a ‘ Ca De ah Sra ges) UNIVERSITI TEKNIKAL MALAYSIA MELAKA UNIVERSITI TEKNIKAL MALAYSIA MELAKA PEPERIKSAAN AKHIR SEMESTER I FINAL EXAMINATION SEMESTER I ‘SESI 2019/2020 SESSION 2019/2020 FAKULTI TEKNOLOGI KEJURUTERAAN MEKANIKAL DAN PEMBUATAN: KOD KURSUS : ‘BMMP 2333 COURSE CODE KURSUS : KAWALAN KUALITI COURSE QUALITY CONTROL PENYELARAS 7 TS. DR. AMIR HAMZAH ABDUL RASIB COORDINATOR PROGRAM : BMMW PROGRAMME MASA PAGI- 11:30 PAGI TIME AM — 11:30AM ‘TEMPOR : 2.JAM 30 MINIT DURATION 2 HOURS 30 MINUTES TARIKH 7 7 SANUARI 2020 DATE 7 JANUARY 2020 TEMPAT : DEWAN SEMINAR, KT VENUE SEMINAR HALL, KT ‘ARAHAN KEPADA CALON INSTRUCTIONS TO CANDIDATES 1. Jawab SEMUA soalan di BAHAGIAN A dan SATU (1) sahaja di BAHAGIAN B. Answer ALL questions in Section A and ONE (1) question in Section B. 2. Tuliskan semua jawapan anda di atas kertas jawapan yang disediakan, Write your answer on the answer sheet provided. 3. Setiap jawapan kepada soalan hendaklah dimulakan di muka surat yang baru. All answers to the questions should be written in a new page KKERTAS SOALAN INI TERDIRI DARIPADA DUA PULUH (20) MUKA SURAT SAHAJA (TERMASUK MUKA SURAT HADAPAN) THIS QUESTION PAPER CONTAINS TWENTY (20) PAGES INCLUSIVE OF FRONT PAGE SULITSULIT PERINGATAN REMINDER: @®O PELAJAR TIDAK DIBENARKAN SAMA SEKALI MEMBAWA APA-APA BUKU, KERTAS, SURATAN, GAMBAR, NOTA, SEBARANG ALAT YANG DI DALAM ATAU DI ATASNYA TERDAPAT CATATAN BERTULIS, ‘PROGRAMMABLE CALCULATOR’, TELEFON MUDAH ALIH ATAU SEBARANG ALAT KECUALI YANG DIBENARKAN OLEH PENGAWAS KE DALAM ATAU KELUAR DARI SESUATU DEWAN PEPERIKSAAN ATAU MENERIMA APA-APA BUKU, KERTAS, SURATAN, GAMBAR, NOTA, SEBARANG ALAT YANG DI DALAM ATAU DI ATASNYA TERDAPAT CATATAN BERTULIS, ‘PROGRAMMABLE CALCULATOR’, TELEFON MUDAH ALIH ATAU SEBARANG ALAT DARI MANA-MANA ORANG LAIN SEMASA DI DALAM DEWAN PEPERIKSAAN KECUALI SESEORANG PELAJAR SEMASA IA BERADA DI DALAM DEWAN PEPERIKSAAN ITU MENERIMA DARIPADA — PENGAWAS_~—sAPA-APA__—BUKU, __KERTAS, DOKUMEN/GAMBAR ATAU LAIN-LAIN ALAT YANG DIBENARKAN OLEH NAIB CANSELOR ATAS SYOR PEMERIKSA ATAU FAKULTI. STUDENTS ARE NOT ALLOWED TO BRING IN ANY BOOKS, PAPERS, DOCUMENTS, PHOTOGRAPHS, NOTES, ANY TOOLS WHICH THERE ARE WRITTEN RECORDS, MOBILE PHONES, OR ANY OTHER DEVICES WITHOUT THE PRIOR PERMISSION OF THE INVIGILATORS INTO OR OUT OF THE EXAMINATION HALL, OR RECEIVE ANY PAPERS, BOOKS, DOCUMENTS, PHOTOGRAPHS, NOTES, ANY DEVICES IN OR ON WHICH THERE ARE WRITTEN RECORDS, 'PROGRAMMABLE CALCULATORS’, OR TOOLS FROM OTHER PERSON(S) PRESENT IN THE EXAMINATION HALL; EXCEPT ‘MATERIALS OR DEVICES PROVIDED BY THE INVIGILATORS AND PERMITTED BY THE VICE CHANCELLOR ON THE RECOMMENDATIONS OF THE EXAMINERS OR FACULTIES. @ SULIT(BMMP 2333) SULIT BAHAGIAN A SOALAN1 (@ _ Nyatakan DUA (2) contoh kriteria yang krtikal di dalam Six Sigma, [2 markab] (b) Six Sigma DMAIC adalah prosedur penyelesaian masalah berstruktur yang digunakan secara meluas dalam peningkatan kualiti dan proses. @ —_ Nyatakan nama penuh bagi DMAIC. [5 markah} i) Terangkan setiap Jengkah dalam prosedur DMAIC. {5 markah] (©) Senaraikan LIMA (5) alat kualiti yang boleh digunakan dalam metodologi Six Sigma. [5 markah] (@® Terangkan EMPAT (4) manfaat utama Six Sigma yang menarik syarikat untuk menggunakan prosedur ini. [8 markeh] [25 MARKAH] fen SULIT(BMMP 2333) SULIT SOALAN2 Pasukan reka bentuk ABC Sdn, Bhd. sedang mempertimbangkan perubahan reka bentuk utama pada Penyerap Hentakan Kereta model ABC. Pasukan ini perlu melakukan Analisis Kesan Mod Kegagalan (FMEA) pada reka bentuk Penyerap Hentakan baru dan juga prosesnya, Rajah $2 menunjukkan reka bentuk baru Penyerap Hentakan bagi Syatikat ABC. @) ) © @ Rajah S2: Penyerap Hentakan ABC Kenalpasti LIMA (5) langkah penting bagi membangunkan kumpulan untuk Analisa ‘Mod Kegagalan Kesan (FMEA) pada proses Penyerap Hentakan yang barv. [5 markah] Terangkan EMPAT (4) perbezaan di antara aplikasi Rekabentuk FMEA (DFMEA) dan Proses FMEA (PEMEA) di dalam proses pengeluaran. [8 markah] Pasukan reka bentuk ABC Sdn. Bhd. akan melakukan pembangunan FMEA. yang dapat digunaken untuk mengenalpasti pertimbangan bagi tindakan. Laksanakan EMPAT (4) langkah yang diperlukan bagi melaksanakan FMEA. [8 markah] Kenalpasti EMPAT (4) kelebihan kepada ABC Sdn. Bhd. dengan penggunaan FMEA dalam proses pembuatan. [4 markah} [25 MARKAH] fae SULIT(BMMP 2333) SULIT QUESTION 3 Behagian pengeluaran produk glass lens berkehendakan ketebalan glass Jens yang seragam. Data bagi Carta X- R data ditunjukan seperti di dalam Jadual $3, Walaupun carta kawalan menunjukan kawalan yang baik, pelanggan telah mengajukan soalan tentang kebolehupayaan proses bagi mengeluarkan ‘glass lens’ mengikut spesifikasi 2.500 mm + 0.05. Jadual $3: Data Ketebalan Glass Lens ‘Subgroup No. 1 2 3 4 x R ‘Subgroup | 2.500 | 2510 | 2490 [2.500 Isubgroup2 | 2510 | 2490 | 2490 | 2.520 (subgroup | 2510 | 2490 | 2510 | 2.410 Subgroup4 | 2.490 | 2470 | 2520 [2.410 [subgroups | 2.500 | 2470 | 2500 | 2.520 Isubgroup6 | 2510 | 2520 | 2490 | 2.510 Subgroup? | 2510 | 2460 | 2500 [2.500 Subgroups | 2.500 | 2490 | 2.490 | 2.520 Isubgroup9 | 2.500 | 2470 | 2500 | 2.510 subgroup 10 | 2.480 | 2.480 | 2510 | 2530 [subgroup i1_| 2500 {| 2500 | 2500 | 2.530 [subgroup 12 | 2510 | 2490 | 2510 | 2530 [subgroup 13 | 2500 | 2470 | 2500 | 2.510 [subgroup ia | 2500 | 2500 | 2490 | 2520 [subgroup 15_| 2.500 | 2470 | 2500 | 2.510 (@) Kira nilai untuk % dan julat (R). {4 markah] (®) — Merujuk kepada nila ¥ (UCL=2.536, LCL= 2.464) dan R (UCL= 0.11, LCL= tiada): @ Plot Carta X bagi tajuan kawalan kualiti pada kertas graf. [3 markab] Gi) Plot Carta R bagi tujuan kawalan kualiti pada kertas graf. {3 markah} SULIT© @ © (BMMP 2333) SULIT Kira nilai bagi sisihan piawai (6°). (2 markeh] Kira keputusan untuk Indek Kebolehupayaan Proses (Cp) and (Cox). [5 markah} Merujuk kepada Soalan 3(b) and Soalan 3(4): (i) Analisa keadaan proses pengeluaran berdasarkan keputusan Carta R—R. [4 marke] (ii) Analisa keadaan proses pengeluaran berdasarkan keputusan Cp and Cpk, {4 markab] [25 MARKAH] | SULIT(BMMP 2333) SULIT BAHAGIAN B SOALAN 4 Syariket Bunga Raya Sdn. Bhd. ingin membuat penelitian tentang Tolok Pengulangan dan Penghasilan (GR&R) yang digunakan untuk mengukur ketebalan gasket bagi menilai spesifikasi antara 0.50 mm ke 1,00 mm. Sepuluh bahan telah dipilih dengan tiga orang pekerja. Setiap bahan diukur dua kali dengan keputusan ditunjukkan dalam Jadual $4. Jadual S4: Data Ketebalan Gasket Bilangan pekerja 3 Had Spesifikasi Ata 20 Bilangen percubean () 2 Hed Spesifkasi Bowel os Bilangen sampel @ 10 Data Pekeriat Pekerja? Pekera3 Pareubaan Pereubaan Pereubaan Sampell z 2 joe | a [2 | see [a [2 | ater 1 0.630 | 0.590. 0.560 | 0.560 6.510 | 0.540 2 1,000 | 1.000 1.040 | 0.960 1,050 | 1.010 3 0.830 | 0.770 0,800 | _ 0.760 0.810 | 0.810 4 0.860 | 0.940 0.820 | 0.780 0.810 |_0.810 5 0.590 | 0.510 0.430 | 0.430 0.460 | 0.490 6 0.980 | 0.980 1.000 | 1.040 1.040 | 1.000 ae 0.960 | 0.960. 0.940 | 0.900 0.950 | 0.950. 8 0.860 | 0.830 0.720 |_0.740 0.810 | 0.810 a 0.970 | 0.970 0.980 | 0.940 1.030 | _1.030 10 0.640 | 0.720. 0.560 |_ 0.520 0.840 | _ 0.810 Purata julat Rye 5 %= Purata sampel 0.830 0.774 0.829 @ — Kiranilai untuk Ry, Ry, dan Rs. [B markah] (®) Kira nilai beza Xaur dan nilai purata keseluruban perbezaan R . {5 markab] ae SULIT© @ © (BMMP 2333) SULIT Kira Pengulangan/ Variasi Alatan (EV) dan Penghasilan/ Variasi Penilaian (AV). [5 markah] Sclesaikan pengiraan keseluruhan peratus bagi Pengulangan & Penghasilan (R&R) berdasarkan keputusan EV dan AV. [5 marke] Merujuk kepada keputusan Soalan 4(d): (@ Analisa situasi keadaan yang terlibat, (3 markah} i) Beriken DUA (2) faktor berdasarkan keputusan analisa anda. (4:markeh] [25 MARKAH] nee SULIT(BMMP 2333) SULIT SOALAN 5 Carta Kkawalan perlu disediakan untuk proses menghasilkan televisyen. Satu subkumpulan televisyen digunakan sebagai unit pemeriksaan dan biasanya, carta untuk ketidakpatuhan akan digunakan. Jadual $5 menyediaken data untuk ketidakpatuhan yang dikira dalam pemeriksaan sebanyak 25 subkumpulan. Jadual $5: Jumlah Ketidakpatuhan Unit Dalam Pemeriksaan Televisyen Bilangan Kuantitt Kuantiti Subkumpulan | diperiksa, » | ketidakpatuhan, np 1 300 12 2 300 3 3 300 9 4 300 4 3 300 0 6 300 6 7 300 6 8 300 1 9 300 8 10 300. UW i 300 2 12 300 10 I 13 300 9 14 300 3 15. 300 0 16 300 5 17 300 EE 18 300 8 19 300 16. 20 300 2 21 300 5 22, 300. 6 23 300 0 24 300 3 25 300 a Jumlah 7500. 138, @ — Kenalpasti carta ketidakpatuhan yang paling sesuai digunakan untuk sampel televisyen ini. (3 markah] SULIT©) ©) @ © (BMMP 2333) SULIT Kira Had Tengah (CL) bagi ketidakpatuhan unit televisyen. [5 mariah} ‘Tetapkan nilai Had Kawalan Atas (UCL) dan Had Kawalan Bawah (LCL). [5 markeh] Plotkan carta ketidakpatuhan yang bersesuaian bagi tujuan aktiviti kawalan kualiti pada kertas graf. [5 markah] Merujuk kepada Soalan 5 (a): (@ Analisa keadaan proses pengeluaran, [3 markah] i) Berikan DUA (2) ulasan anda sebagai seorang Jurutera Kualiti, [4 markah] [25 MARKAH} ~SOALAN PEPERIKSAAN TAMAT- Hoe SULIT(BMMP 2333) SULIT PART A QUESTION 1 @ ) © @ State TWO (2) examples of critical criteria in Six Sigma. (2 marks) Six Sigma DMAIC is a structured problem-solving procedure widely used in quality and process improvement. @ State the full form of DMAIC. [5 marks] (i) Explain each of the steps in DMAIC procedure. [5 marks] List FIVE (5) quality tools that can be used in the Six Sigma methodologies. [5 marks] Explain FOUR (4) major benefits of Six Sigma that attracts companies to apply this system. [8 marks] [25 MARKS] -10- SULIT(BMMP 2333) SULIT QUESTION 2 ‘The ABC Sdn. Bhd. production team is considering a major assembly change on the ABC’s ‘Shook Absorber. The team will need to perform a Failure Mode Effect Analysis (FMEA) on the new shock absorber assembly process. Figure Q2 shows the new series of ABC’s Shock Absorber. @) © © @ Figure Q2: ABC’s Shock Absorber Identify FIVE (6) important steps to develop a team for Failure Mode Effect Analysis (FMEA) on the new series Shock Absorber’s process, [5 marks] Describe FOUR (4) differences between the applications of Design FMEA (DEMEA) and Process FMEA (PFMEA) in the production floor. {8 marks] ‘The ABC Scan. Bhd. design team will perform a development of FMEA that might be used to find suitable action recommendations. Construct FOUR (4) required steps to implement FMEA. [8 marks] Identify FOUR (4) advantages to ABC Sdn. Bhd. by applying FMEA in their manufacturing operation. [4 marks} [25 MARKS] “ie SULIT(BMMP 2333) SULIT QUESTION 3 ‘The production of glass lens requires glass lens of consistent thickness. The Rand R chart with the data shown in Table Q3. Though the the control charts exhibit good control, the customer has raised questions on whether the process is capable of producing the glass lens within their specifications of 2.500 mm + 0.05. Table Q3: Thickness of Glass Lens Data [Subgroup No. | 1 2 3 4 x R ‘Subgroup1 | 2500 | 2510 | 2490 | 2.500 ‘Subgroup2 | 2510 | 2490 | 2490 | 2.520 ‘Subgroup3 | 2510 | 2.490 | 2510 | 2.410 ‘Subgroup | 2490 | 2.470 | 2520 | 2.410 Isubgroups | 2.500 | 2470 | 2500 | 2520 [Subgroup6 | 2.510 | 2520 | 2490 | 2.510 [Subgroup7 | 2510 | 2.460 | 2500 | 2.500 isubgroupe | 2500 | 2490 | 2490 | 2.520 lsubgroup9 | 2.500 | 2470 | 2500 | 2510 [Subgroup 10 | 2.480 | 2480 | 2510 | 2.530 lsubgroup1 | 2.500 | 2500 | 2500 | 2530 lsubgroup 12 | 2510 | 2490 | 2510 | 2530 |subgroup 13 | 2.500 | 2470 | 2500 | 2.510 |subgroup 1a | 2.500 | 2500 | 2490 | 2.520 lsubgroup 15 | 2500 | 2470 | 2500 | 2.510 (@) Determine value for % and Range ( R). [4 marks] (>) —_Refering to value of X (UCL= 2.536, LCL= 2.464) and R (UCL= 0.11, LCL= none): (@ Plot the X Chart for the purpose of quality control on graph paper. (3 marks} (ii) Plot the R chart for the purpose of quality control on graph paper. [3 marks] -12- SULIT©) @ @ (BMMP 2333) SULIT Caleulate value for standard deviation (6). {2 marks] Calculate results for Process Capability Index (Cp) and (Cy), respectively. [5 marks] Referring to result of Question 3(b) and Question 3(d): (@ Analyse the condition of production process based on results of X—R Chart. [4 marks] (ii) Analyse the condition of production process based on results of Cp and Cpk. [4 marks} [25 MARKS] -13- SULIT(BMMP 2333) SULIT PARTB QUESTION 4 Bunga Raya Sdn. Bhd. preffered to illustrate a gauge repeatability and reproducibility study, suppose that 2 gauge used to measure the thickness of a gasket having a specification of 0.50 mm to 1.00 mm is to be evaluated. Ten parts have been selected for measurement by three operators. Each part is measured twice with the results as shown in Table Q4. Table Q4: Gasket Thickness Data ‘Number of operators 3 ‘Upper Specification Limit 2.0 Number of tal © 2 Lower Specification Limit os Number of| ‘samples (n) 10 Data Operators ‘Operator? ‘Operator’ Teal Tal Tial Semple a [2 [ange [a [2 [fangs [1 [2 [Range i 0.630 |_ 0.590. 0.560 | __0.560 0.510 | _0.540 L 2 1.000 |_ 1.000 1.040 | _0.960 1.050} 1.010 3 0.830 | 0,70 0,800 | 0.760 0810 | 0.810 4 0.860 | 0,940 0,820 | 0.780 0,810 | 0.810 Ss 0.590 |_ 0.510 0.430 | 0.430 0.460 | 0.490 6 0.980 | 0.980 1,000 | _ 1.040 1,040 | 1.000 7 0.960 | 0.960 0.940 | 0.900 0.950 | 0.950 8 0.860 | 0.830 0.720 | 0.740 810 | 0.810 a 0,970 |_ 0.970 0.980 | 0.940 1,030 | 1.030. 10 0.640 |_ 0.720 0.560 | 0.520 0.840 | 0.810 Range average Re Re Re % = = a= Sample average 0.830 0.774 0.829 (a) Determine the value for each Ry, Ry, and Ry. [3 marks] (b) Compute the different mean value of Xaur and the overall average range R . [5 marks] 714- SULIT© @ © (BMMP 2333) SULIT Calculate the Repeatability/Equipment Variation (EV) and Reproduceability Nariation (AV). [5 marks] Solve the overall measurement in percentage of Repeatability & Reproduceability (R&R) based on the result of EV and AV. [5 marks] Referring to results of Question 4(d): (@ Analyse the condition of related resources. [3 marks] i) Provide TWO (2) factors based on the analysis result. [4 marks} [25 MARKS} -15- SULIT(BMMP 2333) SULIT QUESTION 5 A control chart is to be established on a process producing televisions. The inspection unit is one subgroup number, and a common chart for nonconforming units is to be used. Table QS provides the data for nonconforming units count in inspecting 25 Subgroup Number. Table QS: Number of Nonconforming units in Television Samples Subgroup | Inspected | Nonconforming Number _| Number,n | _ Number, np I 300 12 2 300 3 3 300 x 4 300 4 3 300 0 6 300 6 7 300 6 8 300 i 9 300 8 10 300 u i 300 2 2 300 10 13 300 9 14 300 3 is 300 0 16 300 5 17 300 7. | 18 300 3 19. 300 16 20 300 2 ] 21 300) 3 | 2 300 6 23 300 0 24 300 3 25 300 2 | Jumlah 7500 138 J (®) _ Identify the suitable attribute chart for the television samples inspection. [3 marks] ® Calculate the Central Line (CL) for television nonconforming units. [5 marks} -16- SULIT(BMMP 2333) SULIT © Determine the Upper Control Limit (UCL) and Lower Control Limit (LCL). [5 marks} @ __ Plotthe chart for the purpose of quality control activity on graph paper. [5 marks] © Referring to result of Question 5(4): (@ Analyse the condition of production process. [3 marks] Gi) Provide TWO (2) comment as a Quality Engineer. [4 marks] [25 MARKS] -END OF EXAMINATION QUESTION- ear SULIT(BMMP 2333) SULIT LAMPIRAN A/ APPENDIX A Various formulas: a 7 _ Be Re X==5 a n § = 2S m UCLE = X+A.R UCLp = DR RAR = LCLy = Feces gl anT TORT Repeatability” + Reproducibility UCL =X+A;§ UCL, = BS LCLg=X-A;5 LCL, = BF 4 3 YE =@3% peZé UCLu=a3 F kd =—-3% LCLu=@-3 4 Po = Prew 7 UCL = 2+ 3VE fai ‘Pe ~~ UCL = po + 3./P LCL =¢- 3VE = po — 3. /Pet ed LCL = po — 3 2 7 2 R os zo 2 now = OE Laie %= 7, g &~ Sa 7 USL=LSL | Reproduci =m = ; 4 o aiff .K2)" — EV" /nr) K 525 K 2585 = a “ Repeatability, EV= R x La -18- SULITSULIT (BMMP 2333) LAMPIRAN B/ APPENDIX B Factors for computing Central lines: v0S') O6VT OTS 6986;0° Gal. STvO--T26S ENT 6x0 SEE 9R7O” oBT'O “1190, . O2 out S8rT, O60 GOST “L6v0 29860 L6S1. EOWO- Tee's ev -ELO 6a9'E 8690 ABE 829°0° 6. 96PT SiH BIST Z8vO PHBE © BOT TEED “SERS yerT GeO “ODE BILD ETD COLO BT TIST SGr'D PEST 9970 SHBGD 229-1 BLED OZ8'S | OGE'T . HHO BSE Gee © B02 820 a 92ST Ov zG'T -ervO- GaeD eT E9ED 29 BCT OSLO -zEFE EOL zIZD O90 ot ST 12V0 ZAGT.< 8270. E2860. S591 LED Tee E071 9500 els e8r0 «E270 SAL. st 9ST 6660 VEST OVO” O18 ZL BZED 9695S ITT f9L0 Le 2180 = SEZD ZOR'O ‘t: GEST. ple BIST -ZREO . H6LGO. E6T LORD Leos. Seo OLL0 SEE 0580 6870 2680 a OT ‘sO SHOT “PSEO 91L60 fez'o -ves's 7260 Bio * eve’ BRO 96e0 SoFO | at LEQT £160. CBT 12E0 PSL60- « 9520 SESS 1180: 2820. eee L260 - S870 S050: 1 6997: “920. SILT ¥8Z0 ° L2U60 LLLT Bez WS L890 LO BLE SLED BORD. HED. OT LOLT "ZEZ'D- TOLT GEO E696 SIRT - VETO BEES Leg 8080 Lee ze0T. L880 00NT 6. ISLT G64TO SIST S8TO 05960 © P9ST ETO GOES ‘SRE'O OZeO Lt 660T E60 TOOT 8 QO8T EIT. ZeeT BITO . vESe0 v261 9/00. .vOz's #070 ev'O vOLe @sll 6IvO ETT He VST 6200: OLET. 0800 SIS: yO0Z 0 BOS «=O HRD. LATT. BBO. Set! 9 $96T- 0 680% «OOOH: 0 BY «0 HARD ETL east, ETS sz. 0 992Z «=H HZ ED | tO ORRD ROT BANT «GED OOF wee. 0 89g% 0 zero rSt 0 Bsey. 0 8880. 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