Pages 2 of 8

ESSAY (100 marks)

Instruction: This section consists of SIX (6) essay questions. Answer only FOUR (4)
questions.
QUESTION 1

(a) Give the definitions for quality and zero defect.
(3 marks)

(b) Inspection of products is important to ensure the products quality level.
State and elaborate TWO (2) types of products inspection.
(6 marks)

(c) In a manufacturing steel industry, steel rods are produced through the pultrusion
process. The average of steel rod diameter is 3.20 cm and standard deviation is
0.05 cm. The acceptance level is 3.200.06 cm. Based on this case, sketch and
label a normal curve.
(4 marks)

Calculate:
i. The percentage of rejected rods. (4 marks)

ii. The percentage of the rods reworked. (4 marks)

iii. The percentage of accepted rods. (4 marks)







Pages 3 of 8

QUESTION 2

(a) Define the following terms:

i. Control Charts for Variables (3 marks)
ii. Assignable causes variation (3 marks)
iii. Random variation (3 marks)

(b) Define process capability (Cp) and illustrate cases where process variability
exceeds specifications.
(4 marks)
(c) Table 1 shows some sampling data. By using the table,

i. Determine the mean and range (X and R). (4 marks)

ii. Determine the upper and lower control limit (UCL and LCL). (4 marks)

iii. Draw a control chart from the data. (4 marks)


TABLE 1
Sample
number
Observations (mm)
1 28.28 33.95 30.47 28.87
2 26.92 27.66 31.47 29.67
3 28.46 28.30 29.00 31.14
4 32.43 26.10 29.84 37.20
5 28.84 30.52 32.24 30.47
6 30.75 33.00 28.08 26.20
7 31.26 24.29 35.46 28.41
8 31.25 28.58 35.01 31.24
9 31.42 35.80 33.61 27.82
10 32.20 32.02 32.71 29.38
Pages 4 of 8

QUESTION 3

(a) Differentiate between defect and defective and briefly describe types of attributes
control charts related to each of them.
(10 marks)
(b) Define the word attributes by giving suitable examples.
(5 marks)
(c) Table 2 represents the observed number of defects from an inspection of 30
successive chocolate wafers, each containing 100 chips.
determine :
i. The average number of defects (c)
(4 marks)
ii. The upper and lower control limits ( UCL and LCL)
(6 marks)
TABLE 2
Number of
Chocolate Wafers
Number of defects Number of
Chocolate Wafers
Number of defects
1 19 16 16
2 17 17 14
3 14 18 28
4 16 19 16
5 15 20 12
6 13 21 20
7 14 22 10
8 16 23 12
9 11 24 10
10 20 25 17
11 15 26 10
12 13 27 12
13 10 28 13
14 15 29 18
15 16 30 11


Pages 5 of 8

QUESTION 4

(a) Give TWO (2) types of Control Chart.
(2 marks)

(b) Explain how to choose a control chart suitable for a specific data.
(4 marks)

(c) Table 3 is a data compilation of the length of steel bars.
TABLE 3
Date Time No. of Inspected Bars (mm) Mean Range
B1 B2 B3 B4
1/8/05

9.00
10.00
11.00
12.00
1.00
2.00
3.00
5.85
5.75
5.80
5.65
5.75
5.60
5.65
5.65
5.85
5.80
5.75
5.70
5.75
5.80

5.65
5.75
5.75
5.60
5.65
5.65
5.60

5.70
5.85
5.70
5.70
5.80
5.70
5.60


2/8/05

9.00
10.00
11.00
12.00
1.00
2.00
3.00

5.80
5.75
5.80
5.65
5.85
5.60
5.70

5.75
5.85
5.80
5.65
5.75
5.60
5.80

5.85
5.75
5.80
5.65
5.85
5.70
5.60

5.65
5.75
5.80
5.65
5.75
5.60
5.70


3/8/05

9.00
10.00
11.00
12.00
1.00
2.00
3.00

5.80
5.75
5.80
5.65
5.85
5.80
5.60

5.80
5.75
5.80
5.65
5.85
5.60
5.70

5.80
5.75
5.80
5.65
5.85
5.60
5.65

5.80
5.75
5.80
5.65
5.85
5.80
5.60





Pages 6 of 8

i. Determine the mean and range (X and R). (4 marks)
ii. Determine the central line and control limits. (6 marks)
iii. Plot the points of the chart. (5 marks)
iv. Analyze the plotted points to determine if the process is in
control. Give a reason for your answer. (4 marks)


























Pages 7 of 8

QUESTION 5

(a) Differentiate producers risk and consumers risk.
(4 marks)

(b) In sampling inspection products that do not meet specifications would be rejected.
Explain in detail THREE (3) actions that are usually taken against the rejected
lot.
(9 marks)

(c) Using Table 4, inspector needs to determine the Single Sampling Plans for the
following information:
TABLE 4
INSPECTION
LEVEL
INSPECTION AQL LOT SIZE
i) II Tightened 1.5% 1,400
ii) I Normal 65% 115
iii) III Reduced 0.40% 160,000
(9 marks)

(d) Explain the sampling plan determined in QUESTION 5 (c) iii. if 6
nonconforming units are found in the sample.
(3 marks)








Pages 8 of 8

QUESTION 6

(a) i. State FOUR (4) types of quality cost. (4 marks)

ii. Explain TWO (2) types of quality cost. (4 marks)

iii. Draw and label the curve of quality cost. (2 marks)


(b) i. State the uses of Pareto Diagram. (2 marks)
iii. Using Table 5, construct the Pareto Diagram and discuss
the results. (10 marks)
TABLE 5
Types of defections Number of nonconforming units
Scratch 42
Broken 20
Color not uniform 108
Short mould 10
Flashing 35
Pin hole 15
etc 5

(c) Give the terms for ISO 9000:2000 listed below.
i. ISO 9000
ii. ISO 9001
iii. ISO 9004
( 3 marks)