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Case Study Assignment

The document outlines a case study assignment for a textile manufacturing company facing fabric defects, requiring a systematic defect analysis. Key tasks include creating a flowchart for the inspection process, a check sheet for defect data, performing a Pareto analysis, and establishing a correlation between machine speed and defect frequency. Additionally, it details the implementation of a Single Sampling Plan (SSP) for quality control, including sampling plan specifics and calculations related to acceptance probabilities and quality limits.

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muneebur024
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2 views

Case Study Assignment

The document outlines a case study assignment for a textile manufacturing company facing fabric defects, requiring a systematic defect analysis. Key tasks include creating a flowchart for the inspection process, a check sheet for defect data, performing a Pareto analysis, and establishing a correlation between machine speed and defect frequency. Additionally, it details the implementation of a Single Sampling Plan (SSP) for quality control, including sampling plan specifics and calculations related to acceptance probabilities and quality limits.

Uploaded by

muneebur024
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Metrology & Quality control(IM-213) Course Teacher: Ms Rabia Siddiqui

Case study Assignment Time allowed: 01 hour

Problem Statement: Textile Industry Defect Analysis

A textile manufacturing company has been facing issues with fabric defects, leading to increased
rework and waste. The company wants to systematically analyze these defects to improve product
quality and reduce losses.

Task:
You are required to perform a defect analysis by following these steps:

1-Draw a Flowchart:

Illustrate the fabric inspection process using a flowchart.

The flowchart below outlines the fabric inspection process:

1️. Start
2️. Fabric roll received from the production line
3. Visual Inspection by Quality Team
4️. If Defect Found, categorize and record it
5️. If No Defect, move to packaging
6️. Analyze defect trends
7️. Take corrective actions if defect rate is high
8️ . End

2-Create a Check Sheet:

During the fabric inspection process, data was collected for 100 fabric rolls, recording the
frequency of different defect types. The observed defects were:

 Weaving Faults occurred 9 times, often due to improper machine tension or yarn
breakage.
 Dyeing Defects were recorded 12 times, primarily caused by uneven dye application or
chemical inconsistencies.
 Printing Errors were noted 11 times, arising from misalignment in the printing process.
 Stains appeared 13 times, making it the most frequent defect, likely due to contamination
during handling or storage.
 Holes/Tears were found 10 times, often resulting from rough fabric handling or machine
issues.
 Misalignment was the least frequent defect, occurring 6 times, typically due to improper
fabric positioning in the production line.

Design a check sheet to collect defect data from the inspection process.
Metrology & Quality control(IM-213) Course Teacher: Ms Rabia Siddiqui
Case study Assignment Time allowed: 01 hour

3-Perform Pareto Analysis:

Using the check sheet data, construct a Pareto Chart to identify the most significant defects
following the 80/20 rule. Prioritize the defects contributing to the majority of quality issues.

Analyze and Conclude Findings:

1. Based on the Pareto Analysis, determine which defect(s) should be addressed first.
2. Provide recommendations on possible process improvements to reduce defect rates and
improve overall quality.

4-Draw a Correlation Chart:

1. Establish a correlation between machine speed and defect frequency using a scatter
plot.
2. Analyze if higher machine speeds contribute to increased defects.

Machine Speed # of Defects


300 5
350 7
400 10
450 9
500 13
550 15
600 17
650 20

Part B: Now, A textile manufacturing company aims to enhance its quality control by
implementing a Single Sampling Plan (SSP) for fabric inspection. The company needs a
structured approach to evaluate incoming fabric rolls while minimizing inspection costs and
maintaining product quality.

Sampling Plan Details:

 Lot Size (N): 5,000 fabric rolls


 Sample Size (n): 100 fabric rolls
 Acceptance Number (c): 3 (If 3 or fewer defective rolls are found, the lot is accepted)
 AQL: 2%
 LQL: 8%
Metrology & Quality control(IM-213) Course Teacher: Ms Rabia Siddiqui
Case study Assignment Time allowed: 01 hour

Proportion Non- Probability of AOQ


Conforming(Po) Acceptance(Pa)
0.01(1%) 0.99 0.0099
0.02(2%) 0.95 0.0190
0.04(4%) 0.78 0.0312
0.06(6%) 0.52 0.0300
0.08(8%) 0.28 0.0224
0.10(10%) 0.10 0.0100
Table 1
1. Plot the Operating Characteristic (OC) Curve using the data from Table 1.
2. What protection offered by the plan at pre-defined quality level.
3. Find AOQL (Average Outgoing Quality Limit).
4. Calculate ATI for 10% Defective Population.

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