Paper / Subject Code: TE1220 / 4)Quality and Reliability TEI220 ‘Total No. of Printed Pages:4 TE. (Mechanical) (Semester-VI) (RC 2019-20) EXAMINATION JULY 2022 Quality and Reliability [Duration : Three Hours} [Total Marks : 100] Instructions: 1. Answer 5 Questions. Answer ANY TWO questions each from PART A, ANY TWO questions each from PART B and ANY ONE question from PARTC. 2. Use of statistical tables is permitted. 3. Assume missing data, if any, giving justification PART A Qi (A)MIL-STD is being used to inspect incoming lots of size N=5000. Single Sampling, general 15 inspection level II, and AQL of 0.65% are being used. (i) Find the normal, tightened and reduced inspection plan. (ii) Determine the probability of switching from Normal to Tightened plan. (iii) Determine the probability of switching from Tightened to Normal plan, (iv) Plot OC curve for a normal Single Sampling Plan, showing at least four points on it. (B) Consider the two processes shown (sample size is 5 Process A__| Process B 05 105 1 Specifications are at 100 10. Calculate Cp, and Cys, and interpret these ratios. Which process would you prefer to use? Q2 (A) The following fraction defective has been found in successive samples of size 100: 10 0.09 [0.03 [0.12 0.10 [0.05 [0.14 0.13 [0.13 [0.06 0.08 [0.10 | 0.05 014 [0.14 0.09 7 0.10 | 0.06 0.15 [0.09 0.13 [0.08 0.06 [0.11 (i) Set up a control chart on the number of defectives. (ii) Compute Type I error. For the chart established in Part (i), if there is a shift in the process fraction defective to 0.12,Paper / Subject Code: TE1220 / 4)Quality and Relial TE1220 what is the probability of detecting this shift on the first sample drawn after the shift? (B) A company wishes to find a double sampling plan for a situation where a lot of 1000 items is 10 shipped from a vendor. The vendor's process operates at a fallout level of 0.7% defective. ‘The company further wants the AOQL from the inspection activity to be 2%. (Find the appropriate Dodge-Romig plan (ii) What is the LTPD for this inspection? Compute ASN, ATI and current AOQ. Q3 Production Manager wanted to check the capacity of the heater used in the process. 20 20 random samples of 4 pieces each were obtained. The results off those samples are shown in the following table. The product specifications are 85 £4 Sample | Sample | Range | Sample | Sample | Range No. Mean No. Mean 1 79.0 60 | it 74.5 80 2 82.5 ao (ou? 85.0 60 3 87.5 60 13 82.5 7.0 4 80.5 60 14 | 87.0 60 5 84.5 3.0 15, 89.0 15 6 96.0 45 16 77.0 | 5.0 1 79.0 60 17 825 | 65 8 92.0 5.0 18 | _79.0 15 9 875 65 9 70.5 85 10 85.0 10 20 84.5 80 (i) Calculate the 36 control Ii for X and R control chart. (ii) Estimate the value of mean diameter and standard deviation of diameter. ii) Carryout process capability studies. (iv) What do you propose as a better target mean of the process in order to minimize the percent defectives? () What would be the percentage of defectives if the process was continued at this better value of target mean? (vi) Carryout process capability studies at better value of target mean. Comment on the difference with part (iii) (vii) Suddenly, the mean of process as obtained in part (ii) shifts to 80, due to presence of assignable cause, without any shift in process standard deviation. What will be type Il error in this case? PARTB Q4 (A)Discuss the use of Taylor series expansion in reliability studies. 04 (B) With example discuss combined series-parallel system. 04 (C)The energy, (E) stored in the flywheel of mass moment of inertia (I) rotating at an 0S angular velocity of (Q) is given by E A716 A6(095 14287D67A72973BF441 BDPaper / Subject Code: TE1220 / 4) Quality and Reliability ‘E1220 Find mean and tolerance on Energy, if 1= 5046 kgm? and 2 = 10 0.9 radis. (D)Stress and Strength of a component follows exponential distribution, Derive the 07 expression for reliability. The mean strength was found to be 1000 MPa. Compute mean stress, if reliability of 95% is desired. Qs (A) The lifetime of a machine is modeled as two-parameter Weibull distribution with 10 shape parameter 6 and scale parameter as 35 hrs. Find (i) RO) (ii) (40) Gil) BI life (iv) MTTF and Standard deviation (WV) tinat and trode (vi) Design fife for reliability of 95% (B) Sketch interference diagram, 10 Derive the expression for reliability if stress and strength follow normal distribution. If Stress ~ N (100, 14) and Strength ~ N (120, 12), compute reliability. If mean strength increases by 10% and mean stress decreases by 10%, with no change in standard deviation, what will be the new system reliability? Notation used to denote normal distribution: N(u, 6°) Q6 (A) Discuss 06 (i) Reliability analysis of Weibull distribution (ii) Reliability-based Design concept (B) For the following configuration, assuming CFR for each component with equal failure 14 rate, obtain expression for reliability and MTTE. If failure rate is 0.5 per hour, what will be the reliability at 3 hours and MTTR. AIT16FA609514287D67A72373BF441BDQ7 Q8 Paper / Subject Code: TE1220 / 4)Quality and Reliability PARTC (A) With an example, illustrate chance and assignable causes of Quality variation. (B)A solid shaft having circular cross section subject to tension, is to be designed for a reliability of 95%. The additional information provided are: Strength: Mean = 50000 Pa, Standard deviation = 5000 Pa. ‘Tensile Load: Mean = 4000N, Standard deviation = 400 N istribution of Strength and Tension: Normal Tolerance fraction: 3% Design the shaft. (C)Failure rates of three components connected in series were found to be 0.005, 0.006 and 0.008 failures/hour, respectively. Allocate reliability to each component if 95% system reliability is expected for 50 hours. (A) How is Six Sigma quality different from Three sigma quality? (B) Observations tabulated below are taken from the output of a company making semiconductors in 25 subgroups of 200 items each, SampleNo. [1 [2 [3 [4 [5 [6 [7 [8 [9 [10 [a1 [12 [13 No. ofdefects [8 [10 [13 [7 [1 [13 [9 [13 [10 [1s [1s [10 [14 SampleNo. [14 [15 [16 [17 [18 |19 [20 [21 [22 [23 [24 [25 No. ofdefects [9 [6 [3 [12 [11 [6 [4 [a1 [16 [20 [16 [13 (i) Find control limits for number of defects chart Gi) Compute Type I error. (iii) When true average number of defects increases by 25%, find probabilit detecting shift (iv) Find control limits for number of defects/unit chart for the above data, AI716FA609514287D67A72373BE441BD TE1220 04 06 05