Practice Questions

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https://forms.gle/5y2fcrpHwWJsFab17 latest by 8th December

1. A mechatronic assembly is subjected to a final functional test. Suppose that defects

occur at random in these assemblies, and that defects occur according to a Poisson
distribution with λ=1.1. What is the probability that an assembly will have exactly one
defect?
[3 marks]
2. Samples of n = 6 items each are taken from a process at regular intervals. A quality
characteristic is measured, and x and R values are calculated for each sample. After
50 samples, we have Assume that the quality characteristic is normally distributed.
50 50

∑ x i=2000∧∑ Ri =200
i=1 i=1
(a) Compute control limits for the x and R control charts.
(b) If the specification limits are 40 ± 5.0, what are your conclusions regarding the
ability of the process to produce items within these specifications?
(c) Assuming that if an item exceeds the upper specification limit it can be reworked,
and if it is below the lower specification limit it must be scrapped, what percent
scrap and rework is the process producing?
(d) What is the probability that a sample mean x fall outside the control limits? What
is α error?
(e) If process mean is shifted to 39, what is the probability that after the shift the first
immediate sample mean x fall within the control limits? What is β error?
[10 marks]
3. x and s charts are constructed for a quality characteristic based on sample size n = 4 and
the process has shown statistical control:
x chart: UCL = 710; Center line = 700; LCL = 690
s−chart :UCL = 18.08; Center line = 7.979; LCL = 0
(a) If the specifications are at 705 ± 16, and the process output is normally
distributed, estimate the fraction nonconforming.
(b) For the chart, find the probability of a type I error, assuming σ is constant.
(c) Find the ARL when the process is under control
(d) Suppose the process mean shifts to 693. Find the probability of detecting this shift
on the chart on the first subsequent sample.
(e) For the shift to 693, find the average run length.
[7 marks]
4. Use the following data to construct p-chart and np-chart. The number of
nonconforming switches in samples of size 180 is given below:
No. of
Sample number defectives
1 8
2 1
3 3
4 0
 5 2
6 4
7 0
8 1
9 10
10 6
11 6
12 0
13 4
14 0
15 3
16 1
17 15
18 2
19 3
20 0

a) Find the number of points falling outside 2σ control limits

b) Find the number of points falling outside 3σ control limits
c) Is the process under control?
d) What should be the appropriate sample size to have LCL non-negative?
e) What is the probability of detecting atleast one defective? Comment on the sample
size?
f) If the process average shifts to UCL how many samples are needed to detect this
shift?
[10 marks]
5. The data on measurement system is given below:
Part No. Inspector 1 Inspector 2 Inspector 3
Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3
1 38 39 37 34 33 34 41 40 40
2 35 35 35 41 42 43 44 44 42
3 39 38 40 39 38 39 36 38 36
4 31 29 33 29 31 27 45 47 47
5 32 32 30 26 24 24 45 47 47
6 39 41 41 36 34 38 39 39 39
7 43 45 42 44 42 42 27 28 25
8 36 37 36 34 35 32 43 43 45
9 40 38 41 44 46 44 45 44 46
10 29 27 28 43 41 44 35 35 34

Find gauge capability using Design of Experiments

(a) P/T Ratio with USL=55; LSL=20
(b) Variability w.r.t. repeatability
(c) Variability w.r.t. reproducibility
(d) Find the variance of Part×Operator
(e) Find the variance of parts?
[10 marks]