Quality Engineering - Tut. Sheet 3 2020

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MECHANICAL ENGINEERING DEPARTMENT

B. Tech. VII Semester (Mechanical Engineering)


QUALITY ENGINEERING (PE-I)
TUTORIAL SHEET- 3 (p and c Control Charts for nonconformities)

1. A certain product is given 100% inspection as it is manufactured, and the resultant data are
summarized by the hour. In the following table, 16 h of data is recorded. Calculate the central
line and variable control limits of a p chart using 3-sigma control limits, and indicate the values
that are out of control.
Hour No. of units inspected No. of units outside specs
1 48 5
2 36 5
3 50 0
4 47 5
5 48 0
6 54 3
7 50 0
8 42 1
9 32 5
10 40 2
11 47 2
12 47 4
13 46 1
14 46 0
15 48 3
16 39 0

2. Example 1 states that "because the daily production is not constant, it would be incorrect to
average the values of p."Compute the correct values of from the following data:
Lot No. inspected No. of units outside specs p
1 1200 18 0.015
2 750 40 0.053
3 150 26 0.173
4 75 15 0.200
5 225 23 0.102
Total 2400 122

3. A manufacturer purchases small bolts in cartons that usually contain several thousand bolts.
Each shipment consists of a number of cartons. As part of the acceptance for these bolts, 400
bolts are selected at random from each carton and are subjected to visual inspection for certain
nonconformities. In a shipment of 10 cartons, the respective percentages of rejected bolts in the
samples from each carton are 0, 0, 0.5, 0.75, 0, 2.0, 0.25, 0, 0.25 and 1.25. Does this shipment
of bolts appear to exhibit statistical control with respect to the quality characteristics examined
in this inspection?
4. Daily inspection records are maintained on production of a special-design electronic device.
100 items have been inspected each day for the past 21 days. A total of 546 items failed during
a particularly severe heat stress test. The four highest and lowest values of p are:
Highest Lowest
0.46 0.18
0.33 0.18
0.31 0.20
0.31 0.21

5. A p chart is used to control brake pad assemblies used in automotive production. The average
number of units inspected in each shift is 500, and the chart uses a target value po of 0.010.
a) What are the control limits on the p chart based on the average number of units inspected on
a shift?
b) Assume that the process actually is operating at a µp of 0.018. Estimate the probability that
any one point plot would fall within the control limits when 500 500 units are inspected.
c) What is the probability that five consecutive points would fall within the control limits?
Assume suitable data, wherever necessary.
6. A p chart has been used to monitor the quality of output of a certain mechanical device. At
present, the process is operating at a constant µp of 0.02. An average of 350 units are produced
each day and subjected to 100% insection.
(a) Calculate the control limits based on the average daily output.
(b) On one particular day 450 units were inspected of which 22 were rejected. Was the process
operating in control that day?
(c) On a day when 350 units are inspected, the process shifts to a µ p of 0.04. Find the
probability that this shift will be detected on this subgroup. Assume that the shift occured at the
beginning of the day.
7. A company purchases a small metal bracket in containers of 5000 each. Ten containers have
arrived at the unloading facility, and 250 brackets are selected at random from each container.
The fraction nonconforming in each sample are 0, 0, 0, 0.004, 0.008, 0.020, 0.004, 0, 0, and
0.008. Do the data from this shipment indicate statistical control?
8. A process is being controlled with a fraction nonconforming control chart. The process average
has been shown to be 0.07. Three-sigma control limits are used, and the procedure calls for
taking daily samples of 400 items.
(a) Calculate the upper and lower control limits.
(b) If the process average should suddenly shift to 0.10, what is the probability that the shift
would be detected on the first subsequent sample?
(c) What is the probability that the shift in part (b) would be detected on the first or second
sample taken after the shift?
9. The following table gives the number of missing rivets noted at an aircraft final inspection:
Airplane number Number of missing rivets
201 8
202 16
203 14
204 19
205 11
206 15
207 8
208 11
209 21
210 12
211 23
212 16
213 9
214 25
215 15
216 9
217 9
218 14
219 11
220 9
221 10
222 22
223 7
224 28
225 9
Compute trial control limits and plot a c chart for c. What values of c o would you suggest for
subsequent period?
10. A c chart is used to monitor surface imperfections on porcelain enameled water heater cabinets.
Each cabinet is checked for nonconformities of a certain classification and the count entered on
the c chart. Two limits are used on the chart: a control limit at +3 and a warning limit at +2.
If a point falls above the control limit or if two points in a row fall between the warning limit
and the control limit, the process is stopped until the problem is identified and corrected. The
centre line is aimed-at value co of 1.5.
Find the value of the control limit and warning limit.
If the process suddenly shifts to a mean value of 4, what is the probability that a point will fall
above the control limit?

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