22
c) .23
d) none of the above
(moderate)

134. Which ratio is a measure of process capability that indicates that the process mean has shifted
away from the design target?
a) Cp
b) Cpk
c) CR
d) none of the above
(moderate)

135. If a process has a Cp of 2.04, and a Cpk of .91, then the process
a) is acceptable, and no action is necessary
b) mean is off center, and corrective action should be taken
c) is not capable of producing within the design specifications
d) none of the above
(moderate)

136. If a process has a Cp of .87, and a Cpk of .75, then the process
a) is acceptable, and no action is necessary
b) mean is off center, and corrective action should be taken to produce the desired quality

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c) is not capable of producing within the design specifications

d) none of the above
(moderate)

137. If a process has a Cp of .1.89, and a Cpk of 1.54, then the process
a) is acceptable, and no action is necessary
b) mean is off center, and corrective action should be taken to produce the desired quality
c) is not capable of producing within the design specifications
d) none of the above
(moderate)

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138. A part has a length specification of 2 inches with tolerances of + .03 inches. The current process
has an average length of 2.01 inches with a standard deviation of .02 inches. What is the value
of the Cp ratio?
a) .05
b) .333
c) .50
d) 1.00
(moderate)

139. A part has a length specification of 2 inches with tolerances of + .03 inches. The current process
has an average length of 2.01 inches with a standard deviation of .02 inches. What is the value
of the Cpk ratio?
a) .167
b) .333
c) .500
d) 1.333
(moderate)

PROBLEMS

140. XYZ Corporation uses statistical quality control to monitor the quality of their product. They have
determined the process average, representing the population proportion defective, is .02, and
size of the samples is 100 units.
a) In constructing a p-chart using 3-sigma limits, what is the UCL?
b) In constructing a p-chart using 3-sigma limits, what is the LCL?
c) Discuss what would happen if one of the sample values is .085.
d) Discuss what would happen if one of the sample values is .01.

141. ABC Corporation has been using statistical process control for several months. Their sampling
plan calls for a sample size of 100 and the most recent five samples have found the number of
defects to be 3, 18, 25, 11, and 15. The population proportion defective is unknown.
a) In constructing a p-chart for 3-sigma limits, what is the UCL?
b) In constructing a p-chart for 3-sigma limits, what is the LCL?

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c) What do you observe about the process based on the most recent five samples?

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Table 15.3

Sampl # Sampl #
e Defective e Defective
1 19 9 37
2 22 10 38
3 26 11 44
4 23 12 32
5 30 13 43
6 28 14 39
7 36 15 41
8 39

142. The data in Table 15.3 represent the number of defects detected in a series of 15 samples taken
from the production of lamps. Each sample contained 4 lamps.
a) What is the estimate of the average number of defects per 4 lamps?
b) What is the estimate of the variance?
c) Using 3-sigma limits, what is the UCL for the c-chart?
d) Using 3-sigma limits, what is the LCL for the c-chart?
e) For this c-chart, what conclusion can be drawn?

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Table 15.4

Sampl # Sample #
e Defective Defective
1 26 9 6
2 23 10 2
3 32 11 5
4 35 12 16
5 25 13 5
6 32 14 9
7 20 15 12
8 0

143. The data in Table 15.4 represent the number of defects detected in a series of 15 samples. Each
sample contained 4 units.
a) What is the estimate of the average number of defects per sample?
b) What is the estimate of the variance?
c) Using 3-sigma limits, what is the UCL for the c-chart?
d) Using 3-sigma limits, what is the LCL for the c-chart?
e) For this c-chart, what conclusion can be drawn?

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Table 15.5

Sampl # Defect Sampl # Defect

e e
1 27 9 26
2 23 10 21
3 26 11 23
4 25 12 32
5 17 13 19
6 22 14 25
7 17 15 18
8 26

144. The data in Table 15.5 represent the number of defects detected in a series of 15 samples. Each
sample contained 4 units.
a) What is the estimate of the average number of defects per sample?
b) What is the estimate of the variance?
c) Using 3-sigma limits, what is the UCL for the c-chart?
d) Using 3-sigma limits, what is the LCL for the c-chart?
e) For this c-chart, what conclusion can be drawn?

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Table 15.6

Sampl Mean Range

e
1 10.47 3.26
2 10.74 6.09
3 11.24 2.39
4 9.14 2.84
5 9.37 3.74
6 8.59 2.22
7 10.27 2.03
8 8.92 3.35
9 11.34 .18
10 8.40 1.47

145. The data shown in Table 15.6 are for ten samples of size 3, and represent measurements of a
vital part measured in centimeters. The company uses this data to develop a 3-sgima X-bar chart
in conjunction with an R-chart.
a) What is the average of the sample means?
b) What is the estimate of the average variation in the samples?
c) For the X-bar chart, what is the UCL?
d) For the X-bar chart, what is the LCL?
e) For the R-chart, what is the UCL?
f) For the R-chart, what is the LCL?
g) What conclusions can be drawn from the two charts?

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Table 15.7

Sampl Mean Range

e
1 8.58 5.06
2 11.52 2.85
3 8.70 7.38
4 11.26 2.81
5 6.94 5.06
6 10.38 3.09
7 9.71 2.53
8 10.65 4.85
9 7.65 2.44
10 8.64 1.83

146. The data shown in Table 15.7 are for ten samples of size 3 and represent measurements of a
vital part measured in centimeters. The company uses this data to develop a 3-sigma X-bar chart
in conjunction with an R-chart.
a) What is the average of the sample means?
b) What is the estimate of the average variation in the samples?
c) For the X-bar chart, what is the UCL?
d) For the X-bar chart, what is the LCL?
e) For the R-chart, what is the UCL?
f) For the R-chart, what is the LCL?
g) What conclusions can be drawn from the two charts?

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Table 15.8

Sampl Mean Range

e
1 11.3 5.00
2 12.8 2.00
3 14.3 1.00
4 13.0 7.00
5 11.0 3.00
6 13.7 5.00
7 11.7 4.00
8 10.7 5.00
9 11.7 1.00
10 12.3 8.00
11 11.0 8.00
12 12.3 4.00

147. The data shown in Table 15.8 are for twelve samples of size 3 and represent measurements of a
vital part measured in centimeters. The company uses this data to develop a 3-sigma X-bar chart
in conjunction with an R-chart.
a) What is the average of the sample means?
b) What is the estimate of the average variation in the samples?
c) For the X-bar chart, what is the UCL?
d) For the X-bar chart, what is the LCL?
e) For the R-chart, what is the UCL?
f) For the R-chart, what is the LCL?
g) What conclusions can be drawn from the two charts?

148. A production was sampled over a period of 28 days. Each day 50 items were sampled from the
production. There were 407 items that were defective.
a) Estimate the process defective.
b) Estimate the standard deviation of the process defective.
c) What is the upper control limit for the p-chart?
d) What is the lower control limit for the p-chart?

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149. An inspection of a process is made 20 times, and the number of defects found in the inspections
was 128.
a) What is the value of c-bar?
b) What is the upper control limit for the c-bar chart?
c) What is the lower control limit for the c-bar chart?

150. A part has a length specification of 5 inches with tolerances of + .004 inches. The current
process has an average length of 5.001 inches with a standard deviation of .001 inches.
Calculate the Cp and Cpk for this process. Indicate the capability of the current process.

151. A process produces resistor that have a target value of 100 ohms. The tolerances call for + 1
ohm. Currently the process is producing resistors with a mean value of 100.5 ohms, and a
standard deviation of 1 ohm. Calculate the Cp and Cpk for this process. Indicate the capability of
the current process.

SHORT-ANSWER QUESTIONS

152. What does statistical process control do?

153. What is an attribute?

154. What is a variable measure?

155. Define a service defect.

156. What is a control chart?

157. Why are the X-bar and R-chart used together?

158. Why do people look for patterns on a control chart?

159. What are tolerances?

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160. What is process capability?

161. What measure of quality are companies using TQM adopting?

162. Explain the different types of variability that processes exhibit.

163. What is the difference between process capability and tolerances?

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