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Chapter 13 – Statistical Quality Control
CHAPTER 13
STATISTICAL QUALITY CONTROL
Discussion Questions
1. The capability index allows for some drifting of the process mean. Discuss what this means
in terms of product quality output.
When Cpk is larger than 1.0, this means that the mean of the process can drift (up to a limit)
while still producing within specifications. This is what is implied by the phrase “a capable
process." The amount of drift allowed (measured in standard deviations) is Cpk – 1.
2. In an agreement between a supplier and a customer, the supplier must ensure that all parts
are within tolerance before shipment to the customer. What would be the effect on the
cost of quality to the customer?
Before the agreement was made, the customer probably inspected each part to protect
against off-spec supplies. This agreement (ideally) eliminates the need for this inspection.
Appraisal costs, such as materials and supplies inspection and reliability testing, will be
reduced since the agreement would ensure that the supplies are totally within tolerance.
This allows the customer to focus attention on quality improvement within his or her own
processes, requiring an increase in prevention cost. Scrap and rework costs will initially drop
because of the improvement in the quality of the part supply. Once prevention programs are
in force, scrap, repair, rework, and downtime costs will drop even further because of
improvements in the internal process. External failure costs will drop because of
improvement in the product and the process.
3. In the situation described in Question 2, what would be the effect on the cost of quality to
the supplier?
If operating under the traditional definition for the quality control function, appraisal costs
will increase since all parts, not just a sample, must be inspected before shipment. This will
also likely increase the cost of internal failure. These increases will be offset to some degree
by the reduction or elimination of external failure costs.
4. Discuss the purposes and differences between the p-charts and X-bar and R charts.
P-charts are used to monitor the process for attribute data. These are typically binomial “go,
no-go” data. An example of a p-chart is percent of pieces nonconforming. X-bar charts are
used for charting population values for continuous measurement. X-bar charts operate
effectively with smaller sample sizes than p-charts, but it is more involved to analyze the
sample for an X-bar chart since a measurement must be taken. A rule of thumb for the
sample size of a p-chart is to have at least one defective in each sample. This can require a
relatively large sample size in some cases. If the process is slow, an X-bar chart will generally
be a better choice since it functions with smaller sample sizes. An example of an X-bar chart
is average time to complete a mile run for one person. R charts are used to compute process
ranges for variable data, and are generally used in concert with X-bar charts.
13-1
Copyright © 2017 McGraw-Hill Education. All rights reserved. No reproduction or distribution without the prior
written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
Student responses will be widely varied. They should hit on the idea of surveys to convert the
customers’ qualitative thoughts about the service into numerical data. They may also
recognize that waiting and service times are also keys to service quality and can easily be
measured on a quantitative scale.
6. Discuss the trade-off between achieving a zero AQL (acceptable quality level) and a positive
AQL (e.g., an AQL of 2 percent).
The tradeoff involves a cost/precision tradeoff. This is analogous to the service level/cost
tradeoff. From a classical economic point of view, if the cost of defects is very high, an AQL
of zero is economical. If defect costs are nominal, the cost of achieving near perfect quality
can be prohibitive. This assumes that conformance is asymptotic to the cost axis.
7. The cost of performing inspection sampling moves inversely to the cost of quality failures.
We can reduce the cost of quality failures by increased levels of inspection, but that of
course increases the cost of inspection. Can you think of any methods to reduce the cost of
quality failures without increasing a company’s cost of inspection? Think specifically in
terms of material purchased from vendors.
The one thing we expect the students might address here is the idea of vendor relationship
management. Partnering with vendors, purchasing representation in the vendor plant, and
negotiating vendor inspections are several ways to try and achieve this.
13-2
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
Objective Questions
1. Defective average = .04, inspection rate = 50 per hour, cost of inspector = $9 per hour, and
repair cost is $10 each.
a.
Per unit: average cost of quality – cost of inspection ((.04)$10 - $.18 = $.22)
2.
b. The process is capable of producing much better quality, but it would need to be
centered. The capability of the process would then be 1.111 (Z-3.333, .09% defective).
3. Defective average = .02, inspection rate = 20 per hour, cost of inspector = $8 per hour, and
replacement cost is $25 each.
Benefit from the current inspection process per unit is: average cost of quality – cost of
inspection ((.02)$25 - $.40 = $.10)
13-3
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
b.
4.
a. Defective average = .03, inspection rate = 30 per hour, cost of inspector = $8 per
hour, and correction cost is $10 each.
5.
c. Many defects will be produced. Assuming a normal distribution, the left tail
(Prob{x<90}) is z = (90 - 92)/4 = -0.50, which corresponds to a probability of .3085. The
right tail (Prob{x>110} = 1-Prob{x<110})is z = (110-92)/4 = 4.5, which approximately
corresponds to a probability of .1-0.9999966 = 0.0000034.
Therefore0.3085+0.0000034=0.3085 or approximately 31% are outside the specification
limits.
13-4
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
6.
a.
b. No, the machine is not capable of producing the part at the desired quality level.
13-5
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
7.
10
P= = .067
10(15)
P(1 − P) .067(1−.067)
Sp = = = 0.0646
n 15
b. Stop the process and look for the special cause, it is out of statistical control.
13-6
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
8.
Sample Irregularities
1 3
2 5
3 2
4 6
5 5
6 4
7 6
8 3
9 4
10 5
Total 43
a.
s p = c = 2.07
13-7
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
9.
X = 999.1, R = 21.733
The process is in statistical control. Students may not samples 4-8 on the X-bar chart, but
strictly speaking there are only 4 decreases in a row there.
13-8
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
10.
Number
Unsatisfactory Sample
Date Meals Size p
1-Dec 74 1000 0.074
2-Dec 42 1000 0.042
3-Dec 64 1000 0.064
4-Dec 80 1000 0.08
5-Dec 40 1000 0.04
6-Dec 50 1000 0.05
7-Dec 65 1000 0.065
8-Dec 70 1000 0.07
9-Dec 40 1000 0.04
10-Dec 75 1000 0.075
Sum: 600 10000
a.
b. The chart indicates that the process is out of control. The administrator should
investigate the quality of the patient meals.
13-9
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
11.
Sample Crime
Month Crimes Size Rate
January 7 1000 0.007
February 9 1000 0.009
March 7 1000 0.007
April 7 1000 0.007
May 7 1000 0.007
June 9 1000 0.009
July 7 1000 0.007
August 10 1000 0.01
September 8 1000 0.008
October 11 1000 0.011
November 10 1000 0.01
December 8 1000 0.008
SUM: 100 12000
The process appears in control. Therefore, it can be stated that the crime rate has not increased.
However, there appears to be a gradual increasing trend in the crime rate in later data, including the new
Jan – Mar figures given in the problem. That may warrant investigation into the cause, or at the least
should be watched to confirm if there is indeed a trend that continues in future periods.
13-10
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
12.
Sample Crime
Area Crimes Size Rate
1 14 1000 0.014
2 3 1000 0.003
3 19 1000 0.019
4 18 1000 0.018
5 14 1000 0.014
6 28 1000 0.028
7 10 1000 0.01
8 18 1000 0.018
9 12 1000 0.012
10 3 1000 0.003
11 20 1000 0.02
12 15 1000 0.015
13 12 1000 0.012
14 14 1000 0.014
15 10 1000 0.01
16 30 1000 0.03
17 4 1000 0.004
18 20 1000 0.02
19 6 1000 0.006
20 30 1000 0.03
SUM: 300 20000
300 p(1 − p ) .015(1 − .015)
p= = .015 Sp = = = .00384
20(1000) n 1000
Process is out of statistical control. Specifically, three areas outside of UCL warrant further
investigation into the excessive crime rate, and four areas below LCL warrant investigation for
causes of the low crime rates.
13-11
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
13.
X = .499, R = .037
Process appears to be in statistical control, though there is a run of five below the center line in
the X-bar chart.
13-12
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
14.
2.613 2.613
n= = = 87.1, round up to 88
AQL .03
15.
a. AQL = .15, LTPD = .40
4.695 4.695
n= = = 31.3, round up to 32
AQL .15
1. Prepare X-bar and R charts using these data using the method described in the chapter.
The following are the values for the X-bar and R charts. These were obtained from the solution
spreadsheet.
Standard deviation of the sample means =
0.281257
Average range =
5.932155
13-13
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
2. Analyze the chart and comment on whether the process appears to be in control and stable.
X-bar Chart
36
34
32
30 Mean
28
UCL
26
24 LCL
22
20
1 3 5 7 9 1113151719212325
Range Chart
15
10 Range
UCL
5
LCL
0
1 3 5 7 9 1113151719212325
Based on just looking at the charts using the sample data, the process appears to be in control.
13-14
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Chapter 13 – Statistical Quality Control
3. Twelve additional samples of curetime data from the molding process were collected from and actual
production run. Update your control charts and compare the results with the previous data.
X-Bar Chart
45
40
35 Mean
UCL
30
LCL
25
20
1 2 3 4 5 6 7 8 9 10 11 12
Range Chart
18
16
14
12
10 Range
8 UCL
6 LCL
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12
From the charts created with the additional sample data, it appears there is a problem with process. The
mean of the process appears to often exceed the upper control limit. In addition, the range is higher than
it was in the original sample. The process should be examined to learn what is causing the problem.
13-15
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written consent of McGraw-Hill Education.
Chapter 13 – Statistical Quality Control
1. If the specification is such that no washer should be greater than 2.4 millimeters, assuming that the
thicknesses are distributed normally, what fraction of the output is expected to be greater than this
thickness?
The average thickness in the sample is 1.9625 and the standard deviation is .209624. The probability
that the thickness is greater than 2.4 is Z = (2.4 – 1.9625)/.209624 = 2.087068 1 -
NORMSDIST(2.087068) = .018441 fraction defective, so 1.8441 percent of the washers are expected
to have a thickness greater than 2.4.
2. What if there is an upper and lower specification, where the upper thickness limit is 2.4 and the lower
thickness limit 1.4, what fraction of the output is expected to be out of tolerance?
The upper limit is given in a. The lower limit is 1.4 so Z = (1.4 – 1.9625)/.209624 = -2.68337.
NORMSDIST(-2.68337) = .003644 fraction defective, so .3644 percent of the washers are expected to
have a thickness lower than 1.4. The total expected fraction defective would be .018441 + .003644 =
.022085 or about 2.2085 percent of the washers would be expected to be out of tolerance
4. What would be the Cpk for the process if it were centered (assume the process standard deviation is the
same)?
The center of the specification limits is 1.9, which is used for X-bar in the following:
UTL − X X − LTL .5 .5
C pk = min , = min , = min..795, .795 = 0.795
3 3 .6289 .6289
5. What percentage of output would be expected to be out of tolerance if the process were centered?
6. Setup X-bar and Range control charts for the current process. Assume the operators will take samples
of 10 washers at a time.
Observation
Sample 1 2 3 4 5 6 7 8 9 10 X-bar R
1 1.9 2 1.9 1.8 2.2 1.7 2 1.9 1.7 1.8 1.89 0.5
2 1.8 2.2 2.1 2.2 1.9 1.8 2.1 1.6 1.8 1.6 1.91 0.6
3 2.1 2.4 2.2 2.1 2.1 2 1.8 1.7 1.9 1.9 2.02 0.7
4 2.1 2 2.4 1.7 2.2 2 1.6 2 2.1 2.2 2.03 0.8
13-16
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Chapter 13 – Statistical Quality Control
Mean
1.9625 0.65
:
From Exhibit 10.13, with sample size of 10, A2 = .31, D3 = .22 and D4 = 1.78
The upper control limit for the X-bar chart = 1.9625 + .31 x .65 = 2.164
The lower control limit for the X-bar chart = 1.9625 - .31 x .65 = 1.761
The upper control limit for the Range chart = 1.78 x .65 = 1.157
The lower control limit for the Range chart = .22 x .65 = .143
7. Plot the data on your control charts. Does the current process appear to be in control?
With respect to the control limits, the process appears to be in control, though it should be noted that it is
difficult to have confidence in that conclusion based on just four samples. Students should also point out
that there appears to be a positive trend, both in process mean and variability. Again, it would be difficult
to say so with much confidence based on just four samples.
8. If the process could be improved so that the standard deviation was only about .10 millimeters, what
would be the best that could be expected with the processes relative to fraction defective?
The best that could be done is for the process to be centered at 1.9, and given a standard deviation of
.10, then Z = (2.4-1.9)/.1 = 5. The fraction defective = 2 x (1 – NORMSDIST(5)) = 5.73303E-07 which
would only be about 573 defects per billion washers.
13-17
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Another random document with
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ja alkoi heti alussa työntää raskaimpia töitä kälynsä tehtäväksi, mutta
Lyydi oli reipas ja tyytyväinen ja mielikseen näki hänen pyöreät,
ruskettuneet käsivarret kyynäspäihin paljaina kiskovan yksinään
toista nuotansivua, kun Johannes oli ohjaamassa perää ja ukko
Efraim veteli toista puolta.
Ukko oli vihainen kun ei keitto ollut valmiina. Äitipuoli syytti Lyydiä,
jonka töitä hänen täytyi suoritella ja Briita syytti lasta, jonka riepuja
hänen oli täytynyt pestä. Lyydi punehtui sängyssään. Mutta ukko
yltyi ja kun Johannes avasi suunsa, löi hän nyrkkinsä pöytään ja
ärjäsi ettei aikonut elättää pojanvaimoa ja tämän kakaroita.
Johannekselle nousi veri kasvoihin. Hän vastasi ettei aikonut olla
isänsä renkinä ja otti vyönsä seinältä. Akat torailivat, Lyydi itki
sängyssään, keräsi riepuja lapsen ympäri ja yritti nousta:
Äitikulta, saanko olla täällä siksi kun kuolen? En minä kauvaa elä,
sai
Lyydi nyyhkytyksiltään sanotuksi.
I.
Anselm Löf, Skoglannin Löfejä, oli jo kolmas renki, josta oli tullut
isäntä. Anna-Mari, kaunis punakka ihminen, mutta suurisuinen kuin
turska, oli ollut Anselmin kanssa perunoita mullittamassa Ison-Aspön
puolella. Anselm oli tukeva pojanjurikka; oli ohjannut sahroja ja kun
oli päästy kymmenkunnan vakoa oli istuttu pientareelle ja Anselm oli
ruvennut vetämään Anna-Maria palmikosta syliinsä. Oli ollut
helteinen kaunis päivä, käki oli kukkunut siinä lähellä rantamännyssä
ja Anna-Maria oli niin suloisesti raukaissut. Sen mullituspäivän
jälkeen oli sitten talvella Eveliina, vanhin lapsista, syntynyt. Anna-
Mari oli silloin yhdeksäntoista.
Sitä myöten kuin neste pullosta joka peilaukselta aleni alkoi juttu
sentään luistaa. Puhuttiin kauan haudottuja asioita, selvitettiin
sotkuisia tilejä ja arvailtiin tulevan vuoden ilmoja ja kalansaaliita.
Tuntui siltä kuin yksi pahka toisensa jälkeen sulaisi ja häviäisi ja
naapureista tulisi ystävykset.
II.
Oli myrskynnyt markkinaviikon, kuten usein tapahtuu. Meri myllersi
pohjiaan myöten, läikkyi raskaana ja sameana heittäen rannoille
rakkoleviä ja ahvenruohoja korkeiksi valleiksi. Aspöläiset olivat
saaneet pysytellä maissa, sillä silakanpyyntiin ei ollut
yrittämistäkään.
Kun Löf oli päässyt kalliolle, josta oli näköala yli saaren, pysähtyi
hän ja viittasi pojat luokseen. Ulkorannat olivat täynnä lautaa ja
komeata lankkua.
Mutta nyt oli pidettävä kiirettä, sillä yksi ja toinen lauta oli tietysti
vienyt sisäsaarelaisille viestin tapahtumasta.
Parempi oli sittekin lähteä ennen poikien tuloa. Nämä olivat tietysti
tunteneet Vennströmin veneen ja tiesivät hänen käyneen
Skytteskärissä, mutta ehkäpä ilmenisi joku neuvo, kun tilinteko vain
hiukankin lykkäytyisi.
Kun oli päästy Aspön tyveneen oli jo hämärä. Pojat saivat purkaa
lastin, Vennström itse meni tupaan ja heittäytyi ovisänkyyn. Hän
vastasi lyhyesti vaimonsa kysymyksiin, ja oli nukkuvinaan, vaikka
tirkisteli seinänrakoon ja mietiskeli. Vihdoin hän vaipui raskaaseen
uneen.
Anna-Mari itki koko kotimatkan. Hän oli nyt varma siitä että
Anselm ja molemmat pojat olivat hukkuneet purjehtiessaan
Skytteskäristä kotiin. He olivat nähtävästi ottaneet liian suuren
lautalastin, joten vene ei jaksanut tarpeeksi kohoilla aallokossa,
selitti Vennström. Biinus oli hänen puhuessaan ja koko matkan
aikana kumman rauhaton. Hän vältteli katsomasta Eveliinaan, joka
vähän väliä pyhki silmiään esiliinan nurkkaan.
Iltapimeässä kuului hankojen kitinää ja ihmisääniä tyyneltä selältä.
Sieltä olivat tulossa Hamberg ja Kalle Krokström ja perässään he
hinasivat Löfin silakkavenettä. Veneen pohjalla oli heillä lakanan alla
ruumis. Anna-Mari ei saanut jalkojaan tottelemaan, hän jäi istumaan
kammarin sänkyyn. Hän tiesi jo kaikki. Hän ei voinut nähdä
poikaansa Eerikkiä kuolleena, vaan käski viedä ruumiin ranta-
aittaan. Vennströmska toimitti kuolleen pesemisen ja pukemisen.
III.
Kuolinpesänhuutokaupassa Anselm Löfin jälkeen oli vähän väkeä.
Sataa tihuutteli koko päivän. Hamberg oli vasaramiehenä kuten
tavallista semmoisissa tilaisuuksissa. Silakkaverkot menivät halvasta
ja enimmät niistä joutuivat Vennströmille. Kun tuli veneen vuoro,
vallitsi tuvassa hiljaisuus. Löfin suurvene oli jo vanha ja vettynyt;
sitäpaitsi oli se upottanut kolme henkeä, minkä seikan katsottiin
pilanneen sen iäksi. Vennström, joka tahtoi esiintyä ikäänkuin Löf-
vainajan puolenpitäjänä, rykäisi paikallaan ikkunan alla ja tarjosi
huudon pohjaksi neljä markkaa. Vene oli hyvä, se oli vanhan Mastin
tekoa. Kun kukaan ei hänen jälkeen avannut suutaan, paukahti
vasara ja vene oli Vennströmin.
16.