Q1 A manufacturer of automotive transmission systems produces a component whose

diameter is a critical dimension for quality Samples are drawn during every shift from the
processes producing the component Every time a sample of five components is drawn, the
diameter is measured Fifteen such measurements are taken during every shift Table below
presents the readings(in cm) take during one shift Set up relevant control charts and
examine if the process is in control

Observations in each sub-group(in cm)

Subgrou
1 2 3 4 5
ps
1 12.45 12.39 12.55 12.38 12.4
2 12.55 12.38 12.4 12.39 12.44
3 12.46 12.44 12.44 12.35 12.36
4 12.38 12.39 12.55 12.38 12.4
5 12.37 12.44 12.45 12.41 12.41
6 12.45 12.37 12.44 12.38 12.41
7 12.46 12.38 12.35 12.5 12.44
8 12.44 12.39 12.37 12.45 12.39
9 12.44 12.55 12.44 12.37 12.55
10 12.35 12.38 12.45 12.44 12.38
11 12.36 12.4 12.41 12.37 12.4
12 12.51 12.36 12.41 12.37 12.39
13 12.38 12.5 12.45 12.37 12.44
14 12.41 12.37 12.45 12.4 12.36
15 12.37 12.44 12.45 12.41 12.37

Sol
Observations in each sub-group(in cm) X_bar
Subgrou
1 2 3 4 5 Average Range
ps
1 12.45 12.39 12.55 12.38 12.4 12.434 0.17
2 12.55 12.38 12.4 12.39 12.44 12.432 0.17
3 12.46 12.44 12.44 12.35 12.36 12.41 0.11
4 12.38 12.39 12.55 12.38 12.4 12.42 0.17
5 12.37 12.44 12.45 12.41 12.41 12.416 0.08
6 12.45 12.37 12.44 12.38 12.41 12.41 0.08
7 12.46 12.38 12.35 12.5 12.44 12.426 0.15
8 12.44 12.39 12.37 12.45 12.39 12.408 0.08
9 12.44 12.55 12.44 12.37 12.55 12.47 0.18
 10 12.35 12.38 12.45 12.44 12.38 12.4 0.1
11 12.36 12.4 12.41 12.37 12.4 12.388 0.05
12 12.51 12.36 12.41 12.37 12.39 12.408 0.15
13 12.38 12.5 12.45 12.37 12.44 12.428 0.13
14 12.41 12.37 12.45 12.4 12.36 12.398 0.09
15 12.37 12.44 12.45 12.41 12.37 12.408 0.08
Average 12.41707 0.119333 =R_Bar

Computation for X-Bar

Process avg= 12.41707 X-double bar Get A2, D3 values from chart for sam
UCL= 12.485922
LCL= 12.3482113

Computation for R-Bar chart

Process avg= 0.119333

UCL= 0.25227067
LCL= 0

Subgrou
ps UCL Center lineAverage LCL
1 12.486 12.417 12.434 12.348
2 12.486 12.417 12.432 12.348
3 12.486 12.417 12.41 12.348
4 12.486 12.417 12.42 12.348
5 12.486 12.417 12.416 12.348
X bar chart
6 12.486 12.417 12.41 12.348
12.500
7 12.486 12.417 12.426 12.348
8 12.486 12.417 12.408 12.348 12.450
9 12.486 12.417 12.47 12.348
12.400
Axis Title

10 12.486 12.417 12.4 12.348

11 12.486 12.417 12.388 12.348 12.350
12 12.486 12.417 12.408 12.348
12.300
13 12.486 12.417 12.428 12.348
14 12.486 12.417 12.398 12.348 12.250
1 2 3 4 5 6 7 8 9 10
15 12.486 12.417 12.408 12.348
Axis Title
For the time being, all the subgroups are betwe
S process isUCL
under contril.
CenterBut
line the 9thAverage
subgroup
UCL which gives indication that it will cross UCL
will lead to the system not being under
Subgrou
ps UCL Center lineAverage LCL
1 0.252 0.119 0.17 0
2 0.252 0.119 0.17 0
3 0.252 0.119 0.11 0 RANGE CHART
4 0.252 0.119 0.17 0 0.3
5 0.252 0.119 0.08 0
0.25
6 0.252 0.119 0.08 0
7 0.252 0.119 0.15 0 0.2
8 0.252 0.119 0.08 0
0.15
9 0.252 0.119 0.18 0
10 0.252 0.119 0.1 0 0.1
11 0.252 0.119 0.05 0
0.05
12 0.252 0.119 0.15 0
13 0.252 0.119 0.13 0 0
1 2 3 4 5 6 7 8 9 10
14 0.252 0.119 0.09 0
15 0.252 0.119 0.08 0 UCL Center line Avera

The range chart is used to look variation in

sample. The variations within samples (all
the 15 sub groups) are within the uCL and
LCL. Which means that the system is
under control.
3 values from chart for sample size 5

X bar chart

5 6 7 8 9 10 11 12 13 14 15
Axis Title
all the subgroups are between UCL and LCL.
ontril.
CenterBut
line the 9thAverage
subgroup value
LCL is nearing
dication that it will cross UCL in futur which
he system not being under control.
 RANGE CHART

5 6 7 8 9 10 11 12 13 14 15

Center line Average LCL

ed to look variation in
ns within samples (all
re within the uCL and
s that the system is
control.
 Q2 A manufacturer of hair oil has an automated process consisting of a
filling machine for filling the 200-ml bottles and a sealing unit. After
filling the bottle, it is automatically sealed with a metallic cap. To monitor
the quality of the process, sample of size 5 are drawn periodically from
the process and the quantity filled is measured. Table below has data on
12 such observations.

Sample 1 2 3 4 5
1 9.21 8.87 8.71 9.08 9.34
2 9.06 8.97 9.13 8.46 8.85
3 9.35 8.95 9.2 9.03 8.44
4 9.21 8.71 9.05 9.35 8.87 Construct a variable control chart a
5 9.01 9.17 9.21 9.05 9.53
6 8.74 8.35 8.5 9.06 8.89
7 9.21 9.05 9 8.78 9.23
8 9.15 9.2 9.23 9.15 9.06
9 8.98 8.81 8.9 9.13 9.05
10 9.03 9.1 9.26 9.44 8.48
11 9.49 9.05 9.12 8.88 8.93
12 8.95 9.1 9.02 9.04 8.96

Sol: Sample 1 2 3 4 5 Average Range

1 9.21 8.87 8.71 9.08 9.34 9.042 0.63
2 9.06 8.97 9.13 8.46 8.85 8.894 0.67
3 9.35 8.95 9.2 9.03 8.44 8.994 0.91
4 9.21 8.71 9.05 9.35 8.87 9.038 0.64
5 9.01 9.17 9.21 9.05 9.53 9.194 0.52
6 8.74 8.35 8.5 9.06 8.89 8.708 0.71
7 9.21 9.05 9 8.78 9.23 9.054 0.45
8 9.15 9.2 9.23 9.15 9.06 9.158 0.17
9 8.98 8.81 8.9 9.13 9.05 8.974 0.32
10 9.03 9.1 9.26 9.44 8.48 9.062 0.96
11 9.49 9.05 9.12 8.88 8.93 9.094 0.61
12 8.95 9.1 9.02 9.04 8.96 9.014 0.15
Average 9.018833 0.561667

Computation for X-Bar

Process avg= 9.019 X-double bar
UCL= 9.343
LCL= 8.695
Computation for R-Bar chart

Process avg= 0.562

UCL= 1.187
LCL= 0.000

Subgroups UCL Center lineAverage LCL X bar chart

1 9.343 9.019 9.042 8.695 9.6

2 9.343 9.019 8.894 8.695 9.4

3 9.343 9.019 8.994 8.695
9.2
4 9.343 9.019 9.038 8.695
9
5 9.343 9.019 9.194 8.695
6 9.343 9.019 8.708 8.695 8.8
7 9.343 9.019 9.054 8.695 8.6
8 9.343 9.019 9.158 8.695
8.4
9 9.343 9.019 8.974 8.695
10 9.343 9.019 9.062 8.695 8.2
1 2 3 4 5 6 7
11 9.343 9.019 9.094 8.695
12 9.343 9.019 9.014 8.695 UCL Center line
Subgroup 6 is touching lcl. So out of control. E

Subgroups UCL Center lineAverage LCL

1 1.187 0.562 0.63 0 R chart
2 1.187 0.562 0.67 0 1.4
3 1.187 0.562 0.91 0 1.2
4 1.187 0.562 0.64 0
1
5 1.187 0.562 0.52 0
6 1.187 0.562 0.71 0 0.8
7 1.187 0.562 0.45 0 0.6
8 1.187 0.562 0.17 0
0.4
9 1.187 0.562 0.32 0
0.2
10 1.187 0.562 0.96 0
11 1.187 0.562 0.61 0 0
1 2 3 4 5 6 7
12 1.187 0.562 0.15 0
UCL Center line
a variable control chart and investigate if the process is in control.
 X bar chart

4 5 6 7 8 9 10 11 12

UCL Center line Average LCL

ng lcl. So out of control. Either operating erroe . So investigate

R chart

4 5 6 7 8 9 10 11 12

UCL Center line Average LCL

 Q2 A manufacturer of an electronic control system (ECS) for musical appliance uses a non-
destructive testing mechanism to assess the quality of ECS A lot of 100 ECSes is drawn
periodically for testing After testing the ECses will be classified as either defective or good
depending on the outcome of the test Table below gives the number of defects for 12 such
samples Establish a p chart for the process

Number
Sample
of
No
Defects
1 10
2 9
3 8
4 11
5 7
6 12
7 7
8 10
9 13
10 12
11 13
12 14

Sol

Lot size n 100

Number
Sample No of p
Defects
1 10 0.1
2 9 0.09
3 8 0.08
4 11 0.11
5 7 0.07
6 12 0.12
7 7 0.07
8 10 0.1
9 13 0.13
10 12 0.12
11 13 0.13
 12 14 0.14
TOTAL 1.26

Process average 0.105

SD 0.031
UCL 0.197
LCL 0.013

Sample No UCL Central LinP LCL

1 0.197 0.105 0.1 0.013 P CHART
2 0.197 0.105 0.09 0.013 0.25
3 0.197 0.105 0.08 0.013 0.2
4 0.197 0.105 0.11 0.013
0.15
5 0.197 0.105 0.07 0.013
6 0.197 0.105 0.12 0.013 0.1
7 0.197 0.105 0.07 0.013
0.05
8 0.197 0.105 0.1 0.013
9 0.197 0.105 0.13 0.013 0
1 2 3 4 5 6 7 8
10 0.197 0.105 0.12 0.013
UCL Central Line P
11 0.197 0.105 0.13 0.013
12 0.197 0.105 0.14 0.013

System is under control

 liance uses a non-
ECSes is drawn
defective or good
efects for 12 such
 P CHART

3 4 5 6 7 8 9 10 11 12

UCL Central Line P LCL

under control
Q1 In the previous example, the organization wants to also assess the
process of fitting the caps. Let us assume that samples are drawn after
process and a count is made of the number of defective metallic caps
per batch. Table has the details of the number of defective caps in the
last ten batches. Assume that batch size is 100.

Number
Batch no. of
defects
1 12
2 8
a)     What type of control chart will you recommend for controlling
3 11
the quality of the cap filling process?
4 14
5 12
b)     Compute the relevant parameters for the chart and plot the data in
6 23
the chart.
7 7
8 10
c)     Is the process in control? If not, revise the control chart by
9 16
recomputing the chart parameters.
10 6

100
Number
Sample
of p
No
Defects
1 12 0.12
2 8 0.08
3 11 0.11
4 14 0.14
5 12 0.12
6 23 0.23
7 7 0.07
8 10 0.1
9 16 0.16
10 6 0.06

TOTAL 1.19

P_Bar 0.119
sigma_p 0.032
UCL 0.216
LCL 0.022

Sample Chart Title

No UCL Central LinP LCL
0.25
1 0.216 0.119 0.12 0.022
0.2
2 0.216 0.119 0.08 0.022
0.15
3 0.216 0.119 0.11 0.022
0.1
4 0.216 0.119 0.14 0.022
0.05
5 0.216 0.119 0.12 0.022
0
6 0.216 0.119 0.23 0.022 1 2 3 4 5 6 7 8 9
7 0.216 0.119 0.07 0.022 UCL Central Line
8 0.216 0.119 0.1 0.022 P LCL
9 0.216 0.119 0.16 0.022
10 0.216 0.119 0.06 0.022

Remove 6th sample

Number
Sample
of p
No
Defects
1 12 0.12
2 8 0.08
3 11 0.11
4 14 0.14
5 12 0.12
7 7 0.07
8 10 0.1
9 16 0.16
10 6 0.06
Total 0.96

P_Bar 0.106667
sigma_p 0.031
UCL 0.199
LCL 0.014
nd for controlling

t and plot the data in

ntrol chart by
Chart Title

5 6 7 8 9 10

CL Central Line
LCL
Q1 Ten Samples, each of sample sizes 100 are drawn. The number of
defectives in each sample are noted as follows.

Sample
1 2 3 4 5 6 7 8
no
No of
defective 5 6 3 4 3 3 4 5
s

Draw a control chart for number of defectives.

No of
Sample
defective
no
s
1 5
2 6
3 3
4 4
5 3
6 3
7 4
8 5
9 4
10 3
TOTAL 40

Approx
P bar 0.04
CL 4 4
UCL 9.878775 1.959592 10
LCL -1.878775 0

Sample
no UCL Central LinD LCL Chart Title
1 10 45 0 12
2 10 46 0 10
8
3 10 43 0
6
4
2
0
1 2 3 4 5 6 7
 Chart Title
12
10
8
6
4 10 44 0 4
5 10 43 0 2
6 10 43 0 0
1 2 3 4 5 6 7
7 10 44 0
UCL Central Lin
8 10 45 0
D LCL
9 10 44 0
10 10 43 0
 9 10

4 3

Chart Title

3 4 5 6 7 8 9 10
 Chart Title

3 4 5 6 7 8 9 10

UCL Central Line

D LCL
 Q2 A manufacturer of perfume has automated the process of filling bottle with cap. To
monitor the quality of process, samples are drawn and a count is made of number of
defective caps per batch. The table below provides details of number of defective caps in
the last 10 batches. Assume the batch size is 100.

Batch no 1 2 3 4 5 6 7 8
No of
12 8 11 14 12 23 7 10
defects

No of
Batch no
defects
1 12
2 8
3 11
4 14
5 12
6 23
7 7
8 10
9 16
10 6
Total 119

Approx
P bar 0.119
CL 11.9 12
UCL 21.61366 3.237885 22
LCL 2.186345 2

Chart Tit
Sample
no UCL Central LinD LCL 25

1 22 12 12 2
20
2 22 12 8 2
3 22 12 11 2
15
4 22 12 14 2
5 22 12 12 2 10
6 22 12 23 2
7 22 12 7 2 5

0
1 2 3 4 5

UCL Central Line

 10

5
8 22 12 10 2
9 22 12 16 2 0
1 2 3 4 5
10 22 12 6 2
UCL Central Line

Remove 6 and recompute

No of
Batch no
defects
1 12
2 8
3 11
4 14
5 12
7 7
8 10
9 16
10 6
Total 96

Approx
P bar 0.107
CL 10.667 11
UCL 19.927 3.08689 20
LCL 1.406 1

Char
Sample
no UCL Central LinD LCL 25

1 20 11 12 1 20
2 20 11 8 1
3 20 11 11 1 15
4 20 11 14 1
10
5 20 11 12 1
7 20 11 7 1 5
8 20 11 10 1
9 20 11 16 1 0
1 2 3 4
10 20 11 6 1
Sample no
D
 9 10

16 6

Chart Title

3 4 5 6 7 8 9 10

UCL Central Line D LCL

 3 4 5 6 7 8 9 10

UCL Central Line D LCL

Chart Title

2 3 4 5 6 7 8 9

Sample no UCL Central Line

D LCL
 Q 3 A Manufacturer of color televisions has a final inspection before the
product is packed for shipping The final inspection involves testing the
television on several parameters and verifying if the set performs satisfactorily
in all the tests It is possible that every television may fail to fulfill the
parameters Therefore , a c chart is used at this stage to control the process
Periodically 10 television sets are drawn for testing Table below shows the
performance during one such test Use data to set up a control chart

Number
Sample
of
No
Defects
1 11
2 9
3 12
4 9
5 12
6 22
7 7
8 10
9 13
10 6
TOTAL 111

c_bar 11.1 11
UCL 21.095 21
LCL 1.105001 1

Sample
C char
no UCL Central LinD LCL
1 21 11 11 1 25

2 21 11 9 1 20
3 21 11 12 1
4 21 11 9 1 15

5 21 11 12 1
10
6 21 11 22 1
7 21 11 7 1 5
8 21 11 10 1
0
9 21 11 13 1 1 2 3 4 5

UCL Central Lin

 5

0
1 2 3 4 5
10 21 11 6 1 UCL Central Lin

Remove 6 and compute

Number
Sample
of
No
Defects
1 11
2 9
3 12
4 9
5 12
7 7
8 10
9 13
10 6
TOTAL 89

c_bar 9.888889 10
UCL 19.32287 19
LCL 0.454908 0
 C chart

3 4 5 6 7 8 9 10

UCL Central Line D LCL

3 4 5 6 7 8 9 10

UCL Central Line D LCL