IM602

RAMAIAH USN 1 M S
INSTITUTE OF
TECHNOLOGY

(Autonomous Institute, Affiliated to VTU)

Bangalore – 560 054

MAKEUP EXAMINATIONS – MAY/JUNE 2017

Course & Branch : B.E. : Industrial Engineering and Mgmt Semester : VI
Subject : Quality Assurance and Reliability Max. Marks : 100
Subject Code : IM602 Duration : 3 Hrs

Instructions to the Candidates:

 Answer one full question from each unit.
 Use of statistical table permitted.

UNIT- I
1. a) Describe the various meanings given to the word “Quality’ and discuss CO1 (10)
the quality function through Juran’s spiral of quality
b) Discuss the eight components or dimensions of quality provided by CO1 (10)
Garvin

2. a) Explain with relevant examples the four categories of quality costs. CO1 (10)
b) Distinguish between sporadic and chronic quality problems with a CO1 (05)
diagram
c) Enlighten briefly five ingredients of a quality audit program CO1 (05)

UNIT- II
3. a) What are chance and assignable causes of variability? CO2 (06)
b) The following are the X - R values of 20 subgroups of 5 readings. CO2 (14)
Sub X R Sub X R
group group
No. No.
1 34.0 4 11 38.4 4
2 31.6 2 12 34.0 14
3 30.8 3 13 35.0 4
4 33.8 5 14 33.8 7
5 31.6 2 15 31.6 5
6 33.0 5 16 33.0 7
7 28.2 13 17 32.6 3
8 33.8 19 18 31.8 9
9 37.8 6 19 35.6 6
10 35.8 4 20 33.0 4

i. Determine trial control limits for the X bar and R charts.

ii. Construct the X bar and R chart and interpret the result
iii. What is process capability
iv. Does it appear that the process is capable of meeting the
specification limits.
v. Determine the percentage of rejections if any. The specification
limits are = 33±5

4. a) Explain the principle of rational sub groups. CO2 (05)

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 IM602
b) A certain product has a specification of 120.0 ± 5.0 At present the CO2 (15)
estimated process average is 120.0 and the Standard deviation is 1.5.
i. Compute 3  control limits for X and R charts based on a sub
group size of 4.
ii. Estimate the percentage of products that fail to meet the
specification if there is a shift in the process average by 2%
iii. What is the probability of detecting the shift by X bar chart

UNIT- III
5. a) Differentiate between X chart and P chart. CO3 (06)
b) Why an np chart is not recommended when the subgroup size is CO3 (04)
variable.
c) An electrical items manufacturer requires that 100% inspection be made CO3 (10)
during the first 6 months of production on any new or revised part. A
total of 600 items were found to be defective in the first 50 lots of a
new item, manufactured in lots of 300.
(i) Compute the trail 3σ limits of control for an np chart for this process.
(ii) If the process average unchanged, what is the probability that the
51st lot will have more 14 defective items.
(iii)If the process average increases by 3, what is the probability that
the 51st lot will exceed the original upper control limits.

6. a) Explain the construction and application of the following: CO3 (10)

(i) Modified control charts.
(ii) CUSUM charts.
b) A textile manufacturer initiates the use of C-chart to monitor the CO3 (10)
number of imperfections found in a bale of cloth. Each is of the same
length, width and fiber composition. A total 191 imperfections were
found in the last 25 bales inspected. The f our highest and lowest counts
were as follows.
Highest Lowest
22 4
19 4
14 5
12 5
(i) Calculate in 3σ control limits.
(ii)Is the process in control?
(iii)If not, what aimed at value of C' and control limits would you
suggest for the future period.

UNIT- IV
7. a) Explain the following with respect to OC curve: CO4 (08)
i) AQL ii) LTPD iii) Producer’s risk iv) Consumer’s risk.

b) A single sampling plan uses the follows N = 5000 n= 80, C = 2 CO4 (12)
i. Construct the OC curve for the plan. (assume p’ values)
ii. What is the Producer’s Risk if AQL is 1.5%.
iii. What is the consumer’s Risk if LTPD is 4.5%.
iv. Find ATI when a large number of 1.25% defective lots are
submitted with Acceptance / rectification plan.

8. a) Draw a flow chart for double sampling plan. CO4 (04)

b) A double sampling plan is as follows: CO4 (16)
N = 4000
n1 = 100 c1 = 1 r1 = 4

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 IM602
n2 = 150 c2 = 7 r2 = 8
p’ = 1.25% defective
Calculate i) Pa, ii) ATI, iii) AOQ with and without rectification iv) ASN.

UNIT- V
9. a) Seven wires are twisted together to make a wire of larger dimension. If CO5 (08)
the standard deviation of the dimension of the wire of each component
wire is 0.0125. What is the standard deviation of the diameter of the
completed wire.
b) An assembly of shafts and bearings are made out of the shafts CO5 (12)
manufactured to a Specification of 40 ± 0.09 mm and the bearings
manufactured to a specification of 40.1 ± 0.1 mm. If the manufacturing
process is dually controlled and are capable of meeting specification.
i) Find the probability of clearance of bearings greater than 0.2 mm
ii)What is the mean clearance to be maintained between two mating
parts, if it is desired that the probability of interference be 0.005.

10. a) The MTBF of a certain unit is 50 hours. Calculate their liability of the unit CO5 (08)
for 75 hours of operation. If the reliability of the unit is to be increased
by 10%, 20%, 30% 40% and 50% Calculate.
i) The corresponding % changes in the MTBF that is necessary.
ii) Plot a graph, % changes in reliability Vs % change in MTBF.
b) A cassette player has got 4 subsystems namely, spool changing system, CO5 (06)
magnification pickup head, amplification & sound systems and other
systems. For a satisfactory performance of a cassette player all the 4
subsystems well. The MTBF of the various subsystems are

Spool changing system = 2000 hrs

Magnification pickup head = 2500 hrs
Amplification & sound systems = 4000 hrs
Other systems = 3000 hrs
Calculate the reliability of the cassette player for 1500 hrs reception
time and what is the MTBF of a cassette player?
c) In a re-rolling mill, two blowers are connected to reheat the furnace CO5 (06)
using pulverized coal. One of the blowers is standby equipment. The
blower system includes – stator, motor, coupling and the blower which
have their reliabilities of 0.9, 0.92, 0.85, 0.95 respectively. The
pulverized coal system has a reliability of 0.99 and the furnace 0.95, all
over an operating period of 150 hours. Draw the system configuration
and determine the reliability of the total system for 150 hrs of
operations.

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