INDU 372 Assignment 6 Solutions

6-3.
(a)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-R
Xbar-R Chart of Ex5-3Dia
U C L=47.53
40
Sample Mean

20 _
_
X=10.9
0

-20
LC L=-25.73
2 4 6 8 10 12 14 16 18 20
Sample

150
U C L=134.3
Sample Range

100

_
R=63.5
50

0 LC L=0
2 4 6 8 10 12 14 16 18 20
Sample

The process is in statistical control with no out-of-control signals, runs, trends, or cycles.
(b)
σˆ x R=
= = 27.3
/ d 2 63.5 / 2.326
(c)
USL = +100, LSL = –100
USL − LSL +100 − (−100)
=Cˆ P = = 1.22 , so the process is capable.
6σˆ x 6(27.3)
MTB > Stat > Quality Tools > Capability Analysis > Normal
Process Capability Analysis of Ex5-3Dia

LSL USL
Process Data W ithin
LSL -100.00000 O v erall
Target *
USL 100.00000 Potential (Within) Capability
Sample Mean 10.90000 Cp 1.22
Sample N 100 CPL 1.35
StDev(Within) 27.30009 CPU 1.09
StDev(Overall) 25.29384 Cpk 1.09
CCpk 1.22
Overall Capability
Pp 1.32
PPL 1.46
PPU 1.17
Ppk 1.17
Cpm *

-90 -60 -30 0 30 60 90

Observed Performance Exp. Within Performance Exp. Overall Performance
PPM < LSL 0.00 PPM < LSL 24.30 PPM < LSL 5.81
PPM > USL 0.00 PPM > USL 549.79 PPM > USL 213.67
PPM Total 0.00 PPM Total 574.09 PPM Total 219.48

1
 6-4.
(a)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-R
Xbar-R Chart of Thickness (Ex5-4Th)
0.0640
U C L=0.063893

0.0635
Sample Mean

_
_
0.0630 X=0.062952

0.0625

0.0620 LC L=0.062011
1
2 4 6 8 10 12 14 16 18 20 22 24
Sa mple

1
0.0024 U C L=0.002368
Sample Range

0.0018

0.0012 _
R=0.00092
0.0006

0.0000 LC L=0

2 4 6 8 10 12 14 16 18 20 22 24
Sa mple

Test Results for Xbar Chart of Ex6-4Th

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 22
TEST 5. 2 out of 3 points more than 2 standard deviations from center line (on
one side of CL).
Test Failed at points: 22

Test Results for R Chart of Ex6-4Th

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 15
* WARNING * If graph is updated with new data, the results above may no
* longer be correct.

The process is out-of-control, failing tests on both the x and the R charts. Assuming assignable causes
are found, remove the out-of-control points (samples 15, 22) and re-calculate control limits. With the
revised limits, sample 14 is also out-of-control on the x chart. Removing all three samples from
calculation, the new control limits are:

Xbar-R Chart of Thickness (Ex5-4Th)

(S amples 15, 22, 14 removed from control limits calculations)
0.0640 1
UCL=0.063787

0.0635
Sample Mean

_
_
0.0630 X=0.062945

0.0625

LCL=0.062104
0.0620
1
2 4 6 8 10 12 14 16 18 20 22 24
Sample

1
0.0024
UCL=0.002118
0.0018
Sample Range

0.0012
_
R=0.000823
0.0006

0.0000 LCL=0

2 4 6 8 10 12 14 16 18 20 22 24
Sample

(b)
σˆ x R=
= = 0.000486
/ d 2 0.000823 /1.693

2
 (c)
Natural tolerance limits are: x ± 3σ=
ˆ x 0.06295 ± 3(0.000486)
= [0.061492, 0.064408]
(d)
Assuming that printed circuit board thickness is normally distributed, and excluding samples 14, 15,
and 22 from the process capability estimation:
USL − LSL +0.0015 − (−0.0015)
=Cˆ P = = 1.028
6σˆ x 6(0.000486)

MTB > Stat > Quality Tools > Capability Analysis > Normal
Process Capability Analysis of Thickness (Ex5-4Th_w/o)
(Estimated without Samples 14, 15, 22)

LSL USL
Process Data W ithin
LSL 0.06150 O v erall
Target *
USL 0.06450 Potential (Within) Capability
Sample Mean 0.06295 Cp 1.03
Sample N 66 CPL 0.99
StDev(Within) 0.00049 CPU 1.07
StDev(Overall) 0.00053 Cpk 0.99
CCpk 1.03
Overall Capability
Pp 0.94
PPL 0.90
PPU 0.97
Ppk 0.90
Cpm *

0.0616 0.0620 0.0624 0.0628 0.0632 0.0636 0.0640 0.0644

Observed Performance Exp. Within Performance Exp. Overall Performance
PPM < LSL 15151.52 PPM < LSL 1467.61 PPM < LSL 3419.33
PPM > USL 0.00 PPM > USL 689.70 PPM > USL 1814.55
PPM Total 15151.52 PPM Total 2157.31 PPM Total 5233.88

6-5.
(a)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-S (Ex6-5Vol)
Under “Options, Estimate” select Sbar as method to estimate standard deviation.
Xbar-S Chart of Fill Volume (Ex5-5Vol)
1.0 U C L=1.037

0.5
Sample Mean

_
_
0.0 X=-0.003

-0.5

-1.0 LC L=-1.043
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sa mple

2.0
U C L=1.830

1.5
Sample StDev

_
S =1.066
1.0

0.5
LC L=0.302
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sa mple

The process is in statistical control, with no out-of-control signals, runs, trends, or cycles.
(b)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-R (Ex6-5Vol)

3
 Xbar-R Chart of Fill Volume (Ex5-5Vol)
1.0 U C L=0.983

0.5

Sample Mean
_
_
0.0 X=-0.003

-0.5

-1.0 LC L=-0.990
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

6.0
U C L=5.686

4.5
Sample Range

_
3.0 R=3.2

1.5
LC L=0.714
0.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

The process is in statistical control, with no out-of-control signals, runs, trends, or cycles. There is no
difference in interpretation from the x − s chart.
(c)
Let α = 0.010. n = 15, s = 1.066.
CL= s= 2
1.066=2
1.136
UCL = s 2 (n − 1) χα2 / 2,n −1 = 1.0662 (15 − 1) ( χ 0.010
2
/ 2,15 −1 ) = 1.066 (15 − 1) ( 31.32 ) = 2.542
2

LCL= s 2 (n − 1) χ12−(α / 2),n −1= 1.0662 (15 − 1) ( χ12−(0.010 / 2),15−1 )= 1.0662 (15 − 1) ( 4.07 )= 0.330

MINITAB’s control chart options do not include an s2 or variance chart. To construct an s2 control
chart, first calculate the sample standard deviations and then create a time series plot. To obtain sample
standard deviations: Stat > Basic Statistics > Store Descriptive Statistics. “Variables” is column
with sample data (Ex6-5Vol), and “By Variables” is the sample ID column (Ex6-5Sample). In
“Statistics” select “Variance”. Results are displayed in the session window. Copy results from the
session window by holding down the keyboard “Alt” key, selecting only the variance column, and then
copying & pasting to an empty worksheet column (results in Ex6-5Variance).

Graph > Time Series Plot > Simple

Control limits can be added using: Time/Scale > Reference Lines > Y positions

Control Chart for Ex5-5Variance

2.5 UCL = 2.542

2.0
s^2 (Variance)

1.5

CL = 1.136
1.0

0.5
LCL = 0.33

0.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

4
 Sample 5 signals out of control below the lower control limit. Otherwise there are no runs, trends, or
cycles. If the limits had been calculated using α = 0.0027 (not tabulated in textbook), sample 5 would
be within the limits, and there would be no difference in interpretation from either the x − s or the x−R
chart.

6-12.
50 50
=n 6 items/sample;=
∑ xi 2000;= =
∑ Ri 200; m 50 samples
=i 1 =i 1

(a)
50 50
∑ xi 2000 ∑ Ri 200
=x i= = 40; =
1 =i 1
R = = 4
m 50 m 50
UCL x =+
x A2 R =
40 + 0.483(4) =41.932
LCL x =−
x A2 R =
40 − 0.483(4) =
38.068
=
UCL R D=
4R = 8.016
2.004(4)
=
LCL R D=
3R = 0
0(4)

(b)
x 3 ( R / d2 ) =
natural tolerance limits: x ± 3σˆ x =± 40 ± 3(4 / 2.534) =
[35.264, 44.736]

(c)
USL - LSL +5.0 − (−5.0)
=Cˆ P = = 1.056 , so the process is not capable.
6σˆ x 6(1.579)

(d)
 36 − 40 
pˆ scrap = Pr{x < LSL} = Pr{x < 36} =Φ   =Φ (−2.533) = 0.0057 , or 0.57%.
 1.579 
 47 − 40 
pˆ rework = Pr{x > USL} = 1 − Pr{x < USL} = 1 − Φ   = 1 − Φ (4.433) = 1 − 0.999995 = 0.000005 or
 1.579 
0.0005%.
(e)
First, center the process at 41, not 40, to reduce scrap and rework costs. Second, reduce variability
such that the natural process tolerance limits are closer to, say, σˆ x ≈ 1.253 .

6-15
(a)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-R

5
 Xbar-R Chart of Strength Test (Ex5-15aSt)
85.0 U C L=84.58

82.5
Sample Mean

_
_
80.0
X=79.53

77.5

75.0
LC L=74.49
2 4 6 8 10 12 14 16 18 20
Sa mple

20
U C L=18.49

15
Sample Range

10 _
R=8.75

0 LC L=0
2 4 6 8 10 12 14 16 18 20
Sa mple

Yes, the process is in control—though we should watch for a possible cyclic pattern in the averages.
(b)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-R
Under “Options, Estimate” use subgroups 1:20 to calculate control limits.
Xbar-R Chart of Strength Test (Ex5-15bSt)
1
85.0 U C L=84.58
8

82.5 8
Sample M ean

8
_
_
80.0 X=79.53

77.5

75.0
LC L=74.49
1 1
3 6 9 12 15 18 21 24 27 30 33
Sample

30 1 1
1
1 1
1
Sample Range

1
20
U C L=18.49

2
10 _
R=8.75

0 LC L=0

3 6 9 12 15 18 21 24 27 30 33
Sample

Test Results for R Chart of Ex6-15bSt

TEST 1. One point more than 3.00 standard deviations from center line.
Test Failed at points: 25, 26, 27, 31, 33, 34, 35
TEST 2. 9 points in a row on same side of center line.
Test Failed at points: 32, 33, 34, 35

A strongly cyclic pattern in the averages is now evident, but more importantly, there are several out-of-
control points on the range chart.

6
 6-30.
30 30
=n 6;=
∑ xi 6000;= =
∑ Ri 150; m 30 samples
=i 1 =i 1

(a)
30
∑ xi 6000
=x = = 200
i =1
m 30
30
∑ Ri 150
=
R = = 5
i =1
m 30
UCL x =+x A2 R =
200 + 0.483(5) =
202.42
LCL x =−
x A2 R =
200 − 0.483(5) =
197.59
=
UCL R D=
4R = 10.02
2.004(5)
LCL =R D= 3R = 0
0(5)
(b)
=σˆ x R= = 1.97
/ d 2 5 / 2.534
USL − LSL +5 − (−5)
=Cˆ p = = 0.85
6σˆ x 6(1.97)
The process is not capable of meeting specification. Even though the process is centered at nominal,
the variation is large relative to the tolerance.
(c)
 202.42 − 199   197.59 − 199 
β − risk = Pr{not detect} = Φ  −Φ 
 1.97 6   1.97 6 
= Φ (4.25) − Φ (−1.75) = 1 − 0.04006 = 0.95994