Statistical Quality Control

Montgomery’s 6th edition

Solutions for Chapter 06
Jan Rohlén
jan.rohlen@hb.se

Question 6.04

Sample No. Ri Xi
1 9 10
2 7 7.75
3 5 7.5
4 7 9
5 6 9.75
6 2 10.75
7 8 10.75
8 6 6.5
9 5 9
10 6 13.5
11 8 12.5
12 7 9.75
13 7 13.25
14 6 10.5
15 9 11
16 5 12.5
17 4 9.75
18 8 10.75
19 6 8.75
20 4 13.25

Table 1: Table 6E.4

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(a)
P P
Ri Xi
R= = 6.25 X= = 10.325
m m

Sample Size A2 D3 D4
4 0.729 0 2.282


U CL = X + A2 R = 10.325 + 0.729 × 6.25 = 14.88



X−R Chart  CL = X = 10.325
LCL = X − A2 R = 10.325 − 0.729 × 6.25 = 5.77




U CL = D4 × R = 2.282 × 6.25 = 14.26



R Chart  CL = R = 6.25
LCL = D4 × R = 0 × 6.25 = 0



The process is in-control.

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(b)
Specs. (350V ± 5V )
R 6.25
The real σ can be calculated: σ= d2
= 2.059
= 3.0355

c = U SL − LSL 3550 − 3450

C p = = 5.491
6×σ 6 × 3.0355
The minimum capability index for existing processes is 1.33 (i.e., 43 ). Ob-
viously, this process is higher (5.49  1.33).

(c)

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Question 6.15
(a)
1000 72
X= = 20 s = = 1.44
50 50

Sample Size A3 B3 B4
4 1.628 0 2.266




U CL = X + A3 R = 20 + 1.628 × 1.44 = 22.34
X −S Chart  CL = X = 10.325
LCL = X − A3 R = 205 − 1.628 × 1.44 = 17.66




U CL = B4 s = 2.266 × 1.44 = 3.26


S Chart CL = s = 1.44
 LCL = B s = 0 × 1.44 = 0

3

(b)
Natural Tolerance Limits
s 1.44
First of all, we need to calculate the real σ: σb = C4
= 0.9213
= 1.563
(
U N T L = X + 3σ = 20 + 3 × 1.563 = 24.69
LN T L = X − 3σ = 20 − 3 × 1.563 = 15.31

(c)
Specs Limits: 19 ± 4

c = U SL − LSL 23 − 15
C p = = 0.85
6σ 6 × 1.563
Cp < 1.33 =⇒ the process is not capable!
(d)

U SL − µ
Pbrework = P (S > U SL) = 1 − P (X ≤ U SL) = 1 − P ( )=
σb

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23 − 20
= 1 − φ( ) = 1 − φ(1.919) = 0.0275 = 2.75%
1.563
15 − 20
Pbscrap = P (X < LSL) = φ( ) = φ(−3.199)
1.563
= 1 − 0.99931 = 0.00069 ∼
= 0.069%
Total: Pb = 2.75% + 0.065 ∼
= 2.8%.

(e)
µ = 19

23 − 19
PbRework = 1−φ( ) = 1−φ(2.56) = 1−0.9947 = 0.0053 = 0.53%
1.563

15 − 19
PbScrap = 1 − φ( ) = φ(−2.563) = 0.0053 = 53%
1.563
Total: Pb = 0.53% + 0.53% = 1.06%
Centring decreased the Rework but increased the Scrap. Cost analysis
should be done.

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Question 6.21
Spec. Limits 100 ± 10, X = 104, R = 9.3 and n=5
d2 of (n=5) = 2.236

R 9.3
σ= = = 3.998
d2 2.326
Natural Tolerance is: 6 × σ = 6 × 3.998 = 23.99
The Tolerance limit is wider than specification limit (2 × 10 = 20).
Therefore, even adjusting the centre of the process (i.e., change the mean
to 100) wouldn’t meet the specification:
U SL − LSL 110 − 90
Cbp = = = 0.83
6σ 6 × 2.998

Question 6.34
)
X ∼ N (µx , σx )
Independent
Y ∼ N (µy , σy )
each sample n=5.
(a)
We have mx = 20 Samples and my = 10
20
X 10
X
Rxi = 18.608 Ryi = 6.978
i=1 i=1

Estimated σx and σy ?
P
Rxi 18.608
Rx = = = 0.9304
20 20
P
Ryi 6.978
Ry = = = 0.6978
20 10
0.9304 0.6978
σbx = = 0.4 σby = = 0.3
2.326 2.326
(b)
Axis must fit into the hole. Condition: P (X − Y < 0.09) = 0.006 What
difference µ0 = µx − µy should be specified?

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D = X − y (if x and y are normally distributed then D would be

normally distributed too).
D ∼ N (µD , σD )
q √
σb = σbx2 + σby2 = 0.42 + 0.32 = 0.5
!
D − µ0 0.09 − µ0
P (D < 0.09) = P <
σ0 σ0
!
0.09 − µ0
φ = 0.0006
σ0
!
  0.09 − µ0
φ(−x) = 1 − φ(x) = φ − = 1 − 0.0006 = 0.994
σ0
By checking the table, the answer is 2.51.
0.09 − µ0
− = 2.51 =⇒ µ0 = 0.09 + 2.51σD = 1.345
σ0

Question 6.41
Type II Error =⇒ alarm by at least 3rd plot point =⇒

1 − P {no alram by 3rd sample}

| {z }
β3

σx = √σ
n
! !
U CL − µ LCL − µ
φ −φ
σx σx
! !
104 − 98 96 − 98
φ √ −φ √ = 0.66578 = β
8/ 5 8/ 5
1 − β 3 = 0.7049

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Question 6.42

1 1
ARL1 = = = 2.992
1−β 1 − 0.66578

Question 6.45

No. Weight MRi

1 16.11
2 16.08 0.03
3 16.12 0.04
4 16.1 0.02
5 16.1 0
6 16.11 0.01
7 16.12 0.01
8 16.09 0.03
9 16.12 0.03
10 16.1 0.02
11 16.09 0.01
12 16.07 0.02
13 16.13 0.06
14 16.12 0.01
15 16.1 0.02
16 16.08 0.02
17 16.13 0.05
18 16.15 0.02
19 16.12 0.03
20 16.1 0.02
21 16.08 0.02
22 16.07 0.01
23 16.11 0.04
24 16.13 0.02
25 16.1 0.03

P24
i=1 M Ri
MR = = 0.02375
24

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MR 0.02375
d2 = 1.128, σb = = = 0.021055
d2 1.128


 U CL = D4 M R = 3.267 × 0.02375 = 0.07759
CL = M R = 0.02375


LCL = D3 M R = 0
! !
LSL − µ 16 − 16.1052 ∼
φ =φ = 3 × 10−7 ∼
= 3 × 10−5 %
σx 0.021055




 U CL = X + 3 Md2R = 16.1052 + 3 × 0.02375 = 16.1683

CL = X = 16.1052
 LCL = X − 3 M R = 16.1052 + 3 × 0.02375 = 16.04204

d2

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Yes, it is normally distributed.

Question 6.49
x chart { U CL = 710, CL = 700 and LCL = 690
y chart { U CL = 18.08, CL = 0 and LCL = 7.979
(a)
s 7.979
µ = x = 700, σbx = = = 8.661
C4 0.9213
(b)
Specs 705 ± 15

!
LSL − µ  U SL − µ 
Pb = P {x < LSL}+p{x > U SL} = φ + 1−φ =
σbx σbx
 690 − 700   720 − 700
=φ + 1−φ
8.661 8.661
φ(−1.15) + 1 − φ(2.31) = 0.1339 ' 13.3%

(c)

! !
LCL − µ  U CL − µ 
P = P {X < LCL}+P {X > U CL} = φ + 1−φ
σ σ

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! !
690 − 700 710 − 700
=φ √ +1−φ √ = 0.0208
8.661/ 4 8.661/ 4

(d)

Pb = P {X − LCL} + P {X > U CL}

!
 LCL − µ  U CL − µnew
new
φ +1−φ
σnew σnew
! !
690 − 693 710 − 693
φ q +1−φ √ = φ(−0.51)+1−φ(2.83) = 0.3108
12 + (4) 12/ 4

(e)

1 1 1 1
ARL1 = = = =
1−β 1 − P {notdetecting} P {detect} 0.3108
In average; after 3 points, we can expect alarm.

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