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STRUCTURED/ESSAY (100 Marks) : Page 2 of 10

This document contains 6 structured/essay questions regarding quality control topics. Question 1 defines quality control terms and asks to analyze sample data through creating tables, calculating statistics, and constructing control charts. Question 2 defines in/out of control processes and asks to calculate sample statistics, determine control chart limits, and construct X-bar and R charts. Question 3 discusses attributes control charts, calculates sample proportions, determines p-chart limits, and constructs/interprets a p-chart. Question 4 defines variation types, control chart purposes, determines c-chart limits, and constructs/interprets a c-chart. Question 5 defines producer/consumer risks, explains sampling plans, and constructs an OC curve. Question 6 defines quality costs, constructs

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Iskandar Ibrahim
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61 views

STRUCTURED/ESSAY (100 Marks) : Page 2 of 10

This document contains 6 structured/essay questions regarding quality control topics. Question 1 defines quality control terms and asks to analyze sample data through creating tables, calculating statistics, and constructing control charts. Question 2 defines in/out of control processes and asks to calculate sample statistics, determine control chart limits, and construct X-bar and R charts. Question 3 discusses attributes control charts, calculates sample proportions, determines p-chart limits, and constructs/interprets a p-chart. Question 4 defines variation types, control chart purposes, determines c-chart limits, and constructs/interprets a c-chart. Question 5 defines producer/consumer risks, explains sampling plans, and constructs an OC curve. Question 6 defines quality costs, constructs

Uploaded by

Iskandar Ibrahim
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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STRUCTURED/ESSAY (100 marks) Instruction: This section consists of 6 structured/essay questions. Answer 4 questions only.

QUESTION 1 (a) Define the following terms: i. Quality control. (2 marks) ii. Continuous Improvement. (2 marks) iii. Total Quality Management. (2 marks) (b) The following data shows the length of products obtained from a sample of a population. 26 35 20 47 32 34 40 40 60 34 23 44 43 44 38 30 37 53 27 22 40 38 52 32 61

Based on the data: i. Build a frequency distribution table consisting of the class data, frequency, class boundary and class midpoint. (8 marks) ii. Find the range of the grouped data (2 marks) iii. Find the mean of the grouped data (4 marks) iv. Find the standard deviation of the grouped data (5 marks)
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QUESTION 2 (a) Define: i. In control process. (2 marks) ii. Out of control process. (2 marks)

(b)

A quality inspector intends to construct a mean ( ) and Range(R) Chart to monitor the quality of service in a bank. 20 samples of the length of time to process loan application were taken. Each sample has four observations and all values are in minutes as shown in Table 1.

TABLE 1 Sample Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 X1 12 9 10 8 13 7 15 14 10 9 14 8 7 10 10 10 14 16 17 8 Observation X2 10 10 10 9 14 8 10 13 9 10 8 9 10 10 9 14 8 16 15 7 X3 11 8 10 12 15 10 10 8 10 10 9 9 9 8 15 14 10 17 14 8


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i.

Calculate the mean and range for each sample (4 marks)

ii.

Refer to the Table of Constant for Variables Control, determine the value of Center Line, Upper Control Limit and Lower Control Limit for a Mean ( ) and Range (R) control chart. (8 marks)

iii.

Construct the Mean( ) and Range (R) Chart on a graph paper (8 marks)

iv.

State whether the process of loan applications is in control or out of control based on the chart (1 mark)

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QUESTION 3 (a) Explain THREE (3) advantages of using attributes control chart (6 marks) (b) A production line supervisor decides to count the number of non conforming units from a process. The supervisor then makes an inspection on 23 samples and records the data as shown in Table 2. Each sample contains 250 units of products.

Number of Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

TABLE 2 Number of NonConforming 30 24 26 34 40 33 32 22 26 21 20 45 32 56 43 44 43 43 44 33 32 23 30

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i.

Calculate the fraction of non conformity for each sample

(2 marks) ii. Determine the value of Center Line, Upper Control Limit and Lower Control Limit for a p-chart

(7 marks) iii. Construct the p-chart of the process (7 marks) iv. Based on the graph in question (b) iii, state whether the process is in control or out of control. Explain your answer. (3 marks)

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QUESTION 4

(a)

Define: i. Random variation. (2 marks) ii. Assignable variation.

(2 marks)

(b)

Explain THREE (3) purposes of using control chart.

(6 marks)

(c)

Table 3 indicates number of defects carried out on 20 samples of rectangular steel plate surface. TABLE 3 Plate Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Number of Defects 0 2 4 1 2 3 0 0 1 2 2 2 3 0 2 3 4 0 1 1
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i.

Calculate the value of Central Line (CL), Upper Control Limit (UCL) and Lower Control Limit (LCL) for c-chart. (7 marks)

ii.

Construct a c-chart on a graph paper (7 marks)

iii.

Interpret the process control based on the chart (1 mark)

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QUESTION 5

(a)

Define: i. Producers risk (2 marks) ii. Consumers risk (2 marks)

(b)

Explain the following sampling plan: i. Single sampling plan (3 marks) ii. Double sampling plan (3 marks) iii. Multiple sampling plan (3 marks)

(c)

Given the following sampling plan:

Lot size, N=5000,

Sample size, n=80

Acceptance number, c=2

Use the Cumulative Poisson Distribution Table in Appendix 3, construct an Operational Characteristics (OC) Curve with the value of fraction defective from 0.01 to 0.08. (12 marks)

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QUESTION 6

(a)

Define the cost of quality below. Give two examples for each cost. i. Appraisal cost. (3 marks) ii. Internal failure cost. (3 marks) iii. External failure cost.

(3 marks)

(b)

Construct a cause and effect diagram based on the following Table 4. TABLE 4 Method Material Staff -Less supervision -Less of training Machine -Type -Age -Maintenance frequency -Maintenance for tension adjustment (6 marks)

- Speed of printer -Paper -Techniques of printing -Carbon density -Carbon types

(c)

State the application of the following ISO series: i. ISO 9000 (2 marks) ii. ISO 9001 (2 marks) iii. ISO 9002 (2 marks) iv. ISO 9003 (2 marks) v. ISO 9004 (2 marks)
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