STATISTICAL METHODS & RELIABILITY ENGINEERING (Module 701007)

ASSIGNMENT A1

A1 is one of two assignments, each representing 10% of the assessment for this module (i.e. A1 +
A2 = 20% in total). A1 consists of two questions on SPC variables. The mathematical approach to
these SPC questions is relatively straightforward, hence the acquisition of high marks from both
questions will tend to be weighted towards the quality of results interpretation and discussion of
possible causes. Thus for A1, 40% of marks will be awarded for results; 20% of marks for
interpretation of results and 20% of marks for discussion of possible causes. The remaining 20% of
the marks will be awarded for the overall presentation quality of your work; however, your work can
be hand-written or word-processed with graphics or hand-drawn graphs (there will be no bias).

Specifically, the maximum marks are as follows (total out of 50):

Q1: Results = 8 Interpretation = 5 Discussion = 5
Q2: Results = 12 Interpretation = 5 Discussion = 5
Presentation = 10 (9-10 = outstanding; 7-8 = very good; 5-6 = fair; 3-4 = poor; 1-2 = awful).

You should submit the work to Canvas, before 4.00 p.m. on Monday, 22 November 2021.

1) Every 15 minutes, a quality control inspector selects a sample batch of seven consecutive
components which are manufactured from a cutting machine with automatic feed. The length of
each component is measured to the nearest 0.01 mm, from which the sample range and mean
length of the sample batch is calculated. After
_ 20 batches, the mean of the means of batches ( =x )
and the mean of the ranges of batches ( w ) are calculated. These are 59.60 mm and 0.35 mm
respectively.

Set up control charts for the mean and for the range, based on the 20 sample batches. The next
10 sample batches recorded are as follows:

Sample number Mean length (mm) Length range (mm)

21 59.58 0.31
22 59.57 0.53
23 59.62 0.49
24 59.67 0.44
25 59.63 0.56
26 59.69 0.60
27 59.71 0.65
28 59.69 0.55
29 59.71 0.68
30 59.73 0.75

Plot these values onto your mean and range control charts. Comment on the behaviour of the
process, suggesting if or when action should have been taken, based on information from each
chart. Discuss possible causes of the behaviour of the process.

Q2 on next page
2) A company has started to manufacture disposable nappies in which all original materials have
been replaced with biodegradable equivalents. The company is experimenting with different
forms of SPC and it is currently looking at relatively simple control charts. Periodically, a
technician selects a sample of four consecutively produced nappies (which have been filled with
absorbent material), weighs them and calculates the sample mean and the sample standard
deviation. The results, from two runs, are given below.

In Run (1), the process was known to be running satisfactorily. Therefore, using the data from
Run (1), calculate the warning and action limits for the mean and standard deviation control
charts. Plot the data from both runs using these limits.

RUN (1)
Sample Mean Weight Std Deviation
Number (g) (g)
1 54.6 1.5
2 53.5 1.1
3 56.0 1.9
4 55.6 1.6
5 55.1 2.4
6 56.2 0.9
7 54.9 0.7
8 53.9 1.7
9 56.1 2.8
10 54.1 1.4

RUN (2)
Sample Mean Weight Std Deviation
Number (g) (g)
1 56.1 1.7
2 55.2 1.6
3 55.7 1.2
4 54.7 1.6
5 53.8 1.8
6 54.8 2.5
7 52.9 2.6
8 53.9 2.9
9 54.7 3.6
10 53.0 3.2
11 54.1 2.8
12 53.4 3.5
13 53.9 3.4
14 53.5 4.3
15 52.0 3.8

Comment on the behaviour of the process, suggesting if or when action should have been taken,
based on information from each chart. Discuss possible causes of the behaviour of the process.
K.S. Fancey, 09/21