Problem 1:

A quality analyst wants to construct a sample mean chart for controlling a packaging
process. He knows from past experience that the process standard deviation is two ounces.
Each day last week, he randomly selected four packages and weighed each. The data from
that activity appear below.

Weight
Day Package 1 Package 2 Package 3 Package 4
Monday 23 22 23 24
Tuesday 23 21 19 21
Wednesday 20 19 20 21
Thursday 18 19 20 19
Friday 18 20 22 20

a) Which chart to use?

b) Calculate all sample means and the mean of all sample means.
c) Calculate upper and lower 2-sigma x-bar chart control limits that allow for natural
variations.

Answer – the parameter being measured is a variable and the process standard deviation is
given (2 ounces). So, we shall use x-bar charts.

Had the process standard deviation not been given, we would have employed the x-bar and
R Charts

Problem 2:

An operator trainee is attempting to monitor a filling process that has an overall average of
705 cc. The average range is 17 cc. If you use a sample size of 6, what are the upper and
lower control limits for the chart that you would use?

Answer – Parameter is a variable. And process standard deviation is not given. So, we shall
used x-bar and R charts.

Problem 3:

The defect rate for a product has historically been about 1.6%. What are the upper and
lower control chart limits for the chart you wish to use, if you use a sample size of 100 and
3-sigma limits?

Answer - Defect rate is an attribute (defective or not). So, we have to choose between p-
chart and c-chart. Since, we have a proportion given, we opt for p-charts.
Problem 4:

A woodworker is concerned about the quality of the finished appearance of her work. In
sampling units of a split-willow hand-woven basket, she has found the following number of
finish defects in ten units sampled: 4, 0, 3, 1, 2, 0, 1, 2, 0, 2.

a) Calculate the average number of defects per basket.

b) If 3-sigma control limits are used, calculate the lower control limit and upper control
limit.

Answer – Parameter being measured here is an attribute (number of defects in a basket).

We have to choose between p-charts and c-charts. Here, there is no proportion of defects
(max defects doesn’t exist), but there is a count of defects. So, we opt for c-charts.

Problem 4:

A bank's manager has videotaped 20 different teller transactions to observe the number of
mistakes being made. Ten transactions had no mistakes, five had one mistake and five had
two mistakes. Compute proper control limits at the 90% confidence level.

Answer - Parameter being measured here is an attribute (number of mistakes made). We

have to choose between p-charts and c-charts. Here, there is no proportion of defects (max
mistakes doesn’t exist), but there is a count of mistakes. So, we opt for c-charts.

Problem 5:

The specifications for a manifold gasket that installs between two engine parts calls for a
thickness of 2.500 mm ± .020 mm. The standard deviation of the process is estimated to be
0.008 mm. The process is currently operating at a mean thickness of 2.49 mm.
a) What are the upper and lower specification limits for this product?
b) What is the Cp for this process?
c) What is the Cpk for this process
d) About what percent of units of this gasket will be defective?
e) If the process mean is adjusted to produce gaskets with mean thickness of 2.50 mm,
what would be the percent defective amongst the gaskets?

Answer – a to c is straightforward application of the relevant of the formula.

For d, find z value to calculate proportion going above the USL and below the LSL, using
standard normal formula (z = (x-µ)/σ).

For e, repeat the same as in d, but with µ changed.