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The document discusses various statistical measures and control charts used to assess process capability and quality characteristics in manufacturing. It includes calculations for Cp, Cpk, and PCR, as well as the estimation of control limits and probabilities of defects in different scenarios. Additionally, it addresses the implications of shifts in process mean and standard deviation on product quality and conformity to specifications.

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mickey
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6 views

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The document discusses various statistical measures and control charts used to assess process capability and quality characteristics in manufacturing. It includes calculations for Cp, Cpk, and PCR, as well as the estimation of control limits and probabilities of defects in different scenarios. Additionally, it addresses the implications of shifts in process mean and standard deviation on product quality and conformity to specifications.

Uploaded by

mickey
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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There are some important differences in the way various capability measures respond to changes

in the process as it is represented by a statistical distribution. Consider a process producing a


product with an important quality characteristic that has a nominal value of 74, an upper
specification of 82, and a lower specification of 66.

For the following process situation, graphically depict each of the 3 cases, assuming the process
to be in control. Find the Cp, Cpk and PCR.
=
a. X = 74,  x = 2.67
=
b. X = 78,  x = 2.67
=
c. X = 82,  x = 2.67
d. Comment on the trends that occur for each index.
Figure below shows an assembly of 4 components. The length of each component is normally
distributed as follows (in cm):
X1 ~ N(2.5,  1 ), X2 ~ N(2.4,  2 ), X3 ~ N(2.4,  3 ), X4 ~ N(3.0,  4 ). If the specifications
2 2 2 2

are 10.30 +/- 0.24cm. Suppose that the natural tolerance limits for each component , and for the
final assembly, are such that the fraction falling out of the limits is 0.0026. Suppose further that
the design calls for PCR = 1.0.

X1 X2 X3 X4

Assembly with 4 components


25 samples of size 5 are drawn from a process at one hour intervals, and the following data are
obtained:

25 25 25
 X i = 362.75 ,  Ri = 8.60 ,  S i = 3.64
i =1 i =1 i =1

_
1. Find the trial control limits for X & R
_
2. Repeat part 1) for X & S
3. Suppose the specification limits are 14.50 +/- 0.50
a. What conclusions can you draw about the ability of the process to operate within
these limits? – Estimate the percentage of defective items that will be produced?
b. Estimate Cp, Cpk and PCR. – Interpret these ratios.
−
Control charts for X and S have been maintained on a process and have exhibited
statistical control. The sample size is n=6. The control charts parameters are as follows:
−
X chart: UCL =708.2, Centerline = 706.0, LCL =703.80
S chart: UCL =3.420, Centerline = 1.738, LCL =0.052

a. Estimate the mean and standard deviation of the process.


b. Estimate the natural tolerance limits for the process.
c. Assume that the process output is well modeled by a normal distribution. If specifications
are 703 and 709, estimate the fraction non-conforming.
d. Suppose the process mean shifts to 702.0 while the standard deviation remains constant.
What fraction nonconforming would results?
e. What are your conclusions regarding the capability of the process to produce items within
specifications?
Samples of n=6 items are taken from a manufacturing process at regular intervals. A normally
−
distributed quality characteristic is measured and X and S are computed for each sample. After
50 subgroups, the following are computed:

50 = 50
 X =1000,  S i = 75
i =1 i =1

−
a. What are the control limits for the X and S Chart?
a. Assuming that all points on both charts within control limits, what are the natural
tolerance limits of the process?
b. If the specification limit are 19 +/- 4, what are your conclusions regarding the ability of
the process to produce items within specifications?
c. Assuming that if an item exceeds the upper specification it can be reworked, and if it is
below the lower specifications limit it must be scrapped, what percent scrap and rework
is the process now producing?.
d. If the process were centered at 19.0, what would be the effect on percent scrap and
rework?
= − = = −
( UCL − = X + A3 . S , Centerline= X , LCL − = X − A3 . S )
X X
− − −
( UCL − = B4 . S , Centerline= S , LCL S = B3 S )
S
−
Control charts for X chart and R chart are maintained for a quality characteristic. The sample
−
size n=6 each and X and R are computed for each sample. After 30 samples, the following are
computed:

30 = 30 −
 X =6690,  R = 1030
i =1 i =1

a. What are the trial limits for the R chart?


−
b. Assuming that the R chart is in control, what are the trial limits for the X charts?
c. Estimate the process mean and standard deviation.
d. If the quality characteristic is normally distributed and specification limits are 220 +/- 35,
estimate the fraction nonconforming.
e. Assuming that the variance remains constant, where should the process mean be located
to minimize the fraction nonconforming?.
= − = = −
( UCL − = X + A2 . R , Centerline= X , LCL − = X − A2 . R )
X X
− − −
( UCL − = D4 . R , Centerline= R , LCL R = D3 R )
R
−
Control charts for X and S have been maintained on a process and have exhibited statistical
control. The sample size is n=6. The control charts parameters are as follows:
−
X chart: UCL =708.2, Centerline = 706.0, LCL =703.80
S chart: UCL =3.420, Centerline = 1.738, LCL =0.052

a. Estimate the mean and standard deviation of the process.


b. Estimate the natural tolerance limits for the process.
c. Assume that the process output is well modeled by a normal distribution. If specifications
are 703 and 709, estimate the fraction non-conforming.
d. Suppose the process mean shifts to 702.0 while the standard deviation remains constant.
What fraction nonconforming would results?
e. What are your conclusions regarding the capability of the process to produce items within
specifications?
A shaft and bearing are to be assembled. The inside diameter of the bearing X 1 is normally
distributed with a mean of 5.0 cm and a standard deviation of 0.02 cm. The outside diameter of

the shaft X 2 is also normally distributed with a mean of 4.92 cm and a standard deviation 0.04

cm. Interference occurs if: Y = X 1 − X 2  0 and wobble occurs if Y = X 1 − X 2  0.18


a. Calculate the probability of interference.
b. Calculate the probability of Wobble.
c. Calculate the probability of Interference or Wobble?
d. How would you reduce the probability of either or both failures? – DISCUSS.

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