Escuela Politécnica Nacional – Carrera de Ingeniería Mecánica

Gestión de la Calidad - Prueba 4 – 27/1/2019

Estudiante: José Cuascota

Resuelva los siguientes ejercicios (7 + 10 + 13 puntos, 30 puntos en total).

1. The following are the data from 24 lots of size 5. Determine whether the system is in control.
Construct the corresponding OC.

Lot Measurement
1 995 997 1002 995 1000 997,8
2 990 1002 997 1003 1005 999,4
3 1003 1005 998 1004 995 1001
4 1002 999 1003 995 1001 1000
5 1001 996 999 1006 1001 1000,6
6 1004 1001 998 1004 997 1000,8
7 1003 1002 999 1003 1004 1002,2
8 1001 1007 1006 999 998 1002,2
9 999 995 994 991 996 995
10 994 993 991 993 996 993,4
11 994 996 995 994 991 994
12 994 996 998 999 1001 997,6
13 1002 1004 999 996 1000 1000,2
14 1003 1000 996 1000 1005 1000,8
15 996 1001 1006 1001 1007 1002,2
16 995 1003 1004 1006 1008 1003,2
17 1006 1005 1006 1009 1008 1006,8
18 996 999 1001 1003 996 999
19 1001 1004 995 1001 1003 1000,8
20 1003 996 1002 991 996 997,6
21 1004 991 993 997 1003 997,6
22 1003 997 998 1000 1001 999,8
23 1006 1001 999 996 997 999,8
24 1005 1000 1001 998 1001 1001 desves
x 999,7 4,4
desves de x 0,2
UCLX 1005,9
CLX 999,7
LCLX 993,5

A3 1,427

1
 X chart
1008

1006

1004

1002
X Average

X chart
1000
UCL
998
LCL
996 CL
994

992
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

2. We report on initial stages of implementing quality control of the production process of the piston of a
fuel pump for Diesel engine. The pumps are manufactured by a small subcontractor of a major U.S.
company. It has been decided that, initially, four operations, all performed on a digitally controlled
multiple-spindle automatic lathe, should be examined. The operations of interest, numbered from 1 to
4, are indicated in Figure 1. The examination was started by selecting 28 lots of pistons. The lots, each
consisting of five pistons, were taken at each full hour during four consecutive working days.

Figure 1. Piston of a fuel pump.

The table below shows the sample means and sample standard deviations of diameter 2 of pistons (see
Figure 1) for 28 lots of size five. (Measurements are in millimeters.) Comment on whether the system is in
control.

2
lot X s
1 7,996 0,017
2 8,028 0,039
3 8,044 0,075
4 8,036 0,075
5 8,008 0,044
6 8,018 0,032
7 7,962 0,064
8 8,022 0,059
9 8,020 0,025
10 7,992 0,030
11 8,018 0,052
12 8,000 0,034
13 7,980 0,023
14 7,952 0,073
15 7,964 0,039
16 7,964 0,045
17 7,944 0,060
18 7,956 0,035
19 7,992 0,019
20 8,032 0,044
21 7,974 0,080
22 7,946 0,029
23 7,978 0,038
24 7,986 0,058
25 8,016 0,059
26 7,988 0,074
27 7,962 0,041
28 8,002 0,024
X Promedio 7,992
S PROMEDIO 0,046
UCLX 8,058
CLX 7,992
LCLX 7,927
A3 1,427
UCLS 0,096
CLS 0,046
LCLS 0,000
B3 0,000
B4 2,089

3
 Ejercicio 2 S1 chart
0.120

0.100

0.080
X Average

S chart
0.060
UCL

0.040 LCL
CL
0.020

0.000
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

Ejercicio 2 X1 chart
8.080

8.060

8.040

8.020
X Average

8.000 X chart

7.980 UCL

7.960 LCL
CL
7.940

7.920

7.900
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

In the table below, the measurements of diameter 2 (see Figure 1) for lots 50 to 77 are summarized. Before
the measurements were taken, some corrections, based on the analysis of earlier data, had been made. The
lots’ size is 5. Determine whether the system is in control. Compare the control charts obtained with those
obtained previously.

4
 lot X s
50 8,038 0,044
51 7,962 0,039
52 8,002 0,008
53 8,010 0,019
54 8,024 0,034
55 8,014 0,023
56 7,974 0,038
57 7,986 0,028
58 8,040 0,029
59 7,986 0,028
60 7,974 0,028
61 7,994 0,011
62 7,974 0,023
63 7,962 0,030
64 7,984 0,021
65 8,006 0,038
66 8,034 0,031
67 8,044 0,023
68 8,005 0,022
69 7,994 0,031
70 7,958 0,018
71 8,006 0,011
72 8,022 0,019
73 8,004 0,018
74 7,990 0,029
75 8,000 0,019
76 7,994 0,027
77 7,998 0,031
X Promedio 7,999
S PROMEDIO 0,026
UCLX 9,426
CLX 7,999
LCLX 6,572
A3 1,427
UCLS 0,054
CLS 0,025
LCLS 0,000
B3 0,000
B4 2,089

Ejercicio 2 X2 chart
10.000
9.000
8.000
7.000
6.000
X Average

X chart
5.000
UCL
4.000
LCL
3.000
CL
2.000
1.000
0.000
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78
Sample

5
 Ejercicio 2 S2 chart
0.060

0.050

0.040
X Average

S chart
0.030
UCL

0.020 LCL
CL
0.010

0.000
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78
Sample

3. In a plant which is a major supplier of shock absorbers for Polish railway cars, the system of statistical
process control includes measurements of the inner diameter of a cylinder turned in a metal casting.
The diameter is specified as 91.4 - .2 mm. Lots of size 5 are taken. The head of the plant’s testing
laboratory verified that the process is in control and that the last control limits are 91.361 and 91.257
for the lot means and .076 for the lot standard deviations. He decided that the line workers and foreman
responsible for the operation monitor the process using the given limits as the control limits for
subsequent lots. Any Pareto glitch observed should call for an immediate action by the line. The results
for new lots are as follows.

No cause of the glitches on lots 10 and 20 (on the X¯ chart) and on lots 1 and 21 (on the s chart) was found.
After detecting still another glitch on lot 25, the foreman asked the plant’s foundry to examine casting
moulds. A failure of one of the moulds in use was detected and corrected. The following are the summary
statistics of subsequent lots:

6
a. Since the cause of the Pareto glitches was found, delete lots 1, 10, 20, 21 and 25, and use the other of
the first 25 lots to calculate control limits. Are the first 25 lots (excluding lots 1, 10, 20, 21 and 25) in
control, relative to the limits obtained?

Lot X s
2 91,259 0,038
3 91,308 0,048
4 91,296 0,046
5 91,29 0,066
6 91,291 0,039
7 91,307 0,065
8 91,35 0,043
9 91,262 0,06
11 91,259 0,031
12 91,309 0,03
13 91,311 0,033
14 91,31 0,064
15 91,337 0,052
16 91,336 0,047
17 91,328 0,029
18 91,32 0,036
19 91,35 0,029
22 91,33 0,048
23 91,331 0,05
24 91,348 0,043
X Promedio 91,312
S PROMEDIO 0,045
UCLX 91,376
CLX 91,312
LCLX 91,248
A3 1,427
UCLS 0,094
CLS 0,045
LCLS 0,000
B3 0,000
B4 2,089

7
 Ejercicio 3 X1 chart
91.4

91.38

91.36

91.34
X Average

X chart
91.32
UCL
91.3
LCL
91.28 CL
91.26

91.24
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

Ejercicio 3 S1 chart
0.1
0.09
0.08
0.07
X Average

0.06
S chart
0.05
UCL
0.04
LCL
0.03
CL
0.02
0.01
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

b. Calculate the limits for lots 26 to 50 and verify whether these lots are in control.

lot X s
26 91,29 0,04
27 91,301 0,009
28 91,271 0,028
29 91,3 0,064
30 91,331 0,035
31 91,333 0,046
32 91,308 0,047
33 91,298 0,02
34 91,337 0,026
35 91,326 0,052
36 91,297 0,031
37 91,32 0,036
38 91,29 0,043
39 91,319 0,034

8
 40 91,29 0,038
41 91,32 0,018
42 91,318 0,051
43 91,291 0,031
44 91,29 0,01
45 91,309 0,046
46 91,287 0,034
47 91,309 0,020
48 91,311 0,055
49 91,328 0,052
50 91,275 0,028
X Promedio 91,306
S PROMEDIO 0,036
UCLX 91,346
CLX 91,306
LCLX 91,266
A3 1,124
UCLS 0,075
CLS 0,036
LCLS 0,000
B3 0,000
B4 2,089

Ejercicio 3 X2 chart
91.36
91.35
91.34
91.33
X Average

91.32
X chart
91.31
UCL
91.3
91.29 LCL
91.28 CL
91.27
91.26
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Sample

9
 Ejercicio 3 S2 chart
0.08
0.07
0.06
0.05
X Average

S chart
0.04
UCL
0.03
LCL
0.02
CL
0.01
0
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Sample

The system of statistical process control referred to in the previous problem includes also measurements
of another cylinder turned in a metal casting. The inner diameter of the cylinder is specified as 97-.2 mm.
Lots of size 5 are taken. The head of the plant’s testing laboratory verified that the process is in control and
that the last control limits are 96.907 and 96.857 for the lot means and .037 for the lot standard deviations.
He decided that the given limits be used as trial control limits for subsequent lots. After a few new in-
control lots were observed, the lots’ sample means suddenly crossed the upper control limit and stayed
consistently above it until the production process was stopped. All the time, lots’ sample standard
deviations were well below the limit .037, in fact never crossing the level of .02. A failure of the turning
tool’s seat was found. The seat was replaced by a new one, but the means’ values proved first to lie barely
below the upper control limit and soon crossed it. Again, the standard deviations stayed well below
the control limit. The production process had to be stopped once more. Investigation revealed excessive
hardness of castings processed. A cause of the material’s excessive hardness was duly removed.
Subsequent lots’ means and standard deviations are given in the following table. Determine whether the
system is in control.

Lot X S
1 96,868 0,01
2 96,874 0,014
3 96,861 0,011
4 96,872 0,019
5 96,878 0,018
6 96,873 0,008
7 96,875 0,012
8 96,874 0,009
9 96,87 0,079
10 96,872 0,008
11 96,882 0,014
12 96,894 0,021
13 96,884 0,011
14 96,877 0,009
15 96,878 0,007
16 96,9 0,008
17 96,877 0,014
18 96,875 0,008
19 96,88 0,013
20 96,879 0,014

10
 21 96,88 0,01
22 96,878 0,013
23 96,876 0,008
24 96,891 0,012
X Promedio 96,878
S PROMEDIO 0,015
UCLX 96,899
CLX 96,878
LCLX 96,857
A3 1,427
UCLS 0,030
CLS 0,015
LCLS 0,000
B3 0,000
B4 2,089

Ejercicio 3 X3 chart
96.905
96.9
96.895
96.89
96.885
X Average

96.88 X chart
96.875 UCL
96.87 LCL
96.865
CL
96.86
96.855
96.85
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

Ejercicio 3 S3 chart
0.09

0.08

0.07

0.06
X Average

0.05 S chart
0.04 UCL

0.03 LCL

0.02 CL

0.01

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Sample

11