MIT 2.

810 Fall 2015 Homework 9 Solutions

MIT 2.810 Manufacturing Processes and Systems

Homework 9 Solutions
Process Control

November 4, 2015

Problem 1. Control Charts

The data shown in Table 1 are x̄ and R values for 24 samples of size n = 5 taken from a process
producing bearings. The measurements are made on the inside diameter of the bearing, with
only the last three decimals recorded (i.e. 34.5 should be 0.50345).

(a) Set up x̄ and R charts on this process. Does the process seem to be in statistical control?
(b) If specifications on the diameter are 0.503 ± 0.0010, find the percentage of non-conforming
bearings produced by this process. What assumption(s) do you have to make to determine
this number?

Sample x̄ R Sample x̄ R
Number Number
1 34.5 3 13 35.4 8
2 34.2 4 14 34.0 6
3 31.6 4 15 37.1 5
4 31.5 4 16 34.9 7
5 35.0 5 17 33.5 4
6 34.1 6 18 31.7 3
7 32.6 4 19 34.0 8
8 33.8 3 20 35.1 4
9 34.8 7 21 33.7 2
10 33.6 8 22 32.8 1
11 31.9 3 23 33.5 3
12 38.6 9 24 34.2 2
Table 1: Bearing diameter data

Answer:
The center line and limits for the x̄ and R charts are given below:

Chart Center Line Control Limits

x̄ 𝑥 𝑥 ± 𝐴! 𝑅
R 𝑅 UCL = D4𝑅, LCL = D3𝑅

1
MIT 2.810 Fall 2015 Homework 9 Solutions

From the given data, we can calculate:

𝑥!   + 𝑥!   + ⋯ +   𝑥!"   34.5 + 34.2 + ⋯ + 34.2
𝑥 =   =   ≅ 34.
24 24
𝑅!   + 𝑅!   + ⋯ +   𝑅!"   3 + 4 + ⋯+ 2
𝑅 =   =   = 4.7.
24 24

From a sample size of 5, the factors required to set the control limits are1: A2 = 0.577, D3 = 0 and
D4 = 2.115. So the control limits are:

x̄ chart:
UCL = 𝑥 + 𝐴! 𝑅 = 34 + 0.577 ∙ 4.7 = 36.719  
LCL = 𝑥 − 𝐴! 𝑅 = 34 − 0.577 ∙ 4.7 = 31.288

41

39

UCL
37

35
Center Line

33

31
LCL

29

27
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1
Standard tables for estimating the necessary factors for plotting control charts can be found here:
http://onlinelibrary.wiley.com/doi/10.1002/0471790281.app6/pdf

2
MIT 2.810 Fall 2015 Homework 9 Solutions

R chart:
UCL = D4𝑅 = 2.115 ∙ 4.7 = 9.94
LCL = D3𝑅 = 0

12

UCL
10

6
Center Line

LCL
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

From the x̄ chart, we can conclude that the process is out of control based on the measurements
of the 12th and 15th samples. Out of 24 samples, we have 2 samples falling outside the 3σ limits
or a probability of 8.3%. We know that for the normal distribution, the probability that a point
will fall outside the 3σ limits is 0.27%. So this occurrence is very unusual and the process needs
to be evaluated.

Note that the R chart does not reveal any irregularities in the process. But the chart would still
be useful if we were to apply the Western Electric rules (see Problem 3) here to give a warning
signal of a process likely to go out of control.

3
MIT 2.810 Fall 2015 Homework 9 Solutions

Problem 2. Control Charts

The fill volume of soft-drink beverage bottles is an important quality characteristic. The volume
is measured (approximately) by placing a gauge over the crown and comparing the height of the
liquid in the neck of the bottle against a coded scale. On this scale, a reading of zero corresponds
to the correct fill height. Fifteen samples of size n = 10 have been analyzed, and the fill heights
are shown in Table 2.

a. Set up x̄ and s control charts on this process. Does the process exhibit statistical control?
If necessary, construct revised control limits.
b. Set up an R chart, and compare it with the s chart in part a.

Sample x1 x2 x3 x4 x5 x6 x7 x8 x9 x10
Number
1 2.5 0.5 2.0 -1.0 1.0 -1.0 0.5 1.5 0.5 -1.5
2 0.0 0.0 0.5 1.0 1.5 1.0 -1.0 1.0 1.5 -1.0
3 1.5 1.0 1.0 -1.0 0.0 -1.5 -1.0 -1.0 1.0 -1.0
4 0.0 0.5 -2.0 0.0 -1.0 1.5 -1.5 0.0 -2.0 -1.5
5 0.0 0.0 0.0 -0.5 0.5 1.0 -0.5 -0.5 0.0 0.0
6 1.0 -0.5 0.0 0.0 0.0 0.5 -1.0 1.0 -2.0 1.0
7 1.0 -1.0 -1.0 -1.0 0.0 1.5 0.0 1.0 0.0 0.0
8 0.0 -1.5 -0.5 1.5 0.0 0.0 0.0 -1.0 0.5 -0.5
9 -2.0 -1.5 1.5 1.5 0.0 0.0 0.5 1.0 0.0 1.0
10 -0.5 3.5 0.0 -1.0 -1.5 -1.5 -1.0 -1.0 1.0 0.5
11 0.0 1.5 0.0 0.0 2.0 -1.5 0.5 -0.5 2.0 -1.0
12 0.0 -2.0 -0.5 0.0 -0.5 2.0 1.5 0.0 0.5 -1.0
13 -1.0 -0.5 -0.5 -1.0 0.0 0.5 0.5 -1.5 -1.0 -1.0
14 0.5 1.0 -1.0 -0.5 -2.0 -1.0 -1.5 0.0 1.5 1.5
15 1.0 0.0 1.5 1.5 1.0 -1.0 0.0 1.0 -2.0 -1.5
Table 2: Fill height data

4
MIT 2.810 Fall 2015 Homework 9 Solutions

Answer:
The center line and limits for the x̄ and S charts are given below:

Chart Center Line Control Limits

x̄ 𝑥 𝑥 ± 𝐴! 𝑠
S 𝑠 UCL = B4𝑠, LCL = B3𝑠

We have m = 15 samples each of size n = 10. The standard deviation for each sample is calculated
using the formula:
! !
!!! 𝑥! − 𝑥
𝑠 =   .
𝑛−1

And,
!
!!! 𝑠!
𝑠 =   .
𝑚

From the data, we get: 𝑥 =   −0.0033  and  𝑠 =  1.066.

For n = 10, we have, A3 = 0.975, B3 = 0.284 and B4 = 1.716. So the control limits are:

x̄ chart:
UCL = 𝑥 + 𝐴! 𝑠 = −0.0033 + 0.975 ∙ 1.066 = 1.036
LCL = 𝑥 − 𝐴! 𝑠 = −0.0033 − 0.975 ∙ 1.066. =   −1.042

1.5
Center Line UCL LCL

0.5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

-0.5

-1

-1.5

5
MIT 2.810 Fall 2015 Homework 9 Solutions

S chart:
UCL = B4𝑠 = 1.716 ∙ 1.066 = 1.829
LCL = B3𝑠 =  0.284 ∙ 1.066. =  0.302
2
Center Line UCL LCL

1.6

1.2

0.8

0.4

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Based on the control charts, the process is in control.

We now plot the R chart to see if we get the same result. From the data, we get, R̄ = 3.2. For n =
10, we have, D4 = 1.777 and D3 = 0.223. The control limits are:
UCL = D4𝑅 = 1.777 ∙ 3.2 = 5.686
LCL = D3𝑅 = 0.223 ∙ 3.2 = 0.713
6
Center
Line
5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

The R chart also indicates that the process is in control.

6
MIT 2.810 Fall 2015 Homework 9 Solutions

Problem 3. Out of Control Detection

[Adapted from Douglas Montgomery’s ‘Introduction to Statistical Control’]

The Western Electric Handbook (1956) suggests a set of decision rules for detecting nonrandom
patterns on control charts. Specifically, it suggests concluding that the process is out of control if
either:
1. One point plots outside the three-sigma control limits, or
2. Two out of three consecutive points plot beyond the two-sigma warning limits, or
3. Four out of five consecutive points plot at a distance of one-sigma or beyond from the
center line, or
4. Eight consecutive points plot on one side of the centerline.
Those rules apply to one side of the centerline at a time. Therefore, a point above the upper
warning limit followed immediately by a point below the lower warning limit would not signal
an out-of-control alarm.

Calculate the probability of the first two patterns occurring assuming the data points are
independent but identically distributed with a normal distribution.

!!
Hint: You can choose r points out of n consecutive points in nCr ways, where, nCr = !! !!! !. Then
calculate the probability of a point falling outside the warning limit. We have r points falling
beyond a warning limit and (n-r) points falling before it. Since the points are independent, the
probability of a pattern of points is the product of their individual probabilities.

Answer:
From Prof. Hardt’s lecture notes, we know that the area under the normal distribution curve for
various spreads, zσ, is approximately written as:

Within 1σ 0.68
Within 2σ 0.95
Within 3σ 0.997

Therefore, by symmetry, the area between 1σ and 2σ limits on either side is (0.95-0.68)/2 =
0.135. The area between 2σ and 3σ limits on either side is (0.997-0.95)/2 = 0.0235.

1. The probability that one point plots outside the 3σ limits is (1 – 0.997) = 0.003 or 0.3%.
2. The probability that a point will fall beyond the 2σ limit on one side of the center line is (1 -
0.95)/2 = 0.025. Therefore, the probability that two out of three consecutive points will fall
outside the 2σ limit on either side is: 2 x 3C2 x 0.0252 x (1 – 0.025) = 0.0036 or 0.36%.

We can also determine the probabilities for the other two rules mentioned above:

7
MIT 2.810 Fall 2015 Homework 9 Solutions

3. The probability that one point falls beyond the 1σ sigma limit on one side of the centerline is
(1 – 0.68)/2 = 0.16. Therefore, the probability that four out of five consecutive points will fall
outside the 1σ limit on either side is: 2 x 5C4 x 0.164 x (1 – 0.16) = 0.005 or 0.5%.
4. The area on either side of the centerline equals 0.5. The probability that eight consecutive
points fall on one side of the center line is (0.5)8 = 0.0039 or. 0.39%.