A QUALITY ANALYSIS OF THE THICKNESS OF PART

AND CORRUGATED ASBETES ROOFING SHEETS OF

EMENITE LIMITED ENUGU

BY

EZEOKOYE ELOCHUKWU JOSHUA

2018 484 004

A RESEARCH SEDMINAR SUBMITTED TO THE

DEPARTMENT OF STATISTICS.

CHUKWUEMEKA ODUMEWU OJUKWU UNIVERSIY

MAY, 2022.
 CERTIFICATION

This is to certify that this research work was carried out by EZEOKOYE

ELOCHUKWU JOSHUA, Registration Number 2018 484 004 of the Department

of Statistics, CHUKWUEMEKA ODUMEWU OJUKWU UNIVERSITY. This is

in partial fulfillment of the award of BACHELOR OF SCIENCE (BSc) in Statistics in

the DEPARTMENT OF STATISTICS. The assistance and help received during

the course of this investigation have been Acknowledged.

…………………………… ……………….…………….

Mrs.N.D. UGWU DATE

PROJECT SUPERVISOR

…………………………… …………………………….

Dr.C.O.ARONU DATE

HEAD OF DEPARTMENT

……………………………… …………………………………

Dr.J.C.OBI

SEMINAR COORDINATOR DATE

 DEDICATION

I dedicate this seminar report to God Almighty for his infinite mercies protection

and guidance throughout my stay in school. I also dedicate this report to my

family.
 ACKNOWLEDGEMENT

I will always firstly remain grateful to God Almighty who gave me the inspiration

and knowledge to further their course, statistics for the I also want to thank my

supervisor, Mrs.N.D.Ugwu for his guidance during the course of this seminar and

making necessary corrections. My gratitude also goes to my HOD Dr.C.O.Aronu

and all the lecturers in statistics department like Dr.J.C.Obi, Mrs.M.N.Egbo and

Dr.C.N Okoli I acknowledged with unalloyed gratitude to my able

ABSTRACT

This seminar is designed to give an insight into the application of statistical quality

control in the building products industries in order to help manufacturers

understand the importance of applying statistical techniques in controlling quality

products. In addition to make consumers have faith in standard quality of

products they buy. It must also be remembered that goods are competitive, for

producers to excel in the competitive market; their products must match in

quality with those of their counterparts. This project work has seemingly and

exhaustively x-rays the quality of Emenite roofing products in order to check why

products are not meeting customers’ expectations. From the analysis using

statistical quality control procedures that discovered that corrugated sheets

staged from their means which consequently resulted from the process average

being out of control. Generally, this research work is a bird eye new of what

quality control techniques can do for checking, monitoring and enhancing

products quality

TABLE OF CONTENTS

TITLE PAGE
Certification

Dedication

Acknowledgement

Abstract
Table of contents

CHAPTER ONE: INTRODUCTION

1.1 Background of the study

1.2 Purpose of the study

1.3 Significance of the study

1.4 Statement of research problem

1.5 Research hypothesis

1.6 Scope of the study

1.7 Definition of key terms

CHAPTER TWO
3.1 Introduction

3.2 Data collection method

3.3 Population and sample

3.4 Technique for analysis

CHAPTER THREE
PRESENTATION, ANALYSIS AND INTEPRETATION UP DATA

4.1 Introduction

4.2 Quality control chart

4.3 Laboratory record of measurement of flatsheets

4.4 Laboratory record of measurement of corrugated sheet

4.5 To check process average & variability for that sheet

4.6 To check process average & variability for corrugated

4.7 Determination of the process standards

CHAPTER FOUR
SUMMARY, CONCLUSION AND RECOMMENDATION
5.1 Summary

5.2 Conclusion

5.3 Recommendation

References

CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

Emenite Limited Enugu a member of the Beligian Etex Group started

operation in 1963 under the name “Turners Asbestos Cement Company Nigeria
Limited: The company was incorporated in 1961 with registration number RC

2712.

The group came to Nigeria with the establishment of her first of four

companies in Ikeja, Lagos, Nigeria Limited. The other three are Eternite Limited,

Sapele, Giwarite Limited, Kano and Emenite Limited, Enugu.

Emenite Limited after being established have to following as shareholders.

Turners & Newall Ltd - 80%

Government of Eastern Nigeria - 20%

As a result of the indigenization decree of 1973, the shareholders of the

company changed as follows

Turners & Newall Ltd - 60%

Government of Eastern Nigeria - 40%

With the name of the company changing to Turners Building Product (Emene)

Limited.

Due to dwindling fortunes of the company, in March 24, 1988 Turners and

Newall Ltd divested its interest in the company and transferred 51% of its

shareholding to Eteroutremer Societe Anonyme of Belgium (now Etex Group S.A)

and the balance of 49% went to the then Anambra and Imo State; now Anambra,

Enugu, Imo, Abia and Ebonyi States.As a result of the new shareholding
arrangement, the company changed its name to Emenite Limited as its presently

known.

Emenite Limited after being established in 1963 rolled out her first finished

sheets in December that year.The company has a total workforce as at its

establishment of 67 staff, its second machine was installed in 1979 while the third

was installed in 1983. From a workforce of 67 to 225 staff, from one shift machine

to three, from 14,000 tonnes of roofing and ceiling sheets to 50,000 tonnes per

year. The company has continued to grow tremendously.

The company has made considerable progress in terms of product

development in the market. It operates in the roofing and ceiling market, its range

of products include: Bigsix & standard ultimate corrugated sheets of different

colours (Grey, Red & Green), prestige concrete tile, Emcee flat sheet, duraceile

decorative ceiling, Emlux decorative ceiling as well as Qualitile decorative ceiling

and a new product called duratile. These products are sold through a wide range of

distribution network located in such a place that they will be close to project sites.

Emenite is 150 certified, 150 9002 in 1998, 180 9001 in 2002.

It is the company’s quality policy to provide high quality building products

to the markets. But much recently there have been complaints from building and

construction companies over the quality durability of her products. It is in view of

this problem this research work is being undertaken.

1.2 PURPOSE OF THE STUDY

Consumers of goods and services rely on quality standard products

displayed for consumers. What is responsible for this trend? Is statistical quality

control standard still made use of in industries? This are what this research project

intend to solve and make appropriate recommendation.

The project research will

1. Determine the process standards and establish the process capability

2. Check if the process average and variability are under control in respect of

the measurement of flat sheet.

3. Check if the process average and variability are under control in respect of

the measurement of corrugated sheets

4. Set up appropriate control charts for monitoring the future output of the

process.

1.3 SIGNIFICANCE OF THE STUDY

The significance of this research work is to provide information for the

management to fine – tune its quality policy concerning their products as obtained

in this analysis of this research work. This will be of benefits t o the producers and

consumers as well.
1.4 STATEMENT OF RESEARCH PROBLEM

There have been complaints and doubts that most asbestos roofing sheets in

recent times full short of required standard, also whether established standardize

are still maintained. This was as a result of reported cases of easy damage and

non-durable nature of these sheets.

In view of this, the researcher intends to carry out this research using

Emenite Limited Enugu as a case study.

1.5 RESEARCH HYPOTHESIS

H0: The process is under control in respect of the average and variability of the

measurement of flat sheets.

H1: The process is not under control in respect of the average and variability of

the measurement of flat sheets

H0: The process is under control in respect of the average and variability of the

measurement of corrugated sheets

H1: The process is not under control in respect of the average and variability of

the measurement of corrugated sheets.

1.6 SCOPE OF THE STUDY

The scope of this study is limited to Emenite only in order to conclude the

research work at the assigned period and the findings will be used to infer on the

industry.

1.7 DEFINITION OF KEY TERMS

VARIATION: This is a deviation from the normal standard or condition

DATA: These are sets of figures, raw information that is yet to be

processed. e.g population data, employment data etc.

CONTROL CHARTS: It is the graphical display of the actual measurement of

the characteristic on a chart showing limit which reflect the

process capability on the particular quality characteristics.

PROCESS CONTROL: This is the act of observing the functions of each of the

factors leading to the production of goods on a continuous basis

to ensure the process or means of production are kept in

optimum conditions.

PRODUCT CONTROL: Product control is the act of measuring or observing

different attributes of quality specification of a product with the

aim of ensuring that the product conform to specification. This

 is done of taking a sample from a batch of inspection lot with

the aim of accepting or rejecting it.

STATISTICAL QUALITY CONTROL: This is the technique of sampling at

every stage of production and statistical inferences are taken

about the variability of the product quality.

PROCESS CAPABILITY: This is the mini9mum spread of specific

measurement variation which will include about 99.73% of all measurements from
the process.
 CHAPTER THREE

RESEARCH METHODOLOGY AND DESIGN

3.1 DESIGN

When a researcher undertakes a study like this he may choose between

collecting the data himself for obtaining the needed figures from already available

published or unpublished compilation. If an individual or organization has

prepared reliable data which are pertinent to the problem, it is vastly less expensive

to make use of the existing information. Although to collect one’s own data is

more costly that procedure may enable the researcher to obtain exactly the

information which is needed to answer the specific questions that are under

consideration.

Not all researchers will be faced with the problem of collecting original

statistical data, many will find it possible to refer to existing source for

information. However, the data from such sources may be evaluated and more

intelligently use may be made of them if the researcher has some knowledge of the

procedure ad pitfalls involved in collecting, editing and marshalling statistical data.

 It is often impracticable to observe the entire group as it is large. Instead of

examining the entire group called the population or universe one examines a part

of the entire group called a sample.

3.2 DATA COLLECTION METHOD

In the course of this research work data was collected via the company’s

quality control laboratory record. There were records on flat sheets, big six

corrugated sheets, ceiling sheets of various brands, concrete tiles and other

accessories.

In the data report, the researcher collected data that were relevant to this

study i.e. Flat sheets and corrugated sheets based on the recorded measurements.

Samples of size 5 measurements were collected from each days measurements for

the flat and corrugated sheets, for a period of 34 days.

Basically, two instruments were used in conducting thus study, they are

interviews and records/documents materials.

3.3 POPULATION AND SAMPLE

 In collecting data concerning the characteristics of a group of individuals or

objects, it may be too expensive or too time consuming to examine the entire

group. Furthermore, to arrive at valid conclusion it may not be necessary to

enumerate all the population. We may study a sample drawn from the large

population and after analysis we should be able to arrive at a valid conclusion.

The population of the available data of this research work covers the

production record of 2000 to 2003 of a wide range of products ranging from

roofing sheets of different brands and sizes to ceiling products.

For proper analysis within the assigned period, the researcher has restricted

his sample to only flat and corrugated sheets.

3.4 TECHNIQUE FOR ANALYSIS

CONTOL CHARTS FOR VARIABLE

The control chart is a decision-making device that gives users information

about the quality of product relating from a manufacturing process. A control

chart usually consists of 3 horizontal lines. The top line represents the upper

control limit, the bottom line the lower control limit and the center line

representing the average for the process. We control chart for variables to indicate

whether for these variables the manufacturing process is in control with respect to

the population means and population dispersion. A control chart for mean is called
x-chart. When control of dispersion is the objective the measurement used is the

standard deviation or range. The chart is  - chart or R-chart respectively. We

usually use range because it is easy to compute. In the case of this project range

chart was used.

3.4.1 STEPS IN CONSTRUCTING CONTROL CHARTS FOR VARIABLE

1. THE X - CHART

When random samples of size ‘n’ are taken on k successive occasions and a

characteristic x is measured on each individual in the sample. Let x i, Ri represent

the sample mean and sample range of the ith sample represent I = 1, 2, 3 . . . . . . k

The data may be tabulated as in the table below

Sample Measurement Xij Xi Range Std.

Sample mean Ri Dev.

1 X11 X12 ………X1n X1 R1 1

2 X12 X13 ………X2n X2 R2 2

3 X13 X14 ………X3n X3 R3 3

. .

. .

. .

. .
 . .

. .

. .

k X11 X12 ………X1n

X R 

Where Xi = 1/n  Xij

i-1

i = 1  ( (Xij – Xi)2)

n i-1

Ri = X(n) – X(n) for the ith sample

X = 1/k  Xi

i-1

k
R = 1  Ri

k i-1

 = 1/k  i

i-1

i. DISTRIBUTION ASSUMPTION

The assumptions made about the X-chart is that the observation (xij) from

the process follow a normal distribution with mean x and s tandard deviation l i.e

Xij  N (x, 2). Hence the sampling distribution of the statistic X follows a

normal distribution with means x and standard error x1/n

Hence, if the process average x and standard deviation x1 are known (such as from

past records), then the control limits for an x-control chart are defined by (a) x 1

1/n = X1  A 1

Where A = 3/n can be read from the tables for various values of n Note that X 1  3

1/n is the minimum interval which includes 99.73% of all possible sample means

Xi of samples of size ‘n’ from the normal population xij  N (X1, 12)
If process standards (X1 and 1) are unknown, the control chart may be constructed

using the unbiased estimates of X1 and 1 as follows:

i. An unbiased estimate of X1 = X = 1/k xi

ii. An unbiased estimate of 1 is /c2, which c2 is u factor depending on ‘n’

and defined by c2 = 2/n

n / n-1 c2 can also be read from the table for

2 2

various value of n. Thus using X and /c2 as estimates of x1 and 1 respectively,

the control limits for the x-chart are defined by

a. X  3 /c2 /n = X + A,  Where A1 = 3 can be

c2/n

Read from tables

Again using X and R/d2 as estimates of the standards the control limit for

the x-control chart are defined by:

b. X  3 R/ d2 /n = X  A2 R, Where A = 3/d2 /n can be read from the tables

ii. CONSTRUCTING OF THE X - CHART

The X control chart is constructed by drawing three horizontal lines showing

the center line (CL), the upper control limit UCL and the lower control limit
(LCL), and then plotting the observed Xi values against the corresponding time of

observation i = 1, 2, 3, . . .. k as below.

If all the plotted Xi values fall between UCL & LCL, the process average is

said to be in control.

FOR EXAMPLE

X + A2 R UCL
x

x x
x x
x x x x x
x
X x x
CL
x x

X – A2 R LCL
R-I 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

2. THE R - CHART

The R – chart is a very popular tool for monitoring process variability. It is

often preferred to  - chart because it is simpler to construct (I involves squares
and squares roots while Ri involves only subtraction).
i. DISTRIBUTIONAL ASSUMPTION
In repeated sampling from N(X1, 12), the sampling distribution of the
sample range ‘R’ has mean E (R) = d2 1 = R, and standard error Se (R) = d31
= d3 R

d2

Hence, 1 is known, the control limits for the R-chart are d 2 1  3d3 1 = (d2  3
d3) 1, with CL = d2 1, LCL = (d2 + 3 d3) 1 = D2 1.
If 1 is not known, we replace 1, by R/d2 to obtain
the control limits as R  3 d3 R = (1 + 3 d3) R, with Cl =
d2 d2

R LCL = (1 – 3d3) R = D3 R;
d2
and UCL = (1 3d3) R = D4 R
d2

Where D1, DVI P3, D4 can be read from tables.

ii. CONSTRUCTION OF THE R - CHART

The R – control chart is constructed by plotting the observed R 1 values and
drawing the control limits CL, LCL & UCL if all the plotted R i values full between
UCL & LCL, the process variability is said to be in control.

D4 R UCL
x

x x
x x
x x x x x
x
R x x
CL
x x

P3 R LCL
i = 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
 CHAPTER FOUR

PRESENTATION ANALYSIS AND INTERPRETATION OF DATA

4.1 INTRODUCTION

There are numerous ways in which statistical data can be presented. They

include different types of diagrams, graphs, charts etc. In manufacturing

industries, one of the most convincing ways of presenting data is the quality

control chart. The quality control chart is used in identifying whether products or

process conform to norms or specifications.

After presentation of data, proper analysis is required. Unless proper

statistical analysis made from the data presented, sound conclusion cannot be

achieved and concrete decision cannot be made from the data.

Owing to the nature of problem we intend to solve in this research work

which involves the following.

1. To check if the process average and variability are under control in

respect of measurement of flat sheets.

2. To check if the process average and variability area under control in

respect of the measurement of corrugated sheets.

The researcher therefore considered that X – control chart R – control chart will be

ideal to analyse the data.

Conclusion drawn from the analysis would be used to infer about the whole

population, whether the process is under control or not.

4.2 QUALITY CONTROL CHART

Control chart is a graphical display of the actual measurement of

characteristics on a chart showing limits which reflect the process capability on the

particular quality characteristics. The control chart is made up of control limits

(upper and lower chart drawn at T + 3R where T is the target value while R is the

standard error of the estimator of T. If an observation flats outside the control

limit, it is an indication that the process has moved out of target and so some form

of action should be taken the action may consist of turning knob, resulting the

machine, replacing faulty pieces of the machine equipment etc.

4.3 LABORTORY RECORD OF MEASUREMENT OF THICKNESS OF

FLAT SHEETS OF EMENITE LTD FOR MARCH – APRIL 2003

SAMPLE NO DATE DAILY READINGS

X1 X2 X3 X4 X5

1 16/03/03 2.9 3.1 3.1 3.0 3.1

2 17/03/03 3.5 3.4 3.3 3.2 3.4

3 18/03/03 3.0 3.2 2.8 2.8 2.9

4 19/03/03 3.3 3.1 3.0 2.9 2.8

5 20/03/03 3.4 3.0 3.6 3.5 3.2

6 21/03/03 2.9 2.9 3.6 3.1 2.9

7 22/03/03 3.5 2.8 3.3 3.1 2.8

8 23/03/03 3.1 2.8 3.4 3.3 3.2

9 24/03/03 3.0 3.0 2.7 2.7 2.9

10 25/03/03 3.4 3.5 2.9 3.3 3.6

11 26/03/03 3.5 2.8 3.3 3.1 2.8

12 27/03/03 3.3 3.5 2.8 3.0 3.0

13 28/03/03 3.0 3.3 3.6 2.7 3.6

14 29/03/03 2.4 3.1 3.0 3.6 2.8

15 31/03/03 3.4 3.5 2.7 3.63.0 3.1

16 1/04/03 3.1 3.6 3.0 3.1 3.3

17 2/04/03 3.2 3.3 3.2 2.9 3.6

18 3/04/03 3.6 2.9 3.4 3.4 3.6

 19 4/04/03 3.4 3.3 3.6 3.1 3.0

20 5/04/03 3.3 2.8 3.5 3.0 3.5

21 6/04/03 3.5 2.8 3.5 3.5 3.6

22 7/04/03 3.0 3.1 2.8 3.6 2.9

23 8/04/03 3.3 3.0 3.1 3.4 3.3

24 9/04/03 3.0 2.7 2.8 3.0 3.2

25 10/04/03 3.2 3.3 3.3 3.6 3.2

26 11/04/03 3.0 3.5 3.2 3.2 3.0

27 13/04/03 2.8 3.4 2.8 3.2 3.3

28 14/04/03 3.2 3.4 3.2 3.2 3.6

29 15/04/03 3.1 3.3 3.1 3.4 3.0

30 16/04/03 3.0 2.7 2.8 3.0 3.2

31 17/04/03 3.2 3.0 2.8 3.2 3.0

32 18/04/03 2.8 2.7 3.2 2.7 3.1

33 19/04/03 3.0 3.0 2.7 2.9 2.9

34 20/04/03 2.7 3.0 3.0 2.7

4.4 LABORATORY RECORD OF MEASUREMNTS OF THICKNESS

OF CORRUUGATED SHEETS OF EMENITE LTD FOR SEPT/NOV. 2003

SAMPLE NO DATE DAILY READINGS

X1 X2 X3 X4 X5

1 20/09/03 4.0 4.2 4.3 4.1 4.0

2 21/09/03 4.1 4.0 3.9 4.1 4.2

3 22/09/03 3.9 4.1 3.8 4.2 4.3

4 23/09/03 4.4 4.5 4.4 4.4 4.5

5 24/09/03 3.9 4.0 4.1 4.2 4.04

6 25/09/03 3.8 4.1 4.1 4.5 .2

7 26/09/03 4.1 4.1 3.9 4.3 4.0

8 27/09/03 3.7 3.9 3.7 3.8 3.8

9 28/09/03 4.1 2.8 4.0 4.4 4.6

10 29/09/03 3.9 4.1 4.0 3.9 4.2

11 30/09/03 4.0 4.1 4.3 4.2 4.3

12 1/10/03 4.1 4.6 4.3 4.2 4.6

13 2/10/03 3.9 4.3 4.6 4.5 4.2

14 2/11/03 3.8 3.8 3.7 3.8 3.8

15 3/11/03 4.0 4.2 4.2 4.0 4.1

16 4/11/03 4.0 3.9 4.1 3.9 4.1

17 5/11/03 4.4 4.3 4.0 4.1 4.0

18 6/11/03 4.0 4.6 4.2 4.5 4.6

 19 7/11/03 4.1 4.0 3.9 4.2 4.3

20 8/11/03 3.7 4.0 3.9 4.0 4.1

21 9/11/03 4.2 4.3 3.7 3.8 4.2

22 10/11/03 4.1 3.9 3.8 4.0 4.0

23 11/11/03 4.0 4.2 4.1 3.9 4.2

24 12/11/03 4.1 4.2 4.3 4.2 4.1

25 13/11/03 4.1 4.5 4.4 4.5 4.4

26 14/11/03 4.3 4.0 4.2 4.3 4.3

27 15/11/03 4.0 3.7 4.1 4.2 4.0

28 16/11/03 4.1 4.2 4.0 4.1 3.9

29 17/11/03 4.0 4.2 4.1 4.3 4.3

30 18/11/03 3.8 3.8 3.7 3.8 3.8

31 19/11/03 3.9 3.8 3.8 3.2 4.0

32 20/11/03 4.5 3.7 4.1 4.2 4.4

33 21/11/03 3.7 3.9 3.7 3.8 3.8

34 22/11/03 3.9 4.0 3.7 3.9 3.8

CONSTRUCTING THE X – CONTROL CHART

Construction of the x-chart is by drawing three horizontal lines showing the

center line (CL), upper control line (UCL) and the lower control line (LCL), and
then plotting the observed Xi values against the corresponding time of observation

1 = 1, 2, 3, . . . . . – k

 CL = X = 1/k Xi

LCL = X - A2 R

UCL = X + A2 R

CONSTRUCTING THE R-CONTROL CHART

The R-control chart is constructed by plotting the observed R i values and

drawing the control limits CL, LCL, & UCL. If all the plotted R i values fall

between UCL & LCL, the process variability is said to be in control.

 CL = R = 1/k Ri

LCL = D3 R

UCL = D4 R

4.5 TO CHECK IF THE PROCESS AVERAGE AND VARIABILITY

ARE UNDER CONTROL WITH RESPECT TO THE MEASUREMENT OF

FLAT SHEETS

LABORATORY RECORD OF MEASUREMENT OF THICKNESS OF

FLAT SHEETS

SAMPLE NO DAILY READING Xi Ri

1 2.9 3.1 3.1 3.0 3.1 3.0 0.2

 3.4

2 3.5 3.4 3.3 3.2 3.4 2.9 0.3

3 3.0 3.2 2.8 2.8 2.9 3.0 0.4

4 3.3 3.1 3.0 2.9 2.8 3.3 0.5

5 3.4 3.0 3.6 3.5 3.2 3.1 0.6

6 2.9 2.9 3.6 3.1 2.9 3.1 0.7

7 3.5 2.8 3.3 3.1 2.8 3.2 0.7

8 3.1 2.8 3.4 3.3 3.2 2.9 0.6

9 3.0 3.0 2.7 2.7 2.9 3.3 0.3

10 3.4 3.5 2.9 3.3 3.6 3.1 0.7

11 3.5 2.8 3.3 3.1 2.8 3.1 0.7

12 3.3 3.5 2.8 3.0 3.0 3.2 0.7

13 3.0 3.3 3.6 2.7 3.6 3.2 0.6

14 3.4 3.1 3.0 3.6 2.8 3.3 0.6

15 3.4 3.5 2.7 3.6 3.1 3.0 0.9

16 3.1 3.6 3.0 3.0 3.3 3.3 0.6

17 3.2 3.2 3.2 3.1 3.6 3.3 0.5

18 3.6 2.9 3.4 2.9 3.6 3.3 0.7

19 3.4 3.3 3.6 3.4 3.0 3.2 0.6

20 3.3 2.8 3.5 3.1 3.5 3.3 0.7

 21 3.5 2.8 3.5 3.0 3.6 3.1 0.8

22 3.0 3.1 2.8 3.5 2.9 3.3 0.7

23 3.3 3.0 3.1 3.6 3.3 3.0 0.6

24 3.0 2.7 2.8 3.4 3.2 3.2 0.7

25 3.2 2.3 3.3 3.0 3.2 3.3 0.3

26 3.0 3.5 3.2 3.6 3.0 3.1 0.6

27 2.8 3.4 2.8 3.2 3.3 3.3 0.6

28 3.2 3.4 3.2 3.2 3.6 3.1 0.4

29 3.1 3.3 3.1 3.2 3.0 3.0 0.3

30 3.0 2.7 2.8 3.4 3.2 3.0 0.7

31 3.2 3.0 2.8 3.0 3.0 3.0 0.4

32 2.8 2.7 3.2 3.2 3.1 2.9 0.5

33 3.0 3.0 2.7 2.7 2.9 2.9 0.3

34 2.7 3.0 3.0 2.9 2.7 0.3

106.9 18.7

The process average of the measurement of flat sheet of March – April 2003

is calculated as follows:

CL = X = 106.9

34

CL = 3.14
R = 18.7

34

= 0.55

LCL = 3.14 - 0.58 (0.55)

= 3.14 - 0.32

= 2.82

UCL = 3.14 + 0.58 (0.55)

= 3.14 + 0.32

= 3.46

The control chart for the process variability of the measurement of flat sheet

of March –April 2003 is calculated as follows:

CL = R = 18.7

34

= 0.55

LCL = 0(0.55)

= 0

UCL = 2.11 (0.55)

= 1.16
 Therefore the x-chart for the measurement of flat sheets of the laboratory

record of March – April 2003 of Emenite Ltd shows the following

CL = 3.14

LCL = 2.82

UCL = 3.46

These represent the center line and the trial control limits for an x – chart

based on samples of size n = 5 if the process is in control.

For R – chart for the measurement of flat sheet of the laboratory record of March –

April 2003 of Emenite Ltd shows the following:

CL = 0.55

LCL = 0

UCL = 1.16

These represent the center line and trial control limits for an R – control

chart based on samples of size 5 if the process is in control.

CONCLUSION ON X AND R CHARTS FLAT SHEETS

These show that the production of March – April 2003 of Emenite Ltd,

Enugu process average and variability y are under statistical control in respect of

the measurement of flat sheet. This is because the means and ranges of the

measurement fall between the upper and lower cosntrol limits which indicate that

the process is stable in respect of the measurements of flat sheets.

 Therefore, we accept the wall hypothesis: H 0: that the process is under

control with respect to the average and variability of the measurement of flat

sheets.

4.6 TO CHECK IF THE PROCESS AVERAGE AND VARIABILITY ARE

UNDER CONTROL IN RESPECT OF THE MEASUREMENT OF

CORRUGATED SHEETS

Laboratory record of measurements of thickness of corrugated sheets of

Emenites Ltd for Sept/Nov. 2003

SAMPLE NO DAILY READING Xi Ri

1 4.0 4.2 4.3 4.1 4.0 4.1 0.3

2 4.1 4.0 3.9 4.1 4.2 4.1 0.3

3 3.9 4.1 3.8 4.2 4.3 4.1 0.5

4 4.4 4.5 4.4 4.4 4.5 4.4 0.1

5 3.9 4.0 4.1 4.2 4.0 4.0 0.3

6 3.8 4.1 4.1 4.5 4.2 4.1 0.7

7 4.1 4.1 3.9 4.3 4.0 4.1 0.4

8 3.7 3.93. 3.7 3.8 3.8 3.8 0.2

9 4.1 8 4.0 4.4 4.6 4.2 0.8

10 3.8 4.1 4.0 3.9 4.2 4.0 0.4

11 4.0 4.1 4.3 4.2 4.3 4.2 0.3

12 4.1 4.6 4.3 4.2 4.6 4.4 0.5

13 3.9 4.3 4.6 4.5 4.2.3 4.3 0.7

14 3.8 3.8 3.7 3.8 .8 3.8 0.1

15 4.0 4.2 4.2 4.0 4.1 4.1 0.2

16 4.0 3.9 4.1 3.9 4.1 4.0 0.2

17 4.4 4.3 4.0 4.1 4.0 4.2 0.4

18 4.0 4.6 4.2 4.5 4.6 4.4 0.6

19 4.1 4.0 3.9 4.2 4.3 4.1 0.4

20 3.7 4.0 3.9 4.0 4.1 3.9 0.4

21 4.2 4.3 3.7 3.8 4.2 4.0 0.6

22 4.1 3.9 3.8 4.0 4.0 4.0 0.2

23 4.0 4.2 4.1 3.9 4.2 4.1 0.3

24 4.1 4.2 4.3 4.2 4.1 4.2 0.2

25 4.1 4.5 4.4 4.5 4.4 4.4 0.4

26 4.3 4.0 4.2 4.3 4.3 4.2 0.3

27 4.0 3.7 4.1 4.2 4.0 4.0 0.5

28 4.1 4.2 4.0 4.1 3.9 4.1 0.3

29 4.0 4.2 4.1 4.3 4.3 4.2 0.3

30 3.8 3.8 3.7 3.8 3.8 3.8 0.1

 31 3.9 3.8 3.8 3.2 4.0 3.7 0.8

32 4.5 3.7 4.1 4.2 4.4 4.2 0.8

33 3.7 3.9 3.7 3.8 3.8 3.8 0.2

34 3.9 4.0 3.7 3.9 3.8 3.9 0.3

138.9 13.1

The process average of the measurement of corrugated sheets of Sept./Nov

2003 is calculated as follows:

CL = X = 138.9

34

CL = 4.09

R = 13.1

34

= 0.39

LCL = 4.09 - 0.58 (0.39)

= 4.09 - 0.23

= 3.86

UCL = 4.09 + 0.58 (0.39)

= 4.09 + 0.23

= 4.32
The process variability of the measurement of corrugated sheets of Sept./Nov.

2003 is calculated as follows:

CL = R = 13.1

34

= 0.39

LCL = 0(0.39)

= 0

UCL = 2.11 (0.39)

= 0.82

Therefore the x-chart for the measurement of corrugated sheets of the

laboratory record of Sept/Nov 2003 of Emenite Ltd shows the following:

CL = 4.09

LCL = 3.86

UCL = 4.32

These represent the center line and the trial control limits for an x-chart based on

samples of size 5 if the process is in control.

The R-chart for the measurement of corrugated sheets of the laboratory

record of Sept/Nov 2003 of Emenite Ltd shows the following.

CL = 0.39

LCL = 0
 UCL = 0.82

The above represent the center line and the trial control limits for an R –

control chart based on samples of size n = 5, if the process is in control.

CONCLUSION ON X & R CHARTS OF CORRUGATED SHEETS

From the x – chart it can be deduced that there was a shift in the process

means manifesting that the process, average was out of control in respect of the

measurements of corrugated sheet. This is because some of the means of the

measurements fall outside the control limits which indicate that the process

average is not stable in respect of the measurements of corrugated sheets.

However, the process variability is stable in respect of the measurements of

corrugated sheets of Emenite Ltd Enugu.

Therefore, we reject the null hypothesis H0 which states that the process is

under control in respect of the average and variability of the measurements of

corrugated sheets of Emenite Ltd Enugu of Oct/Nov 2003.

4.7 DETERMINATION OF THE PROCESS STANDARDS

1. PROCESS STANDARD FOR FLAT SHEETS

X = X = 3.14

1 = R = 0.55
d2 2.326

= 0.26

The process capability for flat sheet is given as

X  3 1

=> X1 - 3 1 = 3.14 – 3 (0.24)

= 3.14 – 09.72

= 2.42

=> 3.14 + 3 (0.24)

= 3.14 + 0.72

= 3.86

 The process capability is 3.14  0.72. This represents the minimum spread

that includes 99.75% of all measurements arising from the process.

In otherwords the individual measurements of thickness are expected to vary

between 2.42 and 3.86 when the process is under control.

2 PROCESS STANDARD FOR CORRUGATED SHEETS

To establish the process standards for the corrugated sheet we first eliminate the

oust of control points and re-calculate X and R.

SAMPLE NO DAILY READING Xi Ri

1 4.0 4.2 4.3 4.1 4.0 4.1 0.3

2 4.1 4.0 3.9 4.1 4.2 4.1 0.3

3 3.9 4.14. 3.8 4.2 4.3 4.1 0.5

4 3.9 0 4.1 4.2 4.0 4.0 0.3

5 3.8 4.1 4.1 4.5 4.2 4.1 0.7

6 4.1 4.1 3.9 4.3 4.0 4.1 0.4

7 4.1 3.8 4.0 4.4 4.6 4.2 0.8

8 3.8 4.1 4.0 3.9 4.2 4.0 0.4

9 4.0 4.1 4.3 4.2 4.3 4.2 0.3

10 3.9 4.3 4.6 4.5 4.2 4.3 0.7

11 4.0 4.2 4.2 4.0 4.1 4.1 0.2

12 4.0 3.9 4.1 3.9 4.1 4.0 0.2

13 4.4 4.3 4.0 4.1 4.0 4.2 0.4

14 4.1 4.0 3.9 4.2 4.3 4.1 0.4

15 3.7 4.0 3.9 4.0 4.1 3.9 0.4

16 4.2 4.3 3.7 3.8 4.2 4.0 0.6

17 4.1 3.9 3.8 4.0 4.0 4.0 0.2

18 4.0 4.2 4.1 3.9 4.2 4.1 0.3

19 4.1 4.2 4.3 4.2 4.1 4.2 0.2

20 4.3 4.0 4.2 4.3 4.3 4.2 0.3

21 4.0 3.7 4.1 4.2 4.0 4.0 0.5

 22 4.1 4.2 4.0 4.1 3.9 4.1 0.3

23 4.0 4.2 4.1 4.3 4.3 4.2 0.3

24 4.5 3.7 4.1 4.2 4.4 4.2 0.8

25 3.9 4.0 3.7 3.9 3.8 3.9 0.3

28

102.4 10.1

X = 102.4 = 4.10

25

R = 10.1 = 0.40

25

DETERMINING THE PROCESS STANDARD FOR THE CORRUGATED

SHEETS
 X = X = 4.10
1 = R = 0.40
d2 2.326
= 0.17
The process variability for the corrugated sheets is given as follow:
X  3 1
=> X1 - 31
=> 4.10 - 0.51
= 4.10 - 0.51
= 3.59
=> 4.10 + 3 (0.17)
=> 4.10 + 0.51

= 4.61

The process capability for corrugated sheets is 4.10  0.51. This represents

the minimum spread that includes 99.73% of all measurements arising from the

reduced process.

In otherwords, the individual measurements of thickness are expected to

vary between 3.59 and 4.61 when the process is under control.
 CHAPTER FIVE

SUMMARY, CONCLUSION AND RECOMMENDATION

5.1 SUMMARY

To obtain result on use of statistical quality as control in the roofing sheets

productive of Emenite Ltd, Enugu, the researcher conducted an in-depth appraisal

of the subject matter by collecting and analyzing relevant data.

From the research work it has been established that the rule of statistical

quality control in industries is enormous. Intact, as maintenance by Daniel W.

Tervel J.C. (1992) “the life and health of a business depend on the quality of the

products it produces. Industries can only perform well when there is proper quality

control this research has revealed tremendous problem facing quality control in

Emenite Ltd which is poor record keeping. It has clearly shown that if the source

of data is wrong, the analysis cannot be right. Therefore, only when we learn how

to keep accurate and comple records for analysis we can achieve measurable

improvement in the quality of our products.

5.2 CONCLUSION

From the practical survey carried out in the course of this research work has

yielded the following findings:

a. The result from the analysis in table 4.1 and 4.2 shows that the process

average and variability of flat sheets was under quality control.

But however, the process average of corrugated sheets as indicated in table 4.3

show that and 5 points fall outside the upper and lower control limits respectively

which implies that the process means was out of control. But the process

variability for the corrugated sheets was in statistical quality control.

b. The process average for flat sheet is 3.14mm.

c. The process range for flat sheet is 0.55 which indicate a low variability in

the flat sheets.

Coefficient of variation (C.V) = 0.55/3.14 x 100% = 17.5%

d. The process average for corrugated sheet is 4.09mm

e. The process range for corrugated sheet is 0.39 which indicate a low

variability in the corrugated sheets.

Coefficient if variation (C.V) 0.39/4.09 x 10 = 9.5%.

5.3 RECOMMENDATION

In order to improve on the quality of Emenite’s flat and corrugated sheets. I

give the following recommendation.

1. The management of Emenite Ltd should endeavour to give priority attention

to record keeping in order to improve quality of its products

2. Operators should be careful in handling the different stages involved in the

production process.

3. The entire process of Bixsix corrugated sheets production should be

modified.

4. The quality control department of Emenite Ltd should device more efficient

method of carrying out test and must report to the appropriate department when a

change in any process mean is detected.

 REFERENCES

Omotsho M.Y.: College and University Test Statistics, Ibadan: NPS Educational

Publishers Limited, 1994.

Frank E.C. et al:Applied general Statistical, New Delta: Prentice Hall of India

Private Ltd, 1958.

Image E.U.L:Theory and Practice of Production Management, Lagos Afri trade

International Ltd, 1994.

Daniel W. and Terrel J.C: Business Statistics for Management and Economics;

USA: Houghton Mifflin Co., 1992

Bester Field D.H.:Quality Control: USA Houghton Mifflin Co. 1996.

Ogbonna Eric: Industrial Statistical Unpublished Lecture Role Abia State

Polytechnic, Aba, 1999.

Ugwu P.:Lecture Compilation Hand-out on Industrial Statistics, IMT Enugu, 2004

Ikuku E.: A research work on building materials UNN Nsukka, 2000.

Anozie, L.C.: A research project on quality control standard in Industries IMT

Enugu, 2002

Emenite Journal: “Emenite: History and Production process” Fourth Dimension

Publishers, Enugu, 1978.