King Abdulaziz University

IE 431 H.W 3
Faculty of Engineering
Department of Industrial
Engineering

IE431
Quality Control
Third Homework
Name ID
1. Mohammed Ahmed Bataweel 1937938
2. Fawaz Zafer Alqrni 1936313
3. Abdulaziz Ali Alahmadi 1935003
4. Mohammed Angawi 1847939
5. Fawaz Alqahtani 1741721

ENGINEERING
ASSIGNMENT
|Page1
IE 431 H.W 3

Table of Contents
List of Tables .............................................................................................................3
List of Figures ............................................................................................................4
Managerial Report......................................................................................................5
Technical Report ........................................................................................................6
Problem Statement .................................................................................................6
Problem.No.1 .........................................................................................................6
Problem.No.2 .........................................................................................................7
Problem.No.3 .........................................................................................................8
Problem.No.4 ....................................................................................................... 11
Problem.No.5 ....................................................................................................... 13
Problem No.6 ....................................................................................................... 14
Problem No.7 ....................................................................................................... 14
Conclusion ........................................................................................................... 14
Reference ............................................................................................................. 15
Appendix.............................................................................................................. 16

|Page2
IE 431 H.W 3

List of Tables
Table 1:P1.X values ...................................................................................................5
Table 2: P2.X values ..................................................................................................5
Table 3: calculations to find the X ..............................................................................6
Table 4: values of X after substitution ........................................................................7
Table 5: Values of X's ................................................................................................8
Table 6: Values ..........................................................................................................9
Table 7: Straight line Equations..................................................................................9
Table 8: Discrete percentages .....................................................................................9
Table 9: Normal Percentages .................................................................................... 10
Table 10: Normal (100%) ......................................................................................... 10
Table 11: Cutoff Values ........................................................................................... 11
Table 12: Needed information .................................................................................. 11
Table 13: Combinations & their values..................................................................... 11
Table 14: Random numbers ...................................................................................... 12
Table 15: P1 R2 V1 L1 values .................................................................................. 12
Table 16: P1 R2 V1 L2 values .................................................................................. 12
Table 17: P1 R2 V2 L1 values .................................................................................. 13
Table 18: P1 R2 V2 L2 values .................................................................................. 13

|Page3
IE 431 H.W 3

List of Figures
Figure 1: data of Failure of a car ................................................................................6
Figure 2: Normal Distribution ....................................................................................9
Figure 3: P4. Alternative 1....................................................................................... 16
Figure 4:P4. Alternative 2........................................................................................ 16

|Page4
IE 431 H.W 3

Managerial Report
This task includes 7 problems to be solved. Problem 1 and 2 are about generating five
chip failure in cars and electronic ships that follows bath and probability density
function distributions. Problem 3 is identifying wither normal distribution is a the best
fit or not. Problem 4 was about identifying the best robust alternative. Problems 5 and
6 were about identifying wither the process are capable or not with identifying how
many defects in each process. Finally, problem 7 was about getting the exact value of
the standard deviation that meat with the six sigma requirements.
The solutions of the problems:
Problem 1
Table 1:P1.X values

R1=0.05 R2=0.95 R3=0.5 R4=0.7324 R5= 0.31

X1= 0.87 X2= 23.07 X3= 13.68 X4= 19.012 X5= 7.83
𝟕𝟎𝟎+𝟑𝟎𝟎+𝟑𝟎𝟎+𝟑𝟎𝟎+𝟓𝟎𝟎
Average failure cost = = $420
𝟓

Problem 2
Table 2: P2.X values

R= 0.15 R= 0.99 R= 0.5 R= 0.8 R= 0.2

7.745967 36.46554 15.50394 24.50159 8.944272
𝟕𝟎𝟎+𝟓𝟎𝟎+𝟓𝟎𝟎+𝟓𝟎𝟎+𝟕𝟎𝟎
Average failure cost = = $580
𝟓

Problem 3
Cutoff Discrete= 247.75, Cutoff Normal = 540.12, Diff= 540.12/247.75= 2.18% Closer
to Discrete
Problem 4
The final robust design is 𝑃1 𝑅2 𝑉2 𝐿1 with Mean = 1287.3630 and STD = 562.3997
Problem 5
110.5−79.5
𝐶𝑝 = = 15.6 , 𝑃𝑃𝑀 = [1 − 0.000001] ∗ 106 = 1,000,000
6∗0.33

Problem 6
C𝑝𝑘 = min(𝐶𝑃𝐿, 𝐶𝑃𝑈) = min(740,293.3) = 293.33
Problem 7
92 − 88 = 6(𝜎)
𝜎 = 0.6667

|Page5
 IE 431 H.W 3

Technical Report
Problem Statement
In this report there are some problems that need to be solved. Firstly, a cars company
wants to know when a failure of a car will occur and calculate the average failure cost
of a car paid by the warranty. The failure of a car was following a “Bath-Tub”
probability distribution. Secondly, an electronic chips company wants to find the
average failure cost of electronic chips paid by the warranty. Thirdly, an industrial case
needs to compare two distributions (discrete and normal distribution) and choose the
best for that case. Fourthly, an oil pipes need a ROBUST design using Poiseuille's Law.
Finally, a company wants to find the capability of the process and the variance that
meet six-sigma requirements.

Problem.No.1

Figure 1: data of Failure of a car

- In this figure, we can see the failure of a car follows a “Bath-Tub” probability
distribution
Table 3: calculations to find the X

3
f1(x) = − 500 𝑥 + 0.06 f2(x) = 0.03 f3(x) =0.002143x+0.00857

5 ≤ 𝑥2 ≤ 10 10 ≤ 𝑥3 ≤ 24
0 ≤ 𝑥1 ≤ 5
3
F1(x) =− 1000 𝑥 2 + 0.06𝑥 F2(x) = 0.03x+0.075 F3(x) = 0.0010715𝑥 2 + 0.00857𝑥 + 0.18215
3
R1 ==− 1000 𝑥 2 + 0.06𝑥 R2 =0.03x+0.075 R3 = 0.0010715𝑥 2 + 0.00857𝑥 + 0.18215

0.225 ≤ R2 ≤ 0.375 0.375 ≤ R3 ≤ 1

0 ≤ R1 ≤ 0.225
X1 = X3 =
3 −0.075+𝑅 −0.00857±√(−0.00857)2 −4(0.0010715)(0.18215−𝑅)
−0.06±√(0.06)2 −4(− )(−𝑅) X2 =
1000 0.03 2(0.0010715)
3
2(− )
1000
- From the above table first, we try to find the f(xi) and thin find the F(xi) after
that as shown we find the X to substitute the below random numbers into the
equations

|Page6
IE 431 H.W 3

Table 4: values of X after substitution

R1=0.05 R2=0.95 R3=0.5 R4=0.7324 R5= 0.31

X1= 0.87 X2= 23.07 X3= 13.68 X4= 19.012 X5= 7.83

- Here we can see that each value of X follows its range which we found it in
step f(x)

a) Calculate the Average failure cost paid by the warranty if the cost per
failure for thethree intervals are: $700, $500, and $300 respectively.
X1 FC = $700
X2 FC = $300
X3 FC = $300
X4 FC = $300
X5 FC = $500
𝟕𝟎𝟎+𝟑𝟎𝟎+𝟑𝟎𝟎+𝟑𝟎𝟎+𝟓𝟎𝟎
Average failure cost = = $420
𝟓

Problem.No.2
A)
In this problem, the needed calculations are f(x), F(x), R and X. After that, its required
to calculate the years(X) based on the given values of R’s. Each f(x) represents a line
which have starting and ending points. By calculating the equations of each line, f(x)’s
can be found:

𝑓1(x) = 0.005X
𝑓2(x) = − 0.01666𝑋 + 0.06666666

The next step is finding F(x)’s by integrating each line function and not forgetting to
add the result of the integrated 𝐹1 (x) to 𝐹2 (x) because it’s a cumulative function. After
doing all the required steps, 𝐹1 (x), 𝐹2 (x) are:

𝟎.𝟎𝟎𝟓𝑿𝟐
F1(x) = 𝟐
−𝟎.𝟎𝟏𝟔𝟔𝟔
F2(x) = ( ) 𝑋2 + (0.06666666)X - 0.333366
𝟐

Now it’s easy to generate the values of R’s because R=F(x):

𝟎.𝟎𝟎𝟓𝑿𝟐
R1= 0 ≤ 𝑅1 ≤ 0.25
𝟐

|Page7
IE 431 H.W 3

−𝟎.𝟎𝟏𝟔𝟔𝟔
𝑹𝟐 = ( )𝑋2 + (0.06666666)X - 0.333366 0.25 ≤ 𝑅2 ≤ 1
𝟐

The values of X’s can be generated now using the previous functions:

𝟐𝑹𝟏
𝑿𝟏 = √ 𝟎.𝟎𝟎𝟓 0 ≤ 𝑋1 ≤ 10

Finding 𝑿𝟐 will be by using the law of:

−𝑏 ± √𝑏 2 − 4𝑎𝑐
𝑥=
2𝑎
−0.001666
Values of a, b, and c are: , 0.06666666, - 0.333366
2

−𝟎.𝟎𝟎𝟏𝟔𝟔𝟔
−𝟎.𝟎𝟔𝟔𝟔𝟔𝟔𝟔𝟔±√(𝟎.𝟎𝟔𝟔𝟔𝟔𝟔𝟔𝟔)𝟐 −𝟒( )(−𝟎.𝟑𝟑𝟑𝟑𝟔𝟔−𝑹𝟐 )
𝟐
𝑿𝟐 = −𝟎.𝟎𝟎𝟏𝟔𝟔𝟔
𝟐( )
𝟐

10 ≤ 𝑋2 ≤ 40

The final step is to calculate the values of X’s using the given R values:

Table 5: Values of X's

R= 0.15 R= 0.99 R= 0.5 R= 0.8 R= 0.2

7.745967 36.46554 15.50394 24.50159 8.944272

B)
To find the Average Failure cost:

𝟕𝟎𝟎+𝟓𝟎𝟎+𝟓𝟎𝟎+𝟓𝟎𝟎+𝟕𝟎𝟎
= 580
𝟓

Problem.No.3
As can be seen in the figure this is the normal distribution for the company. What need
to be decided is whether the data follows a normal or discrete distribution.

|Page8
IE 431 H.W 3

Figure 2: Normal Distribution

First the mean and standard deviation must be obtained using these formulas:

̅̅̅̅2
∑(𝑋−𝑋)
,𝜎= √ 𝜇 = ∑𝑥 × 𝑃(𝑥)
𝑛
As can be seen in the table these are the values.
Table 6: Values

Mean STD
74 20.88061

Then three straight line equations must be obtained since we have the lines in the first
figure. They have been obtained using the calculator as can be seen in the table.
Table 7: Straight line Equations

Using calculator
fx1 0.14
fx2 (0.0135x-0.715)
fx3 (-0.005x+0.556)
Then the discrete percentages every x value will be substituted with the corresponding
value depending on where the values are in first, second, or third line. The total
percentages must equal 1.
Table 8: Discrete percentages

Discrete
X Y
50 0.14
60 0.095

|Page9
IE 431 H.W 3

70 0.23
80 0.365
90 0.106
100 0.056
110 0.006
Total 1

Now the normal percentages we have lower and upper values for each x. each stem is
equal to 10 so the lower will be -5 of the x value and the upper +5 of the x value. The
mean and standard deviation are available so the normal percentage can be calculated.
Table 9: Normal Percentages

Normal
L U X Y
45 55 50 0.098989
55 65 60 0.151798
65 75 70 0.185872
75 85 80 0.181737
85 95 90 0.141889
95 105 100 0.088455
105 115 110 0.044029
Total 0.892769

Since the total percentages is not equal to 100 it must be converted by dividing each
value with the total of percentages as can be seen in the next table.

Table 10: Normal (100%)

Normal (100%)
L U X Y
45 55 50 0.110879
55 65 60 0.17003
65 75 70 0.208198
75 85 80 0.203565
85 95 90 0.158931
95 105 100 0.099079
105 115 110 0.049318
Total 1

Last step is to calculate the cutoff by using this formula. With this information we can
decide which distribution the data follows. The results can be seen in the table.
𝐷𝑖𝑠𝑐𝑟𝑒𝑡𝑒 𝑜𝑟 𝑛𝑜𝑟𝑚𝑎𝑙(100%)
𝐶𝑢𝑡𝑜𝑓𝑓 = 1 −
𝐺𝑖𝑣𝑒𝑛 𝑃

| P a g e 10
IE 431 H.W 3

Table 11: Cutoff Values

Cutoff Discrete Cutoff Normal

X Y X Y
50 0 50 20.80104
60 26.92308 60 30.79259
70 43.75 70 30.12347
80 8.75 80 49.10869
90 11.66667 90 32.44278
100 86.66667 100 230.2642
110 70 Difference of Totals 110 146.5886
Total 247.7564 2.18004977 Total 540.1213
Data are closer to discrete Distribution by 2.18 %

It’s clear that the data are closer to the discrete than normal. We can get how much
closer exactly by dividing the normal cutoff with the discrete cutoff and its 2.18 %
closer.

Problem.No.4
In this problem, the researchers have been asked to build a robust design for an oil pipe
using two available parts, the next table shows the required information.
Table 12: Needed information

Formula 𝑭 = (𝝅 𝑷 𝑹𝟐 )/ (𝟖 𝑽 – 𝑳).
Flow range 1200 - 1400

To solve such a problem, first the researchers have to calculate the combinations.
• # 𝑜𝑓 𝑐𝑜𝑚𝑏𝑖𝑛𝑎𝑡𝑖𝑜𝑛𝑠 = 2 ∗ 2 ∗ 2 ∗ 2 = 16
Then they have to determine the combinations and calculate their values using the
previous formula as shown in Table 12.
Table 13: Combinations & their values

i Combination Value
1. 𝑃1 𝑅1 𝑉1 𝐿1 942.477
2. 𝑃1 𝑅1 𝑉1 𝐿2 950.397
3. 𝑃1 𝑅1 𝑉2 𝐿1 883.5729
4. 𝑃1 𝑅1 𝑉2 𝐿2 890.5302
5. 𝑃1 𝑅2 𝑉1 𝐿1 1282.817
6. 𝑃1 𝑅2 𝑉1 𝐿2 1293.5969
7. 𝑃1 𝑅2 𝑉2 𝐿1 1202.6409
8. 𝑃1 𝑅2 𝑉2 𝐿2 1212.1106
9. 𝑃2 𝑅1 𝑉1 𝐿1 1130.9733
10. 𝑃2 𝑅1 𝑉1 𝐿2 1140.4773
11. 𝑃2 𝑅1 𝑉2 𝐿1 1060.2875

| P a g e 11
IE 431 H.W 3

12. 𝑃2 𝑅1 𝑉2 𝐿2 1068.6362
13. 𝑃2 𝑅2 𝑉1 𝐿1 1539.3804
14. 𝑃2 𝑅2 𝑉1 𝐿2 1552.3164
15. 𝑃2 𝑅2 𝑉2 𝐿1 1443.1691
16. 𝑃2 𝑅2 𝑉2 𝐿2 1454.5327

These combinations with orange background values have fallen in the range (1200 –
1400). The researchers now must generate random numbers between Zero and One to
find the best combination among these four combinations. Table 14 shows the used
random numbers.

Table 14: Random numbers

Set 1 0.1227 0.3487 0.8361 0.5

Set 2 0.0038 0.0889 0.0217 0.0080
Set 3 0.9762 0.9912 0.3288 0.9166

Now the researchers have to use these numbers with each chosen combination to find
the Mean and Standard Deviation of each combination, based on that the researchers
have to choose the best combination for the oil pipe.
• 𝑃1 𝑅2 𝑉1 𝐿1
Table 15: P1 R2 V1 L1 values

Set P R V L F
1 45.3536 67.6670 84.8928 40 1020.7464
2 39.3226 61.9146 69.9008 32.7733 899.5702
3 57.9237 84.2436 77.7839 44.1477 2233.8776
Mean 1384.7314
STD 602.4715

• 𝑃1 𝑅2 𝑉1 𝐿2
Table 16: P1 R2 V1 L2 values

Set P R V L F
1 45.3536 67.6670 84.8928 45 1028.7946
2 39.3226 61.9146 69.9008 40.1822 912.4113
3 57.9237 84.2436 77.7839 47.7651 2247.9433
Mean 1396.3831
STD 604.0157

• 𝑃1 𝑅2 𝑉2 𝐿1

| P a g e 12
IE 431 H.W 3

Table 17: P1 R2 V2 L1 values

Set P R V L F
1 45.3536 67.6670 88.9142 40 971.8294
2 39.3226 61.9146 76.9206 32.7733 812.8569
3 57.9237 84.2436 83.2271 44.1477 2077.4028
Mean 1287.3630
STD 562.3997

• 𝑃1 𝑅2 𝑉2 𝐿2
Table 18: P1 R2 V2 L2 values

Set P R V L F
1 45.3536 67.6670 88.9142 45 979.1219
2 39.3226 61.9146 76.9206 40.1822 823.3273
3 57.9237 84.2436 83.2271 47.7651 2089.5617
Mean 1297.3369
STD 563.7866

• After calculating the Means and Standard Deviations of each combination, then
the best combination will be the one that has the lowest Standard Deviation,
which is 𝑃1 𝑅2 𝑉2 𝐿1 .
• The final robust design is 𝑃1 𝑅2 𝑉2 𝐿1 with Mean = 1287.3630 and STD =
562.3997.

Problem.No.5
If the USL = 110.5 and LSL =79.5. Find the capability of the process by using the two
methods (Cp and ppm) given that: 𝜎 = 0.333, 𝜇 = 100?
𝑈𝑆𝐿 − 𝐿𝑆𝐿
𝐶𝑝 =
6∗𝜎
110.5 − 79.5
𝐶𝑝 = = 15.6
6 ∗ 0.33

𝑈𝑆𝐿 − 𝜇 𝐿𝑆𝐿 − 𝜇
𝑃𝑃𝑀 = [𝑝 (𝑍 ≥ ) + 𝑝 (𝑍 ≤ )] ∗ 10^6
𝜎 𝜎
110.5 − 100 79.5 − 100
𝑃𝑃𝑀 = [𝑝 (𝑍 ≥ ) + 𝑝 (𝑍 ≤ )] ∗ 10^6
0.333 0.333
𝑃𝑃𝑀 = [∅(𝑍 ≥ 31.88) + ∅(𝑍 ≤ −61.56)] ∗ 10^6

| P a g e 13
IE 431 H.W 3

𝑃𝑃𝑀 = [1 − 𝑝(𝑍 ≤ 31.88) + 𝑝(𝑍 ≤ −61.56)] ∗ 10^6

𝑃𝑃𝑀 = [1 − ∅(31.88) + ∅(61.56)] ∗ 10^6
𝑃𝑃𝑀 = [1 − 0.000001] ∗ 106 = 1,000,000
The process is capable of meeting specification. However, the process variation is
large it may produce many defective items

Problem No.6
If the USL = 110.5 and LSL =79.5. Find the capability of the process (Cpk) given
that: σ=0.01, μ=101.7?
μ − 𝐿𝑆𝐿 101.7 − 79.5
𝐶𝑃𝐿 = = = 740
3∗𝜎 3 ∗ 0.01
𝑈𝑆𝐿 − μ 110.5 − 101.7
𝐶𝑃𝑈 = = = 293.33
3∗𝜎 3 ∗ 0.01
𝐶𝑝𝑘 = min(𝐶𝑃𝐿, 𝐶𝑃𝑈) = min(740,293.3) = 293.33

Problem No.7
the process is shifted to 88. Find the variance that meet six-sigma requirements? given
that: LSL=80, USL 92 μ=86?
𝑀𝑒𝑎𝑛 − 𝑈𝑆𝐿 = 6(𝜎)
92 − 88 = 6(𝜎)
𝜎 = 0.6667

Conclusion
In this Assignment, several problems with different methods were covered by applying
the strategies of Industrial Engineering. Researchers in this Assignment faced some
interesting problems and solved it using the knowledge that they learned from IE 431
Course (Quality Control) which was very beneficial during the whole journey of
solving the problems. The topics which were solved in this Assignment include Normal
Distribution, Generating Random Variates, Robust Design, Process Capability, and
Six-Sigma. The first three problems were solved using the process of Generating
Random Variates. After that, the fourth problem was about Robust Design with the
usage of Poiseuille’s Law. Finally, the last three problems were about the Process
Capability and Six-Sigma.

| P a g e 14
IE 431 H.W 3

Reference
Amar, R. (n.d.). Normal distributions. Retrieved September 11, 2022, from
https://www.stapplet.com/normal.html

| P a g e 15
IE 431 H.W 3

Appendix

Figure 3: P4. Alternative 1

Figure 4:P4. Alternative 2

| P a g e 16