Sample Problems of X-bar, Sigma, and R Charts (ME-361) - Batch 15 (ME)

Problem # 1 Control charts for X̅ and R are maintained on the outside diameter of a shaft . The
subgroup size is 04. After 20 subgroups ∑ X̅ = 43.75 and ∑R = 0.286. The specification of the product
is 2.15±0.002 unit. Products falling above and below the specification limit are rejected. The process
is statistical controlled and normally distributed. Find the control limits for X̅ and R charts , Process
capability, RPI of the process and % rejection. How to reduce the % of rejection if any?

Problem # 2 Small boxes of snacks are labeled “Net weight 10 ounces”. Each hour, random sample
sizes of 04 boxes are weighted to check the process control. Five hours of observations yielded the
following;

Time Weights
Box 1 Box 2 Box 3 Box 4
9.00 am 9.8 10.4 9.9 10.3
10.00 am 10.1 10.2 9.9 9.8
11.00 am 9.9 10.5 10.3 10.4
Noon 9.7 9.8 10.3 10.2
1.00 pm 9.7 10.1 9.9 9.9

Using these data, construct limits for X̅ and R charts. Is the process in controlled? What other steps
should the QC department follow at this point of production?

Problem # 3 The dimension of a certain manufactured part is specified as 2.05±.020. If the

dimension falls below lower specification limit, the part must be rejected,, if above upper
specification limit, rework is needed. Control charts for X̅ and R are maintained on the dimensions .
The subgroup size is 04. After 20 subgroups, ∑ X̅ = 41.340 and ∑R = 0.320. If the process is in
statistically controlled and normally distributed, what can you conclude regarding its ability to meet
specification? If not, determine the percentage of rework and that of scraped. Can you make any
suggestion for improvement? Find also control limits for X̅ and R –charts.

Problem # 4 Control chart for X̅ and σ are maintained on the resistance in ohms of a certain
rheostat coil based on subgroup size of 05. After 30 subgroups ∑ X̅ = 58.395 and ∑σ = 1356.

i) Determine the centerlines and 3-sigma control limits for the process.

ii) Establish the value σ’ assuming that the process is operating in satisfied control.

iii) Assuming that the distribution generated by the process is approximately normal, what
proportion of the rheostat coils meets specification 2000±150 ohm?

Problem #5 A manufacturer of bolts maintains X̅ and R for certain bolts . The bolt is made at a
diameter of 0.25 inch and required specification is 0.25 ± 0.005 inch. After 25 subgroups of four
items in each subgroup, it was found that ∑ X̅ = 6.250 and ∑R = 0.1287. Compute 3-sigma limits for X̅
and R. Find σ’, assuming the process is in control. What % of manufactured bolts will not meet
required specification under assumption that process generates a normal distribution? What is RPI?

By Dr. Md. Arafat Rahman, Dept. of Mechanical Engineering, CUET