Defect Count Cost Count*Cost

Missing button 217 0.17 36.89

Loose thread 67 0.89 59.63
A clothing manufacturer has had numerous returns due
Misaligned fabric 18 5.12 92.16 The manufacturer wants to correct the problems but is
Fabric flaws 23 4.89 112.47 decide to track the number and type of defects in their
Stitching errors 112 1.89 211.68 sources of their most common problems will help them
efforts.
Hemming errors 43 4.23 181.89
d numerous returns due to various quality complaints.
rect the problems but isn't sure where to begin. They
d type of defects in their clothing line. Identifying the
problems will help them to target their improvement
efforts.
Durability Carpet Composition
18.95 1 A
12.62 1 B
11.94 1 A You want to examine the overall durability of your carpet product
the carpet products are placed in four homes and you measure du
14.42 1 B 60 days. Create a boxplot to examine the distribution of durabi
10.06 2 A
7.19 2 B
7.03 2 A
14.66 2 B
10.92 3 A
13.28 3 B
14.52 3 A
12.51 3 B
10.46 4 A
21.4 4 B Min 7.03
18.1 4 A Max 22.5
22.5 4 B Q3 17.24
Q1 10.575
durability of your carpet products. Samples of
four homes and you measure durability after
amine the distribution of durability scores.
Fertilizer Height
None 23
None 18 A plant fertilizer manufacturer wants to develop a formula of fertilizer that yields the m
None 18 To test fertilizer formulas, a scientist prepares three groups of 50 identical seedlings: a
group with the manufacturer's fertilizer, named GrowFast, and a group with fertilizer n
None 17 manufacturer. After the plants are in a controlled greenhouse environment for three m
None 25 plants' heights.
None 8
None 23
None 20
None 24
None 22 As part of the initial investigation, the scientist creates a boxplot of the plant heights fro
differences in plant growth between plants with no fertilizer, plants with the manufactu
None 26 competitor's fertilizer.
None 16
None 27
None 16
None 17
None 14
None 17
None 25
None 13
None 17
None 25
None 19
None 20
None 19
None 26
None 10
None 9
None 24
None 17
None 16
None 15
None 15
None 27
None 9
None 26
None 18
None 11
None 21
None 20
None 12
None 19
None 23
None 17
None 23
 None 18
None 19
None 14
None 18
None 12
None 13
GrowFast 23
GrowFast 22
GrowFast 26
GrowFast 25
GrowFast 37
GrowFast 24
GrowFast 27
GrowFast 23
GrowFast 20
GrowFast 21
GrowFast 19
GrowFast 26
GrowFast 20
GrowFast 22
GrowFast 17
GrowFast 30
GrowFast 31
GrowFast 27
GrowFast 32
GrowFast 21
GrowFast 27
GrowFast 30
GrowFast 25
GrowFast 21
GrowFast 26
GrowFast 19
GrowFast 23
GrowFast 22
GrowFast 20
GrowFast 21
GrowFast 33
GrowFast 27
GrowFast 26
GrowFast 23
GrowFast 26
GrowFast 27
GrowFast 18
GrowFast 31
GrowFast 22
 GrowFast 21
GrowFast 26
GrowFast 31
GrowFast 25
GrowFast 25
GrowFast 28
GrowFast 28
GrowFast 28
GrowFast 28
GrowFast 29
GrowFast 29
SuperPlant 24
SuperPlant 23
SuperPlant 14
SuperPlant 22
SuperPlant 21
SuperPlant 21
SuperPlant 19
SuperPlant 30
SuperPlant 23
SuperPlant 24
SuperPlant 19
SuperPlant 28
SuperPlant 28
SuperPlant 14
SuperPlant 23
SuperPlant 21
SuperPlant 24
SuperPlant 27
SuperPlant 15
SuperPlant 22
SuperPlant 27
SuperPlant 26
SuperPlant 12
SuperPlant 11
SuperPlant 34
SuperPlant 22
SuperPlant 20
SuperPlant 9
SuperPlant 28
SuperPlant 18
SuperPlant 22
SuperPlant 15
SuperPlant 15
SuperPlant 24
SuperPlant 19
SuperPlant 19
SuperPlant 23
SuperPlant 27
SuperPlant 18
SuperPlant 21
SuperPlant 25
SuperPlant 20
SuperPlant 16
SuperPlant 16
SuperPlant 16
SuperPlant 13
SuperPlant 13
SuperPlant 12
SuperPlant 17
ula of fertilizer that yields the most increase in the height of plants.
oups of 50 identical seedlings: a control group with no fertilizer, a
ast, and a group with fertilizer named SuperPlant from a competing
nhouse environment for three months, the scientist measures the
ants' heights.

a boxplot of the plant heights from the three groups to evaluate the
lizer, plants with the manufacturer's fertilizer, and plants with their
petitor's fertilizer.
Appraiser Response Sample Trial Standard
Britt 5 1 1 5 0
Britt 5 1 2 5 0
Britt 3 2 1 3 0
Britt 3 2 2 3 0
Britt 1 3 1 1 0
Britt 1 3 2 1 0
Britt 2 4 1 2 0
Britt 2 4 2 2 0
Britt 1 5 1 1 0
Britt 1 5 2 1 0
Britt 2 6 1 3 1
Britt 2 6 2 3 1
Britt 4 7 1 4 0
Britt 4 7 2 4 0
Britt 5 8 1 5 0
Britt 5 8 2 5 0
Britt 2 9 1 2 0
Britt 2 9 2 2 0
Britt 1 10 1 1 0
Britt 1 10 2 1 0
Britt 5 11 1 5 0
Britt 5 11 2 5 0
Britt 4 12 1 4 0
Britt 4 12 2 4 0
Britt 1 13 1 1 0
Britt 1 13 2 1 0
Britt 3 14 1 3 0
Britt 3 14 2 3 0
Britt 2 15 1 2 0
Britt 2 15 2 2 0
Britt 4 16 1 4 0
Britt 4 16 2 4 0
Britt 1 17 1 1 0
Britt 1 17 2 1 0
Britt 2 18 1 2 0
Britt 3 18 2 2 -1
Britt 3 19 1 3 0
Britt 3 19 2 3 0
Britt 5 20 1 5 0
Britt 5 20 2 5 0
Britt 5 21 1 5 0
Britt 5 21 2 5 0
Britt 4 22 1 4 0
Britt 4 22 2 4 0
Britt 3 23 1 3 0
Britt 3 23 2 3 0
Britt 2 24 1 2 0
Britt 2 24 2 2 0
Britt 2 25 1 2 0
Britt 2 25 2 2 0
Britt 4 26 1 4 0
Britt 4 26 2 4 0
Britt 1 27 1 1 0
Britt 1 27 2 1 0
Britt 2 28 1 2 0
Britt 2 28 2 2 0
Britt 5 29 1 5 0
Britt 5 29 2 5 0
Britt 3 30 1 3 0
Britt 3 30 2 3 0
Sample Trials Standard Response Appraiser
1 1 G G Ajay
1 2 G G Ajay Calculate the agreement variable (kappa) an
2 1 G G Ajay
2 2 G G Ajay
3 1 G G Ajay
3 2 G NG Ajay
4 1 G G Ajay
4 2 G G Ajay
5 1 NG G Ajay
5 2 NG NG Ajay
6 1 G G Ajay
6 2 G G Ajay
7 1 NG NG Ajay
7 2 NG G Ajay
8 1 G G Ajay
8 2 G G Ajay
9 1 NG NG Ajay
9 2 NG G Ajay
10 1 G G Ajay
10 2 G G Ajay
11 1 G G Ajay
11 2 G G Ajay
12 1 G G Ajay
12 2 G G Ajay
13 1 G G Ajay
13 2 G G Ajay
14 1 G G Ajay
14 2 G G Ajay
15 1 NG G Ajay
15 2 NG NG Ajay
16 1 G G Ajay
16 2 G G Ajay
17 1 NG NG Ajay
17 2 NG G Ajay
18 1 G G Ajay
18 2 G G Ajay
19 1 NG NG Ajay
19 2 NG G Ajay
20 1 G G Ajay
20 2 G G Ajay
1 1 G G Pawan
1 2 G G Pawan
2 1 G G Pawan
2 2 G G Pawan
3 1 G G Pawan
3 2 G G Pawan
4 1 G G Pawan
4 2 G G Pawan
5 1 NG NG Pawan
5 2 NG G Pawan
6 1 G G Pawan
6 2 G G Pawan
7 1 NG NG Pawan
7 2 NG G Pawan
8 1 G G Pawan
8 2 G G Pawan
9 1 NG NG Pawan
9 2 NG G Pawan
10 1 G G Pawan
10 2 G G Pawan
11 1 G G Pawan
11 2 G G Pawan
12 1 G G Pawan
12 2 G G Pawan
13 1 G G Pawan
13 2 G G Pawan
14 1 G G Pawan
14 2 G G Pawan
15 1 NG NG Pawan
15 2 NG G Pawan
16 1 G G Pawan
16 2 G G Pawan
17 1 NG NG Pawan
17 2 NG G Pawan
18 1 G G Pawan
18 2 G G Pawan
19 1 NG NG Pawan
19 2 NG G Pawan
20 1 G G Pawan
20 2 G G Pawan
greement variable (kappa) and suggest
Part Operator Response Trial
3 3 413.75 3
Conduct Gauge R & R to study if the
3 3 268.75 2 measurment system is acceptable
3 3 420 1
3 2 426.25 3
3 2 471.25 2
3 2 432.5 1
3 1 368.75 3
3 1 270 2
3 1 398.75 1
2 3 386.25 3
2 3 478.75 2
2 3 436.25 1
2 2 406.25 3
2 2 531.25 2
2 2 435 1
2 1 408.75 3
2 1 608.75 2
2 1 443.75 1
1 3 383.75 3
1 3 373.75 2
1 3 446.25 1
1 2 388.75 3
1 2 157.5 2
1 2 456.25 1
1 1 405 3
1 1 273.75 2
1 1 476.25 1
Part Operator Response
5 3 120.78
4 3 121.55
7 3 121.33
7 3 121.99 An engineer wants to monitor the impact strength of ceramic comp
2 3 118.14 The engineer randomly selects 30 samples that represent the expect
of the process variation and gives 10 random samples to 3 randomly
3 3 119.35
operators. The 3 operators measure the temperature of the 10 di
6 3 122.87 samples twice, for a total of 60 measurements. Each part (sample) is
10 3 121 operator; no 2 operators measured the same part.
1 3 118.03
1 3 117.92
10 3 121.11
6 3 122.87
8 3 119.68
2 3 117.7
8 3 119.9
3 3 119.57
9 3 120.12
9 3 119.68
5 3 120.67
4 3 121
16 2 121.33
13 2 119.68
20 2 120.12
20 2 119.68
13 2 119.24
15 2 115.94
11 2 122.21
14 2 119.9
12 2 119.24
19 2 118.58
11 2 121.88
16 2 121.33
19 2 118.69
12 2 119.46
18 2 119.13
18 2 119.02
17 2 121.33
14 2 120.89
17 2 121
15 2 116.49
21 1 117.92
23 1 121.11
22 1 122.87
26 1 119.68
21 1 117.7
23 1 119.9
30 1 119.57
24 1 120.12
25 1 119.68
28 1 120.67
26 1 121
22 1 122.43
24 1 119.68
27 1 117.37
29 1 121.55
28 1 120.56
25 1 119.24
29 1 121.33
27 1 118.03
30 1 118.47
trength of ceramic components.
hat represent the expected range
m samples to 3 randomly selected
emperature of the 10 different
ts. Each part (sample) is unique to
ured the same part.
Part Operator Response
1 1 0.65
1 1 0.6
2 1 1 An automotive supplier wants to know if the currently used measurem
2 1 1 precisely measuring the thickness of an engine part.
3 1 0.85
Ten parts that represent the expected range of the process variation wer
3 1 0.8 operators measured the thickness of each of the ten parts, two times
4 1 0.85 random order.
4 1 0.95
5 1 0.55
5 1 0.45
6 1 1
6 1 1
7 1 0.95
7 1 0.95
8 1 0.85
8 1 0.8
9 1 1
9 1 1
10 1 0.6
10 1 0.7
1 2 0.55
1 2 0.55
2 2 1.05
2 2 0.95
3 2 0.8
3 2 0.75
4 2 0.8
4 2 0.75
5 2 0.4
5 2 0.4
6 2 1
6 2 1.05
7 2 0.95
7 2 0.9
8 2 0.75
8 2 0.7
9 2 1
9 2 0.95
10 2 0.55
10 2 0.5
1 3 0.5
1 3 0.55
2 3 1.05
2 3 1
3 3 0.8
3 3 0.8
4 3 0.8
4 3 0.8
5 3 0.45
5 3 0.5
6 3 1
6 3 1.05
7 3 0.95
7 3 0.95
8 3 0.8
8 3 0.8
9 3 1.05
9 3 1.05
10 3 0.85
10 3 0.8
 he currently used measurement system is
hickness of an engine part.

of the process variation were selected. Three

h of the ten parts, two times per part, in a
m order.
Diameter
74.03
74.002 An engine manufacturer uses a forging process to produce piston
74.019 rings. The forging process is in control, and now the quality
engineers want to assess the process capability. They collect
73.992 twenty-five samples of five piston rings. The specification limits for
74.008 piston ring diameter are 74.0 ± 0.05.
73.995
73.992
74.001
74.011
74.004
73.988
74.024
74.021
74.005
74.002
74.002
73.996
73.993
74.015
74.009
73.992
74.007
74.015
73.989
74.014
74.009
73.994
73.997
73.985
73.993
73.995
74.006
73.994
74
74.005
73.985
74.003
73.993
74.015
73.988
74.008
73.995
74.009
74.005
74.004
73.998
74
73.99
74.007
73.995
73.994
73.998
73.994
73.995
73.99
74.004
74
74.007
74
73.996
73.983
74.002
73.998
73.997
74.012
74.006
73.967
73.994
74
73.984
74.012
74.014
73.998
73.999
74.007
74
73.984
74.005
73.998
73.996
73.994
74.012
73.986
74.005
74.007
74.006
74.01
74.018
74.003
 74
73.984
74.002
74.003
74.005
73.997
74
74.01
74.013
74.02
74.003
73.982
74.001
74.015
74.005
73.996
74.004
73.999
73.99
74.006
74.009
74.01
73.989
73.99
74.009
74.014
74.015
74.008
73.993
74
74.01
73.982
73.984
73.995
74.017
74.013
 If the average number of orders for raw material was
100 and standard deviation was 5, what percentage of
the orders fall in the range: 95 to 105?
TAT
27 The following data shows the no. of days taken for making the payment
9
32
49 If the specification is 30 + 2, Calculate the process capability index Cp & Cpk?
24 Subgroup = 4
20
31 Assume data is sorted according to group
19
10
38
42
25
27
31
17
12
18
30
32
29
18
13
23
19
10
29
34
39
23
22
19
26
31
27
16
34
28
15
26
12
Diameter
0.738
0.735 The following data shows the diameter (in inches) of a sample of
40 ball bearings manufactured by certain process. If the
0.728
specification is 0.734 + 0.02, Calculate the process capability index
0.745 Cp & Cpk? Subgroup is 4
0.733
0.735
0.732
0.737
0.736 0.754
0.73
0.729
0.731
0.737
0.736
0.742
0.732
0.735
0.731
0.735
0.74
0.743
0.726
0.724
0.728
0.739
0.734
0.735
0.733
0.738
0.734
0.74
0.737
0.735
0.742
0.725
0.738
0.736
0.729
0.736
0.733
 Step Equation Result
Determine number of defecet opportunities per unit O=
Determine number of units processed N=
Determine total number of defects made D=
Calculate defects per opportunity DPO = D / (N X O)= #DIV/0!
DPMO DPMO = D / (N X O)*1000000= #DIV/0!
Calculate yield Yield = (1-DPO)*100 #DIV/0!
Sigma Level from Sigma conversion table proces sigma = #DIV/0!