Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) © MPGroover 2007

44 QUALITY CONTROL
Review Questions
44.1 What are the two principal aspects of product quality?
Answer. The two quality aspects are (1) product features and (2) freedom from deficiencies.
44.2 How is a process operating in statistical control distinguished from one that is not?
Answer. The process in statistical control is characterized by only random variations. A process
that is out of control exhibits additional variation that is not normal, called assignable variation.
This indicates that something is wrong with the process.
44.3 Define process capability.
Answer. Process capability is the limits of the random variations of the process when it is in
statistical control. The limits are defined as the process mean ± 3 standard deviations.
44.4 What are the natural tolerance limits?
Answer. The natural tolerance limits are when the tolerance on a part is set equal to the process
capability; that is ±3σ of the process mean.
44.5 What is meant by robust design, as defined by Taguchi.
Answer. Robust design means that a product or process is designed so that its function and
performance are relatively insensitive to variations in design and manufacturing parameters that are
bound to occur.
44.6 What is the difference between control charts for variables and control charts for attributes?
Answer. In control charts for variables, measurements of the characteristic of interest are made. In
control charts for attributes, the characteristic of interest is identified as being acceptable of not
acceptable.
44.7 Identify the two types of control charts for variables.

Answer. The two charts are (1) x chart for sample means and (2) R chart for ranges.
44.8 What are the two basic types of control charts for attributes?
Answer. The two charts are (1) p chart for proportion of defects in a sample, and (2) c chart for
count of defects in a sample.
44.9 When interpreting a control chart, what does one look for to identify problems?

Answer. Problems are indicated by the following: (1) x or R lie outside their respective LCL or
UCL limits; (2) trends or cyclical patterns in the data; (3) sudden changes in average; and (4) points
consistently near the upper or lower limits.
Multiple Choice Quiz
There is a total of 12 correct answers in the following multiple-choice questions (some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given.
Each correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point,
and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
score on the quiz is based on the total number of correct answers.

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44.1 Which of the following would be classified as examples of product features, rather than freedom
from deficiency (three correct answers): (a) components within tolerance, (b) location of ON/OFF
switch, (c) no missing parts, (d) product weight, and (e) reliability?
Answer. (b), (d), and (e).
44.2 If the product tolerance is set so that the process capability index = 1.0, then the percentage of parts
that are within tolerance will be closest to which one of the following when the process is operating
in statistical control: (a) 35%, (b) 65%, (c) 95%, (d) 99%, or (e) 100%?
Answer. (e).
44.3 Which of the following principles and/or approaches are generally credited to G. Taguchi (two
correct answers): (a) acceptance sampling, (b) control charts, (c) loss function, (d) Pareto priority
index, and (e) robust design?
Answer. (c) and (e).
44.4 In a control chart, the upper control limit is set equal to which one of the following: (a) process
mean, (b) process mean plus three standard deviations, (c) upper design tolerance limit, or (d) upper
value of the maximum range R?
Answer. (b).
44.5 The R chart is used for which one of the following product or part characteristics: (a) number of
rejects in the sample, (b) number of reworked parts in a sample, (c) radius of a cylindrical part, or
(d) range of sample values?
Answer. (d).
44.6 Which one of the following best describes the situations for which the c chart is most suited: (a)
control of defective parts, (b) mean value of part characteristic of interest, (c) number of defects in a
sample, or (d) proportion of defects in a sample?
Answer. (c).
44.7 Which of the following identify an out-of-control condition in a control chart (three correct
answers): (a) consistently increasing value of x , (b) points near the central line, (c) points
oscillating back and forth across the central line, (d) R outside the control limits of the R chart, and
(e) x outside the control limits of the x chart?
Answer. (a), (d), and (e).
Problems
Note: Problems identified with an asterisk (*) in this set require the use of statistical tables not included in
this text.
Process Capability and Statistical Tolerancing
44.1 An automatic turning process is set up to produce parts with a mean diameter = 6.255 cm. The
process is in statistical control and the output is normally distributed with a standard deviation =
0.004 cm. Determine the process capability.
Solution: Process capability PC = μ ± 3σ = 6.255 ± 3(0.004) = 6.255 ± 0.012 cm
The upper and lower limits of the process capability range are: 6.243 to 6.267 cm
44.2 * In the previous problem, the design specification on the part is: diameter = 6.250 ±0.013 cm. (a)
What proportion of parts fall outside the tolerance limits? (b) If the process were adjusted so that its

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mean diameter = 6.250 cm and the standard deviation remained the same, what proportion of parts
would fall outside the tolerance limits?
Solution: (a) Given process mean μ = 6.255 cm and σ = 0.004 cm and tolerance limits 2.237 to
2.263. On the lower side of the tolerance limit, using the standard normal distribution,
z = (6.237 - 6.255)/0.004 = -4.50. Conclusion: there are virtually no defects on the lower side of the
tolerance. On the upper side of the tolerance limit, z = (6.263 - 2.255)/0.004 = +2.00
Using tables of the standard normal distribution, Pr(z > 2.00) = 0.0227
The proportion of defects with the current process mean = 0.0227 = 2.27%.
(b) Given process mean μ = 6.250 cm and σ = 0.004 cm and tolerance limits 6.237 to 6.263. On the
lower side of the tolerance limit, z = (6.237 - 6.250)/0.004 = -3.25. Using tables of the standard
normal distribution, Pr(z < -3.25) = 0.0006. On the upper side of the tolerance limit, z = (6.263 -
6.250)/0.004 = +3.25.
Using tables of the standard normal distribution, Pr(z > 3.25) = 0.0006
The proportion of defects with the current process mean = 0.0006 + 0.0006 = 0.0012 = 0.12%.
44.3 A sheet metal bending operation produces bent parts with an included angle = 92.1°. The process is
in statistical control and the values of included angle are normally distributed with a standard
deviation = 0.23°. The design specification on the angle = 90 ±2°. (a) Determine the process
capability. (b) If the process could be adjusted so that its mean = 90.0°, determine the value of the
process capability index.
Solution: (a) PC = 92.1 ± 3(0.23) = 92.1° ± 0.69°.
The upper and lower limits of the process capability range are: 91.41° to 92.79°.
(b) If μ = 90°
T = 92° - 88° = 4°
PCI = 4°/(6 x 0.23°) = 2.9 → virtually no defects.
44.4 A plastic extrusion process produces extrudate with a critical cross-sectional dimension = 28.6 mm.
The process is in statistical control and the output is normally distributed with standard deviation =
0.53 mm. Determine the process capability.
Solution: Process capability PC = μ ± 3σ = 28.6 ± 3(0.53) = 28.6 ± 1.59 mm
The upper and lower limits of the process capability range are: 27.01 to 30.19 mm.
44.5 * In the previous problem, the design specification on the part is: diameter = 28.0 ±2.0 mm. (a)
What proportion of parts fall outside the tolerance limits? (b) If the process were adjusted so that its
mean diameter = 28.0 mm and the standard deviation remained the same, what proportion of parts
would fall outside the tolerance limits? (c) With the adjusted mean at 28.0 mm, determine the value
of the process capability index.
Solution: (a) Given process mean μ = 28.6 mm and σ = 0.53 mm and tolerance limits 26.0 to 30.0
mm. On the lower side of the tolerance limit, using the standard normal distribution,
z = (26.0 - 28.6)/0.53 = -4.01. Conclusion: there are virtually no defects on the lower side of the
tolerance.
On the upper side of the tolerance limit, z = (30.0 - 28.6)/0.53 = +2.64
Using tables of the standard normal distribution, Pr(z > 2.64) = 0.0041
The proportion of defects with the current process mean = 0.0041 = 0.41%.
(b) Given process mean μ = 28.0 mm and σ = 0.53 mm and tolerance limits 26.0 to 30.0 mm.
On the lower side of the tolerance limit, z = (26.0 - 28.0)/0.53 = -3.77. Using tables of the standard
normal distribution, Pr(z < -3.77) = approx. 0.0001
On the upper side of the tolerance limit, z = (30.0 - 28.0)/0.53 = +3.77
Using tables of the standard normal distribution, Pr(z > 3.77) = approx. 0.0001
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The proportion of defects with the current process mean = 0.0001 + 0.0001 = 0.0002 = 0.02%.
(c) Process capability index PCI = 4.0/(6 x 0.53) = 1.258
44.6 An assembly consists of four components stacked to create an overall dimension of 2.500 in, with a
bilateral tolerance = 0.020 in (±0.010 in). The dimensions of the individual parts are each 0.625 in.
All parts will have identical bilateral tolerances. Determine the tolerance (a) under a worst case
design approach, and (b) using a statistical tolerancing approach.
Solution: (a) Worst case: Ti = 0.020/4 = 0.005 in. Interpret this to be ± 0.005 in
(b) Statistical tolerancing: Ta = (4 Ti2)0.5
Ta2 = 4 Ti2
(0.020)2 = 0.0004 = 4 Ti2
Ti2 = 0.0004/4 = 0.0001 = 10-4
Ti = 10-2 = 0.010. Interpret this to be ± 0.010 in
44.7 An assembly is made by stacking 20 flat pieces of sheet metal to produce a thick laminated
structure. The sheet metal blanks are all cut with the same punch and die to the desired profile, so
that the thick assembly has the same profile. All of the parts are cut from the same sheet metal coil,
whose thickness specification is 1/16 in ±0.002 in. The thickness of the final assembly is specified
as 1.250 ±0.010 in. Does a statistical tolerancing approach apply in this situation? Why?
Solution: If statistical tolerancing were used, Ta = (20 x 0.0042)0.5 = (0.00032)0.5 = 0.0179 in
Expressing this as a bilateral tolerance, Ta = ± 0.00895 in, which is well within the specified
tolerance of ± 0.010 in.
However, this would not be a good application of statistical tolerancing because the process making
the components is the same process; specifically the rolling process making the starting piece of
sheet metal from which the laminating pieces are fabricated. The absence of independent processes
making the individual components is a violation of one of the fundamental assumptions of statistical
tolerancing. It would be more appropriate to use worst-case tolerancing here, which would yield Ta
= 20(± 0.002) = ± 0.040 in, significantly beyond the specified tolerance.
44.8 The assembly in Figure P44.8 has a critical assembly dimension C = 5.000 cm. If each part is made
from an independent process with process means for part thickness all set to 2.500 cm and standard
deviation = 0.005 cm, what is the process capability of the critical dimension C. Assume the
opposite sides of each part on the 2.50 cm dimension are parallel.
Solution: Dimension C is determined by two middle parts. σa2 = 2 σi2 = 2(0.005)2 = 0.00005
σa = (0.00005)0.5 = 0.00707 cm
PC = μ ± 3σ = 2(2.500) ± 3(0.00707) = 5.000 ± 0.0212 cm
44.9 An assembly consists of three parts stacked to form a final dimension of 30.0 mm with tolerance =
±0.20 mm. The relevant part dimensions making up the 30 mm total are 5 mm, 10 mm, and 15 mm.
Parts are produced by independent manufacturing operations, whose process capabilities are
proportional to their respective dimensions. Given that the part tolerances are to be a constant
proportion of the respective dimensions, determine the tolerance for each part using: (a) worst case
design and (b) statistical tolerancing.
Solution: (a) Worst case tolerancing: Ta = 0.40 mm. Let us apportion the tolerances among parts in
proportion to their size. Thus, T1 = T, T2 = 2T, T3 = 3T.
T1 + T2 + T3 = T + 2T + 3T = 6T = 0.40 mm.
T = 0.40/6 = 0.0667 mm.
T1 = 0.0667 mm = ± 0.0333 mm , T2 = 0.1333 mm = ± 0.0667 mm,
T3 = 0.200 mm = ± 0.100 mm.

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(b) Statistical tolerancing: Ta = 0.40 mm.

Again, let us apportion the tolerances among parts in proportion to their size. Thus, T1 = T, T2 = 2T,
T3 = 3T.
Ta = 0.40 = (T1 2 + T22 + T32)0.5 = (T2 + (2T)2 + (3T)3)0.5
= (T2 + 4T2 + 9T2)0.5 = (14T2)0.5 = 3.7417 T
T = 0.40/3.7417 = 0.1069
T1 = 0.1069 mm = ± 0.0535 mm , T2 = 0.2138 mm = ± 0.1069 mm,
T3 = 0.3207 mm = ± 0.1604 mm.
44.10 Figure P44.10 shows an assembly in which the critical dimension is C. Each part used in the
assembly, including the base part, has a thickness = 10.0 mm, with process capability = ±0.1 mm
for the thickness. Given that the process capability index for the parts PCI = 1.0, and the PCI for the
assembly will also be 1.0, determine the recommended tolerance for C using: (a) worst case design
and (b) statistical tolerancing.
Solution: Given that PCI = 1.0, then Ti = 6σ = 0.2 mm and σ = 0.2/6 = 0.0333 mm.
Critical dimension C = 5(10) - 3(10) = 20 mm.
(a) Worst case tolerancing: there are 8 parts that determine critical dimension C, each with
independent variability. Therefore, Ta = 8Ti = 8(0.2) = 1.6 mm = ± 0.80 mm.
(b) Statistical tolerancing: Ta = (8Ti2)0.5 = (8(0.2)2)0.5 = (0.32)0.5 = 0.566 mm = ± 0.283 mm.
44.11 Solve part (b) of the previous problem, except that the process capability index for the assembly is a
more conservative 1.5. The PCI for the individual parts is still 1.0.
Solution: Given that parts PCI = 1.0, then Ti = 6σ = 0.2 mm and σ = 0.2/6 = 0.0333 mm.
Critical dimension C = 5(10) - 3(10) = 20 mm.
Given that assembly PCI = 1.5, Ta = 1.5 PC = 1.5 σa = 9 σa
Statistical tolerancing: σa = (8σi2)0.5 = (8(0.03333)2)0.5 = (0.008889)0.5 = 0.0943 mm
Ta = 9(0.0943) = 0.8485 = ± 0.424 mm
Control Charts
44.12 Ten samples of size n = 8 have been collected from a process in statistical control, and the
dimension of interest has been measured for each part. (a) Determine the values of the center, LCL,
and UCL for the x and R charts. The calculated values of x and R for each sample are given below
(measured values are in mm). (b) Construct the control charts and plot the sample data on the charts.
s 1 2 3 4 5 6 7 8 9 10
x 9.22 9.15 9.20 9.28 9.19 9.12 9.20 9.24 9.17 9.23
R 0.24 0.17 0.30 0.26 0.27 0.19 0.21 0.32 0.21 0.23

Solution: x = Σ x /m = Σ x /10
= (9.22 + 9.15 + 9.20 + 9.28 + 9.19 + 9.12 + 9.20 + 9.24 + 9.17 + 9.23)/10 = 9.20
R = Σ R/10 = (0.24 + 0.17 + 0.30 + 0.26 + 0.27 + 0.19 + 0.21 + 0.32 + 0.21 + 0.23)/10 = 0.24
(a) x chart: x = 9.20 mm = CL
LCL = x - A2 R = 9.20 - 0.373(0.24) = 9.1105 mm.
UCL = x + A2 R = 9.20 + 0.373(0.24) = 9.2895 mm.

R chart: R = 0.024 = CL
LCL = D3 R = 0.136(0.24) = 0.0326 mm.

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UCL = D4 R = 2.114(0.0133) = 0.4474 mm.

(b) Student exercise.
44.13 Seven samples of 5 parts each have been collected from an extrusion process that is in statistical
control, and the diameter of the extrudate has been measured for each part. (a) Determine the values
of the center, LCL, and UCL for x and R charts. The calculated values of x and R for each sample
are given below (measured values are in inches). (b) Construct the control charts and plot the
sample data on the charts.
s 1 2 3 4 5 6 7
x 1.002 0.999 0.995 1.004 0.996 0.998 1.006
R 0.010 0.011 0.014 0.020 0.008 0.013 0.017

Solution: x = Σ x /7 = (1.002 + 0.999 + 0.995 + 1.004 + 0.996 + 0.998 + 1.006)/7 = 1.000

R = Σ R/7 = (0.010 + 0.011 + 0.014 + 0.020 + 0.008 + 0.013 + 0.017)/7 = 0.0133
(a) x chart: x = 1.000 in = CL
LCL = x - A2 R = 1.000 - 0.577(0.0133) = 0.9923 in
UCL = x + A2 R = 1.000 + 0.577(0.0133) = 1.0077 in

R chart: R = 0.0133 = CL
LCL = D3 R = 0(0.0133) = 0
UCL = D4 R = 2.114(0.0133) = 0.0281 in
(b) Student exercise.

44.14 In 12 samples of size n = 7, the average value of the sample means is x = 6.860 cm for the
dimension of interest, and the mean of the ranges of the samples is R = 0.027 cm. Determine (a)
lower and upper control limits for the x chart and (b) lower and upper control limits for the R chart.
(c) What is your best estimate of the standard deviation of the process?

Solution: (a) x chart: x = 6.860 cm = CL

LCL = x - A2 R = 6.860 - 0.419(0.027) = 6.8487 cm
UCL = x + A2 R = 6.860 + 0.419(0.027) = 6.8713 cm

(b) R chart: R = 0.027 = CL

LCL = D3 R = 0.076(0.027) = 0.0205 cm
UCL = D4 R = 1.924(0.027) = 0.0519 cm

(c) The x chart is based on ± 3 σx/ n

Therefore, A2 R = 3 σx/ n
σx = A2 R n /3 = 0.419(0.027) 7 /3 = 0.00998 cm

44.15 In nine samples of size n = 10, the grand mean of the samples is x = 100 for the characteristic of
interest, and the mean of the ranges of the samples is R = 8.5. Determine (a) lower and upper
control limits for the x chart and (b) lower and upper control limits for the R chart. (c) Based on the
data given, estimate the standard deviation of the process?

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Solution: (a) x chart: x = 100 = CL

LCL = x - A2 R = 100 - 0.308(8.5) = 102.618
UCL = x + A2 R = 100 + 0.308(8.5) = 97.382

(b) R chart: R = 8.5 = CL

LCL = D3 R = 0.223(8.5) = 1.8955
UCL = D4 R = 1.777(8.5) = 15.1045

(c) The x chart is based on ± 3 σx/ n

Therefore, A2 R = 3 σx/ n
σx = A2 R n /3 = 0.308(8.5) 10 /3 = 2.7596
44.16 A p chart is to be constructed. Six samples of 25 parts each have been collected, and the average
number of defects per sample was 2.75. Determine the center, LCL and UCL for the p chart.
Solution: p = 2.75/25 = 0.11 = CL
LCL = p - 3 p (1 − p ) / n = 0.11 - 3 0.11(0.89) / 25 = 0.11 - 3(0.0626) = -0.078 → 0
UCL = p + 3 p (1 − p ) / n = 0.11 + 3 0.11(0.89) / 25 = 0.11 + 3(0.0626) = 0.298

44.17 Ten samples of equal size are taken to prepare a p chart. The total number of parts in these ten
samples was 900 and the total number of defects counted was 117. Determine the center, LCL and
UCL for the p chart.
Solution: d = 117/10 = 11.7.
p = 11.7/90 = 0.13 = CL
LCL = p - 3 p (1 − p ) / n = 0.13 - 3 0.13(0.87) / 90 = 0.13 - 3(0.03545) = 0.024
UCL = p + 3 p (1 − p ) / n = 0.11 + 3 0.13(0.87) / 90 = 0.11 + 3(0.03545) = 0.236

44.18 The yield of good chips during a certain step in silicon processing of integrated circuits averages
91%. The number of chips per wafer is 200. Determine the center, LCL, and UCL for the p chart
that might be used for this process.
Solution: Use p = 1 - 0.91 = 0.09 = CL
LCL = p - 3 p (1 − p ) / n = 0.09 - 3 0.09(0.91) / 90 = 0.09 - 3(0.0202) = 0.0293
UCL = p + 3 p (1 − p ) / n = 0.11 + 3 0.09(0.91) / 90 = 0.09 + 3(0.0202) = 0.1507

44.19 The upper and lower control limits for a p chart are: LCL = 0.19 and UCL = 0.24. Determine the
sample size n that is used with this control chart.
Solution: p = 0.5(UCL + LCL) = 0.5(.24 + .10) = 0.17
UCL - LCL = 0.24 - 0.10 = 0.14 = 6 p (1 − p ) / n = 6 0.17 (0.83) / n
(0.14)2 = 62 (0.17 x 0.83/n)
0.0196 = 36(0.17)(0.83)/n = 5.0796/n
n = 5.0796/0.0196 = 259.2 → 259
44.20 The upper and lower control limits for a p chart are: LCL = 0 and UCL = 0.10. Determine the
minimum possible sample size n that is compatible with this control chart.
Solution: p = 0.5(UCL + LCL) = 0.5(.10 + 0) = 0.05

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LCL = p - 3 p (1 − p ) / n = 0
Therefore, p = 3 p (1 − p ) / n
0.05 = 3 0.05(0.95) / n
(0.05)2 = 0.0025 = 32 (0.05)(0.95)/n = 0.4275/n
n = 0.4275/0.0025 = 171
44.21 Twelve cars were inspected after final assembly. The number of defects found ranged between 87
and 139 defect per car with an average of 116. Determine the center and upper and lower control
limits for the c chart that might be used in this situation.
Solution: CL = 116
LCL = c - 3 c = 116 - 3 116 = 83.7 → 83
UCL = c + 3 c = 116 + 3 116 = 148.3 → 148

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