Mechatronics & Electrical Engineering Departments

Second Semester 2022/2023- Level 4

Course Title: Quality Control
Course Code: MTE 210

Assignment No.: 2 Subject: Control charts for variables

[1] Control charts for X and R are to be established on a certain dimension part, measured
in millimeters. Data were collected in subgroup sizes of 6 and are given below. Determine
the trial central line and control limits. Assume assignable causes and revise the central line
and limits.

[2] The following table gives the average and range in kilograms for tensile tests on an
improved plastic cord. The subgroup size is 4. Determine the trial central line and control
limits. If any points are out of control, assume assignable causes and calculate revised limits
and central line.

Dr. Sayed Ali Zayan Page 1

 Mechatronics & Electrical Engineering Departments
Second Semester 2022/2023- Level 4
Course Title: Quality Control
Course Code: MTE 210

[3] Control charts for X and R are kept on the weight in kilograms of a color pigment for a
batch process. After 25 subgroups with a subgroup size of 4,  X = 52.08 kg (114.8 lb),
 R = 11.82 kg (26.1 lb). Assuming the process is in a state of control, compute the X and
R chart central line and control limits for the next production period.

[4] The following table gives the average width in millimeters for each of 20 samples of
five panels used in the manufacture of a domestic appliance. The range of each sample is
also given.

Calculate the control chart limits for the control charts and plot the values on the charts.
Interpret the results. Given a specification of 540±5 mm, comment on the capability of the
process.

[5] The thickness of sheet metal (mm) used for making automobile bodies is a characteristic
of interest. Random samples of size 4 are taken. The average and standard deviation are
calculated for each sample and are shown in the following table for 20 samples. The
specification limits are 9.95 ±0.3 mm.

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 Mechatronics & Electrical Engineering Departments
Second Semester 2022/2023- Level 4
Course Title: Quality Control
Course Code: MTE 210

a) Find the control limits for the X - and s-charts. If there are out-of-control points,
assume special causes and revise the limits.
b) Estimate the process mean and the process standard deviation.
c) If the thickness of sheet metal exceeds the upper specification limit, it can be
reworked. However, if the thickness is less than the lower specification limit, it cannot
be used for its intended purpose and must be scrapped for other uses. The cost of
rework is $0.25 per linear foot, and the cost of scrap is $0.75 per linear foot. The
rolling mills are 100 feet in length. The manufacturer has four such mills and runs 80
batches on each mill daily. What is the daily cost of rework? What is the daily cost of
scrap?
d) If the manufacturer has the flexibility to change the process mean, should it be moved
to 10.00?
e) What alternative courses of action should be considered if the product is
nonconforming?

[6] Light bulbs are tested for their luminance, with the intensity of brightness desired to be
within a certain range. Random samples of five bulbs are chosen from the output, and the
luminance is measured. The sample mean X and the standard deviation s are found. After 30
samples, the following summary information is obtained:

The specifications are 90 ±15 lumens.

a) Find the control limits for the X - and s-charts.
b) Assuming that the process is in control, estimate the process mean and process
standard deviation.
c) Comment on the ability of the process to meet specifications. What proportion of the
output is nonconforming?
d) If the process mean is moved to 90 lumens, what proportion of output will be
nonconforming? What suggestions would you make to improve the performance of the
process?

[7] In filling bags of nitrogen fertilizer, it is desired to hold the average overfill to as low a
value as possible. The lower specification limit is 22.00 kg (48.50 lb), the population mean
weight of the bags is 22.73 kg (50.11 lb), and the population standard deviation is 0.80 kg
(1.76 lb). What percentage of the bags contains less than 22 kg? If it is permissible for 5% of
the bags to be below 22 kg, what would be the average weight? Assume a normal
distribution.

[8] Plastic strips that are used in a sensitive electronic device are manufactured to a
maximum specification of 305.70 mm (approximately 12 in.) and a minimum specification

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 Mechatronics & Electrical Engineering Departments
Second Semester 2022/2023- Level 4
Course Title: Quality Control
Course Code: MTE 210

of 304.55 mm. If the strips are less than the minimum specification, they are scrapped; if
they are greater than the maximum specification, they are reworked. The part dimensions are
normally distributed with a population mean of 305.20 mm and a standard deviation of 0.25
mm. What percentage of the product is scrap? What percentage is rework? How can the
process be centered to eliminate all but 0.1% of the scrap? What is the rework percentage
now?

[9] A company that manufactures oil seals found the population mean to be 49.15 mm
(1.935 in.), the population standard deviation to be 0.51 mm (0.020 in.), and the data to be
normally distributed. If the internal diameter of the seal is below the lower specification limit
of 47.80 mm, the part is reworked. However, if it is above the upper specification limit of
49.80 mm, the seal is scrapped. (a) What percentage of the seals is reworked? What
percentage is scrapped? (b) For various reasons, the process average is changed to 48.50
mm. With this new mean or process center, what percentage of the seals is reworked? What
percentage is scrapped? If rework is economically feasible, is the change in the process
center a wise decision?

[10] A new process is started, and the sum of the sample standard deviations for 25
subgroups of size 4 is 750. If the specifications are 700±80, what is the process capability
index? What action would you recommend? What is the Cpk value when the process average
is 700, 740, 780, and 820? Explain.

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