IPE-3714 Quality Management Sessional

An Experiment on Development of a Control Chart.

Experiment No: 01

Submitted To
Hasina Tabassum Chowdhury
Assistant Professor, IPE

Prithbey Raj Dey

Assistant Professor, IPE

Submitted by
Md. Nazrul Islam
Std. ID: 167019
Year/Semester: 3/2

Department of Industrial and Production Engineering

Dhaka University of Engineering and Technology, Gazipur
Objectives:
1) To study and develop a control chart.
2) To learn how to find out the value of X and R
3) To gather knowledge about 6σ and it’s apply.
4) To analyze the quality control by 6σ.

Equations:
1. Calculate upper control limit and lower control limit for X chart:

UCL X = X + A2 R (see table for A2 values of appropriate subgroup sizes)

LCL X = X – A2 R

2. Calculate upper control limit and lower control limit for R chart:

UCLR = D4 R (see table for D4 and D3 values of appropriate subgroup sizes)

LCLR = D3 R

Data Calculations and Results:

A1: A soft drink is sold in bottles marked 325 ml. An automatic machine fills the bottles.
Samples of 5 bottles taken every 15 minutes of production during the first shift produced the
results shown in below. The measurement x is the number of milliliters over 300. The range
is in milliliters. Show that whether the process is in control or not by X -R charts.

Table 01: Data table for soft drink.

Sample X Sample X Range
Range number
number
1 29.0 11 16 23.8 4

2 25.0 8 17 27.0 5

3 26.0 5 18 28.4 3

4 25.2 5 19 25.4 7
 5 25.4 3 20 26.2 6

6 28.0 4 21 27.0 5

7 26.0 5 22 26.0 5

8 27.0 4 23 28.0 3

9 24.8 7 24 26.4 6

10 21.4 4 25 27.3 4

11 23.9 3 26 24.0 4

12 24.1 5 27 22.6 2

13 27.0 4 28 28.0 6

14 26.8 6 29 24.4 5

15 26.4 2 30 26.4 3

Table 02: Data table for R chart.

Sample
Range R Bar UCL LCL
number
1 11 4.80 10.13 0.00
2 8 4.80 10.13 0.00
3 5 4.80 10.13 0.00
4 5 4.80 10.13 0.00
5 3 4.80 10.13 0.00
6 4 4.80 10.13 0.00
7 5 4.80 10.13 0.00
8 4 4.80 10.13 0.00
9 7 4.80 10.13 0.00
10 4 4.80 10.13 0.00
11 3 4.80 10.13 0.00
12 5 4.80 10.13 0.00
13 4 4.80 10.13 0.00
14 6 4.80 10.13 0.00
15 2 4.80 10.13 0.00
16 4 4.80 10.13 0.00
17 5 4.80 10.13 0.00
18 3 4.80 10.13 0.00
19 7 4.80 10.13 0.00
20 6 4.80 10.13 0.00
21 5 4.80 10.13 0.00
22 5 4.80 10.13 0.00
23 3 4.80 10.13 0.00
 24 6 4.80 10.13 0.00
25 4 4.80 10.13 0.00
26 4 4.80 10.13 0.00
27 2 4.80 10.13 0.00
28 6 4.80 10.13 0.00
29 5 4.80 10.13 0.00
30 3 4.80 10.13 0.00

12

10 UCL

6
Range

0
LCL
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Range R Bar UCL LCL

Sample
Number
Graph 01: R-bar Chart
Table 03: Modified R-Chart Data table

Sample number Range R Bar UCL LCL

2 8 4.58 9.68 0.00

3 5 4.58 9.68 0.00
4 5 4.58 9.68 0.00
5 3 4.58 9.68 0.00
6 4 4.58 9.68 0.00
7 5 4.58 9.68 0.00
8 4 4.58 9.68 0.00
9 7 4.58 9.68 0.00
 10 4 4.58 9.68 0.00
11 3 4.586 9.68 0.00
12 5 4.58 9.68 0.00
13 4 4.58 9.68 0.00
14 6 4.58 9.68 0.00
15 2 4.58 9.68 0.00
16 4 4.58 9.68 0.00
17 5 4.58 9.68 0.00
18 3 4.58 9.68 0.00
19 7 4.58 9.68 0.00
20 6 4.58 9.68 0.00
21 5 4.58 9.68 0.00
22 5 4.58 9.68 0.00
23 3 4.58 9.68 0.00
24 6 4.58 9.68 0.00
25 4 4.58 9.68 0.00
26 4 4.58 9.68 0.00
27 2 4.58 9.68 0.00
28 6 4.58 9.68 0.00
29 5 4.58 9.68 0.00
30 3 4.58 9.68 0.00

12

10
UCL
8

6
Range

0 LCL
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Range R Bar UCL LCL

Sample Number

Graph 02: Modified R-bar Chart

Table 04: Data Table for X-bar chart

Sample Number X-Bar X dbar UCL LCL

1 29 25.897 28.66 23.12

2 25 25.897 28.66 23.12
3 26 25.897 28.66 23.12
4 25.2 25.897 28.66 23.12
5 25.4 25.897 28.66 23.12
6 28 25.897 28.66 23.12
7 26 25.897 28.66 23.12
8 27 25.897 28.66 23.12
9 24.8 25.897 28.66 23.12
10 21.4 25.897 28.66 23.12
11 23.9 25.897 28.66 23.12
12 24.1 25.897 28.66 23.12
13 27 25.897 28.66 23.12
14 26.8 25.897 28.66 23.12
15 26.4 25.897 28.66 23.12
16 23.8 25.897 28.66 23.12
17 27 25.897 28.66 23.12
18 28.4 25.897 28.66 23.12
19 25.4 25.897 28.66 23.12
20 26.2 25.897 28.66 23.12
21 27 25.897 28.66 23.12
22 26 25.897 28.66 23.12
23 28 25.897 28.66 23.12
24 26.4 25.897 28.66 23.12
25 27.3 25.897 28.66 23.12
26 24 25.897 28.66 23.12
27 22.6 25.897 28.66 23.12
28 28 25.897 28.66 23.12
29 24.4 25.897 28.66 23.12
30 26.4 25.897 28.543 23.12
 30

29
UCL
28

27

26

25
X-Bar

24
LCL
23

22

21

20
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031

X-Bar X dbar UCL LCL

Sample Number

Graph 03: X-bar chart

Table 05: Data table for modified X-bar chart

Sample
X-Bar X dbar UCL LCL
Number
2 25 25.79 28.43 23.14
3 26 25.79 28.43 23.14
4 25.2 25.79 28.43 23.14
5 25.4 25.79 28.43 23.14
6 28 25.79 28.43 23.14
7 26 25.79 28.43 23.14
8 27 25.79 28.43 23.14
9 24.8 25.79 28.43 23.14
11 23.9 25.79 28.43 23.14
12 24.1 25.79 28.43 23.14
13 27 25.79 28.43 23.14
14 26.8 25.79 28.43 23.14
15 26.4 25.79 28.43 23.14
16 23.8 25.79 28.43 23.14
17 27 25.79 28.43 23.14
 18 28.4 25.79 28.43 23.14
19 25.4 25.79 28.43 23.14
20 26.2 25.79 28.43 23.14
21 27 25.79 28.43 23.14
22 26 25.79 28.43 23.14
23 28 25.79 28.43 23.14
24 26.4 25.79 28.43 23.14
25 27.3 25.79 28.43 23.14
26 24 25.79 28.43 23.14
28 28 25.79 28.43 23.14
29 24.4 25.79 28.43 23.14
30 26.4 25.79 28.43 23.14

30

29

28

27

26

25
X-bar

24

23

22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

X-Bar X dbar UCL LCL

Sample Number

Graph 04: Modified X-bar chart

A2: A cable insulation manufacturing company wants to monitor the diameter of cable
insulators. During the base period 25 samples are observed the sample size is 4. The
measurements of individual diameters are as follows:

X1 X2 X3 X4 X BAR RANGE

4.9 4.8 5.1 5.4 5.05 0.6

5 5.8 5.3 5.3 5.35 0.8

4.4 4.7 4.8 4.6 4.625 0.4

 4.6 5.8 5.4 4.9 5.175 1.2

5.2 5.3 6.1 5.2 5.45 0.9

5 5.9 5.8 4.8 5.375 1.1

4.3 4.6 4.7 4.5 4.525 0.4

4.9 4.9 5.5 5.7 5.25 0.8

5.9 6.4 6.1 6.5 6.225 0.6

5.3 5.9 6.1 4.8 5.525 1.3

4.6 4.6 5.3 5 4.875 0.7

5.3 5.8 5.4 5.1 5.4 0.7

4.9 5.3 5.2 5.7 5.275 0.8

5.2 5.4 4.6 5.5 5.175 0.9

5.4 4.8 4.4 5.1 4.925 1

4.6 4.4 4.9 5.1 4.75 0.7

5.7 5.4 5 4.8 5.225 0.9

5.1 4.3 5.7 5.8 5.225 1.5

5.9 6.4 6.2 6.1 6.15 0.5

5 5.1 4.5 4.8 4.85 0.6

4.9 5.9 5.3 5.2 5.325 1

5.4 5.9 4.4 5 5.175 1.5

5.2 4.7 5.7 5.8 5.35 1.1

4 4.8 5.1 5.8 4.925 1.8

5.3 5.8 6 6.3 5.85 1

Table 06: Data Table for R-bar chart

Sample
RANGE R-Bar UCL LCL
Number
1 0.6 0.912 2.07936 0.00
2 0.8 0.912 2.07936 0.00
3 0.4 0.912 2.07936 0.00
4 1.2 0.912 2.07936 0.00
5 0.9 0.912 2.07936 0.00
6 1.1 0.912 2.07936 0.00
7 0.4 0.912 2.07936 0.00
8 0.8 0.912 2.07936 0.00
 9 0.6 0.912 2.07936 0.00
10 1.3 0.912 2.07936 0.00
11 0.7 0.912 2.07936 0.00
12 0.7 0.912 2.07936 0.00
13 0.8 0.912 2.07936 0.00
14 0.9 0.912 2.07936 0.00
15 1 0.912 2.07936 0.00
16 0.7 0.912 2.07936 0.00
17 0.9 0.912 2.07936 0.00
18 1.5 0.912 2.07936 0.00
19 0.5 0.912 2.07936 0.00
20 0.6 0.912 2.07936 0.00
21 1 0.912 2.07936 0.00
22 1.5 0.912 2.07936 0.00
23 1.1 0.912 2.07936 0.00
24 1.8 0.912 2.07936 0.00
25 1 0.912 2.07936 0.00

2.5

2
UCL

1.5

1
Range

0.5

0 UCL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
RANGE R-Bar UCL LCL

Sample Number

Graph 05: R-Bar chart

Table 07: Data table for X-bar chart
Sample
X BAR X-Dbar UCL LCL
Number
1 5.05 5.24 7.32 3.16
2 5.35 5.24 7.32 3.16
3 4.625 5.24 7.32 3.16
 4 5.175 5.24 7.32 3.16
5 5.45 5.24 7.32 3.16
6 5.375 5.24 7.32 3.16
7 4.525 5.24 7.32 3.16
8 5.25 5.24 7.32 3.16
9 6.225 5.24 7.32 3.16
10 5.525 5.24 7.32 3.16
11 4.875 5.24 7.32 3.16
12 5.4 5.24 7.32 3.16
13 5.275 5.24 7.32 3.16
14 5.175 5.24 7.32 3.16
15 4.925 5.24 7.32 3.16
16 4.75 5.24 7.32 3.16
17 5.225 5.24 7.32 3.16
18 5.225 5.24 7.32 3.16
19 6.15 5.24 7.32 3.16
20 4.85 5.24 7.32 3.16
21 5.325 5.24 7.32 3.16
22 5.175 5.24 7.32 3.16
23 5.35 5.24 7.32 3.16
24 4.925 5.24 7.32 3.16
25 5.85 5.24 7.32 3.16

8
7.5
UCL
7
6.5
6
5.5
5
4.5
X-Bar

4
3.5
LCL
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
X BAR X-Dbar UCL LCL

Sample Number

Graph 06: X-bar chart

Discussion and Results:

For problem A1: During this experiment problem, the upper control limit (UCL) and lower
control limit (LCL) was out of control chart (R bar chart graph-01). For solving this problem,
higher sample number is removed, that’s why the chart is controllable. Hence, the X-bar chart
is depends on the R-bar chart. When the X-bar chart is performed then there was problem
because of having some sample size were not accepted (i.e. graph-03).The evaluation of X-
bar chart and R-bar chart we can see in the graph-04. Finally the R-bar and X-bar chart is
controlled respectively.

For problem A2: Firstly, the range and average is calculated from four sample size into 25
sample number. Then, R-bar, UCL, LCL is calculated respectively. Hence, the R-bar control
chart has been drawn carefully by using excel spreadsheet. Again, X-bar, X-double bar, UCL,
LCL is calculated respectively. But there was no out of sample size. That’s why, there has no
sample is removed. Finally, the control chart has been ready. Therefore, many assumptions
and knowledge has been gathered.