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PART A
QUESTION 1

a) A control chart begins with a time series graph. A central line (X) is added as a visual
reference for detecting shifts or trends – this is also referred to as the process location.
Upper and lower control limits (UCL and LCL) are computed from available data and
placed equidistant from the central line. This is also referred to as process dispersion.
Control limits (CLs) ensure time is not wasted looking for unnecessary trouble – the goal
of any process improvement practitioner should be to only take action when warranted.
Control limits are calculated by:

b) Based on the chart, the production of bullet is increasing.

c) As a rule of thumb, you can start calculating control limits after you have 5 points.
Recalculate the control limits after each point until you reach 20. Then you can "lock"
these control limits for the future and use them to judge how the process is behaving
d) Total quality management (TQM) describes a management system wherein a company
attains organizational advancement through a commitment to customer requirements. A
company meets those requirements when it empowers every employee in every
department to maintain high standards and strive for continuous improvement. Total
quality management is the predecessor of many quality management systems, such as Six
Sigma, Lean, and ISO.

QUESTION 2
a) There are two main types of variables control charts. One (e.g. x-bar chart, Delta
chart) evaluates variation between samples. Non-random patterns (signals) in the data
on these charts would indicate a possible change in central tendency from one
sampling period to the next.
i) np-chart
An np-chart is an attributes control chart used with data collected in subgroups that are
the same size. Np-charts show how the process, measured by the number of
nonconforming items it produces, changes over time.
ii) p-chart

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the p-chart is a type of control chart used to monitor the proportion of nonconforming
units in a sample, where the sample proportion nonconforming is defined as the ratio of
the number of nonconforming units to the sample size, n.
iii) c-chart
In statistical quality control, the c-chart is a type of control chart used to monitor "count"-
type data, typically total number of nonconformities per unit. It is also occasionally used
to monitor the total number of events occurring in a given unit of time.

PART B
QUESTION 1

a) For X́
UCL = X́ + A 2 ( Ŕ)
LCL = X́ −A 2 ( Ŕ)
For Ŕ
UCL = D 4 ( Ŕ)
LCL = D3 ( Ŕ)

  X-bar chart R-Bart Chart

UC LC U
A B C D X-bar R-Bar LCL CL L L CL CL
11. 12. 12. 12. 11. 11. 12. 0. 0. 0.
95 00 03 01 12.00 0.08 95 99 03 00 05 12
12. 11. 11. 12. 11. 11. 12. 0. 0. 0.
01 97 98 00 11.99 0.04 95 99 03 00 05 12
12. 12. 12. 12. 11. 11. 12. 0. 0. 0.
00 03 02 01 12.02 0.03 95 99 03 00 05 12
12. 12. 12. 11. 11. 11. 12. 0. 0. 0.
01 03 00 98 12.01 0.05 95 99 03 00 05 12
12. 12. 11. 11. 11. 11. 12. 0. 0. 0.
00 02 96 98 11.99 0.06 95 99 03 00 05 12
11. 11. 11. 12. 11. 11. 12. 0. 0. 0.
97 96 95 00 11.97 0.05 95 99 03 00 05 12
11. 11. 11. 11. 11. 11. 12. 0. 0. 0.
93 98 94 96 11.95 0.05 95 99 03 00 05 12
12. 11. 11. 11. 11. 11. 12. 0. 0. 0.
00 98 95 94 11.97 0.06 95 99 03 00 05 12
12. 11. 11. 11. 11. 11. 12. 0. 0. 0.
02 98 97 98 11.99 0.05 95 99 03 00 05 12
11. 12. 12. 11. 12.00 0.06 11. 11. 12. 0. 0. 0.

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97 03 01 99 95 99 03 00 05 12
X- R-
dblba DblBa
  r12 r0.1  

b) X-Bar Chart
12.04

12.02

12.00

11.98

11.96

11.94

11.92

11.90
1 2 3 4 5 6 7 8 9 10

R-Chart
0.14

0.12

0.10

0.08

0.06

0.04

0.02

0.00
1 2 3 4 5 6 7 8 9 10

QUESTION 2
c ∑ c , UCL=ú+3 ú , LCL=ú−3 ú
a) U= , ú=
n ∑n n n√ √
  n c u U-bar UCL LCL
1.00 1.00 4.00 4.00 2.95 8.11 -2.20

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2.00 1.00 5.00 5.00 2.95 8.11 -2.20
3.00 1.00 3.00 3.00 2.95 8.11 -2.20
4.00 1.00 3.00 3.00 2.95 8.11 -2.20
5.00 1.00 5.00 5.00 2.95 8.11 -2.20
6.00 1.30 2.00 1.54 2.95 7.47 -1.57
7.00 1.30 5.00 3.85 2.95 7.47 -1.57
8.00 1.30 3.00 2.31 2.95 7.47 -1.57
9.00 1.30 2.00 1.54 2.95 7.47 -1.57
10.00 1.30 1.00 0.77 2.95 7.47 -1.57
11.00 1.30 5.00 3.85 2.95 7.47 -1.57
12.00 1.30 2.00 1.54 2.95 7.47 -1.57
13.00 1.30 4.00 3.08 2.95 7.47 -1.57
14.00 1.30 2.00 1.54 2.95 7.47 -1.57
15.00 1.20 6.00 5.00 2.95 7.66 -1.75
16.00 1.20 4.00 3.33 2.95 7.66 -1.75
17.00 1.20 0.00 0.00 2.95 7.66 -1.75
18.00 1.70 8.00 4.71 2.95 6.91 -1.00
19.00 1.70 3.00 1.76 2.95 6.91 -1.00
20.00 1.70 8.00 4.71 2.95 6.91 -1.00
∑ n=¿ ¿ ∑ c=¿ ¿
  25.40 75        
b) U -chart
10.00

8.00

6.00
No of pinholes

4.00
u
U-bar
2.00
UCL
LCL
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

-2.00

-4.00
Subgroup no

QUESTION 5
P a p( N −n)
a) AOQ¿ , ATI= n+ ( 1−Pa ) (N −n)
N
n=150, N=3000, c=2
When P=0.01 and Pa=0.8095 ,

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( 0.8095 ) (0.01)(3000−150)
AOQ¿
3000
= 0.0077
ATI= 150+ ( 1−0.8095 ) (3000−150)
= 692.93

When P=0.02 and Pa=0.4209 ,

( 0.4209 ) (0.02)(3000−150)
AOQ¿
3000
= 0.0079
ATI= 150+ ( 1−0.4209 ) (3000−150)
= 1800.44

When P=0.03 and Pa=0.1693 ,

( 0.1693 ) (0.03)(3000−150)
AOQ¿
3000
= 0.0048
ATI= 150+ ( 1−0.1693 ) (3000−150)
= 2517.50

P Pa AOQ ATI
0.01 0.8095 0.0077 692.93
0.02 0.4209 0.0079 1800.44
0.03 0.1693 0.0048 2517.50

Average Outgoing Quality

0.01
0.01
0.01
AOQ

0
0
0
0.01 0.01 0.02 0.02 0.03 0.03 0.04
p=Incoming Quality Level
b)
The maximum ordinate on the AOQ curve represents the worst possible quality that
results from the rectifying inspection program. It is called the average outgoing
quality limit, (AOQL). From the table we see that the AOQL=0.0079 at p=0.02 for
the above example.