INDIAN INSTITUTE OF TECHNOLOGY KHARAGPUR Departament of Industrial and Systems Engineering End Autumn Semester Examination, 2015 Third Year BTech(IiyDual Degree in IM, QE and QM. Subject Number: IM31005 ‘Subject Name: Quality Design and Control Full Marks: 100 Time: 3 Hours Date, Time, and Venue of Examination: 26.11.2015, 14.00-17.00 F232/8302/NR221/NR322 Number of Students appearing in the Examination: 46 Tnstructions : 1. Attempt Question No, | and any five from the rest 2. Maximum inarks are shown against each question. 3. Answers should be short and to the point, 4, Statistical and other tables as required are attached with the Question Paper. QUI (a) Discuss how the precision of measuring instruments may affect the process Distinguish between gauge repeatability and gauge (3+2) (b) What are the parameters of a variable sampling plan for which the process average quality is of interest? Explain the working procedure of such a plan when single and double specification limits are given. What are the limitations of such plans? (1+2+2) (e). Reliability of a product can be inceeased by several means, What are they Explain the procedure of conducting: sequential reliability test. (2+ 3) (4) Cite an example of a ‘robust’ product, How is ‘robustness’ of such a product assured and sustained with Laguchi’s method? Mention the steps involved in ‘this respect. (i+) Q.2 (a) What is *failure-rate” curve’? How is ii modelled by Weibull distibution? 044 (b) A standby system has-a basic unit with three standby components, The time to failure of each component has an exponential distribution with a failure rate of 0.008 per hour. For a $00-h operation period, find the reliability of the stindby syste. What is its mean time to failure? Suppose all four components are operating simultaneously in parallel What would the system reliability be in that situation? What would the mean time us failure he? (2+1+241) (© Construct the OC curve for the life testing plan n= 6, T= 800 h, e = 2. Kor a producer's risk of 0.05. what is the associated quality of batches as indicated by their mean life? Tor a consumer's risk of 0.10, what is the associated quality level of batches as indicated by their meun life? (S+1+1) PTO@ Q.3 (a) A dairy has to control the amount of butterfat in its Low-fat milk. ‘The upper specification limit of the fat content is 4 for 4-L containers, ‘The standart deviation of the fat content for these containers is estimated to be 0.3 g. Ik is desired to accept 95% of the shipments when the proportion of containers that are nonconforming is 1%, Additionally, when 7% of the containers are noncontirming. the probability af acceptance is desired to be 8%. Find the parameters of @ variable sampling plan and explain ils operation, assuming: that the first condition is to be satisfied exactly. Demonstrate the use of both Farm 1 and Form 2 a) (b) Lf reetification inspection is used, state and derive the possible criteria to use in choosing attribute sampling plans. +2) (c) Compare and contrast (i) ChSP and SeqSP and {ii} CSP-| and SKSP-1, How ‘would you explain the working of a Double Sampling Plan in variable category”? (Lt l+3p Qe (a) Explain, with a flowchart only, the working of a CSP-T and a CSP-¥ plan, What are the limitations of a typical Continuins Sampling Plan? (542541) 32, plot the OC curve. rc) (b) For the CSP-1 plan with f= 4 and (e) Define “Inspection level’ and “Inspection type’ under £14 standards Fxplain, with a flowehart only, the working of 'Switching Rules’ under this standard (0.540544) Q.5 (a) What is the motivation behind constructing makivartate contol charts? Explain the procedure of a constructing a bivariate control chart with an example. a+) (b) ‘The data that follow are temperature readings from a chemical process i "C. taken every 2 minutes. 953 | vas | 949 | 937 | 959 [yay oss | 952 94s | 973 946 | 939 355 [931 bag [95s | oF 945 | 950 ai | 997 | 975 | o4e | 934 [oat 970 | 957 | 937 | 933 62 946 | Gon | 949 | 963 | 963 | 933973. $2 | 948 | gor | you | 940 969 934 | 996 | 973 | 9a | 1 965 | 980 [927 The target value for the mean is yy ~ 950. (3) Set up and apply a tabular cusum fir this process using standardized values h= 5 and k = 0.5. Interpret this chart, (i@) What is the main limitation of V-mask template in this regurd? m+ PTO3) (e) Why do you use a trend control chart? Write dawn its control timits expressions. ara 0.6 (a) What are the main purposes of applying ‘Taguehi’s Method for products or processes? Describe, in brief, the three phases of Taguchi's Method. (2+ 4) (b) The foree needed ta break apart parts joined by the adhesive determines the strength of an adhesive. Assume the functional limits for the strength of the adhesive are m + 4.2 kgf. Assume that the average cost for repairing oF seplacing an adhesive with unacceptable strength is Rs 3,000. The target value of strength is 3 kyf. Determine (i) the quulity loss to customers who purchased the adhesi wgth of 2 ket, and (ii) the average quality loss for a set of adhesives, Assuming that there are twa machines making the adhesives, one new machine and an older model, that has a good deal of wear and tear on it (44) New Machine [2.80 [290 | S10] 270 [330 [ms [273385 SIS ‘Old Machine [3.50 [2.70 [3.40] 1.20 [2.90345 [3.35 2.80 | 2.75 (©) What is a ‘manufacturing tolerance"? Why is it used? a+ Q.7 (a) Define S/N ratio. Is this ratio acceptable for all types of products? For a “target is best’ quality characteristic, derive the expression of S/N ratio in two situations; variance is independent of mean, and variance is related to- mean. (4+142+2) pare the quality levels of two metals, Ml and M2 that cost Rs 6,000 and 01) per unit weight, respectively. The lower specification Timit for tensile strength is 5 Nim’, The out-ospecification units are discarded, resulting in a lows of Rs 4,000 per unit. The annual production rate is 20,000 units, 20 units were tested for each (ype of metal, and the following data for the tensile strength were obtained. (443) Heal Tene reg NP ML 32) 153 |_ 180 5 | is | 135 | 13 | s{ ws ist ss ast is2[ eT 2s! M2 2, i] 03] iso | 12 98 |_ws| 113] 1s] 97] {e) Cite two examples of ‘interference’ fit, Define ‘statistical tolerance limits’ of 8 component, (0.54242)