Practice problem set on Control charts

X and R chart:
1 A certain dimension is specified in inches as 3.51Error! Bookmark not defined.00  0.0050. Control
charts for X and R indicate that X chart shows lack of statistical control but the R chart always shows
control. From the R chart the estimate of process dispersion  ’is 0.0010. If the aimed at process
average X ’is to be 3.5100, what should be the upper control limit for X with a subgroup size of 4? What
should be the upper reject limit on the X chart assuming the use of 3  reject limits?

2 Here are daily analysis of a chemical at an intermediate stage in a chemical manufacturing process
Date % chemical Date % of chemical Date % of Chemical

Jan 1 0.53 14 0.65 27 0.71

2 0.62 15 0.59 28 0.68
3 0.63 16 0.60 29 0.74
4 0.54 17 0.69 30 0.66
5 0.50 18 0.65 31 0.67
6 0.50 19 0.65
7 0.51 20 0.67
8 0.53 21 0.71
9 0.56 22 0.78
10 0.64 23 0.82
11 0.57 24 0.82
12 0.56 25 0.88
13 0.55 26 0.82
Compute 3 day moving averages and moving ranges and plot a chart for each. Base your control limits on
an X ’of 0.66 and an R bar of 0.085, both obtained from past data.

3: Subgroups of 5 items each are taken from a manufacturing process at regular intervals. A certain quality
characteristic is measured, and X and R values are computed for each subgroup. After 25 subgroups,
 
X = 357.50 and R = 8.80. Compute the control chart limits. All points on both the charts fall within these
limits. If the specification limits are 14.40  0.40 what conclusions can you draw about the ability of the
existing process to produce items within these specifications? Suggest possible ways in which the situation
could be improved.

4. Rupa textile mill’s development group determines that it is required to have a fiber which, among other
properties must have a minimum allowable tensile strength of 1.30 grams in 99% of fibers used.
Manufacturer offers to supply the textile mill with the fiber and a contract is signed.
a) Manufacturer knows that Standard deviation  ’of his process is 0.02.What is the lowest possible target
tensile strength to ensure that exactly 99% of the fiber will have at least 1.30 grams required tensile
strength?.
b) The quality control group of manufacturer A then decides that control charts will be based on a subgroup
size of 16.Determine 3 sigma control limits for X and  charts assuming that the process average is set at
the value computed in part a).

p-chart:
1: Compute the value of p from the following data.
Lot Number inspected No of defectives
1 500 27
2 50 12
3 800 12
4 100 14
5 150 15
Total 1600 80
Establish control limits for the above.
2 : A manufacturer purchases small bolts in cartons that usually contain several thousand bolts. Each
shipment consists of several cartons. As part of the acceptance procedure for these bolts, 400 bolts are
selected at random from each carton and are subjected to visual inspection for certain defects. In a
shipment of 10 cartons, the respective percentages of defectives in the samples from each carton are 0, 0,
0.5, 0.75, 0, 2, 0.25, 0, 0.25 and 1.25. Does this shipment of bolts appear to exhibit statistical control with
respect to the quality characteristic explained in this inspection?

3: A p chart is maintained for a certain product subject to 100% inspection. Each day’s production is
responsible for a new point on the chart. The new 3  control limits are drawn on the chart at the first of each
month based on the standard fraction defective p ’set for the coming month. If for June, p’ is 0.0315 and the
estimated maximum days output is 1400 units, what control limits should be shown on the charts?

4 In the above problem during June 4 points fell outside the control limits drawn on the chart as follows.
Date No inspected No of defectives Fraction defectives
June 7 1100 15 0.0136
14 600 7 0.0117
21 400 22 0.0550
25 900 47 0.0522

Make the necessary calculations to determine on which, if any, of these days the fraction defective was
outside the 3  limits appropriate to the days output.

5 A p chart is to be used to analyze the September record for 100% inspection for certain radio transmitting
tubes. The total no inspected during the month was 2196 and total no of defectives was 158.
Compute p .Compute individual 3 sigma control limits for the following three days, state whether the fraction
defective fell within control limits for each day.
Day No inspected No of defectives
Day 1 54 8
Day 2 162 24
Day3 213 3

c- charts:
1 A control chart for defects per units u uses probability limits corresponding to the probabilities of 0.95 &
0.05. The central line on the control chart is at u’= 1.5. The limits vary with value of n. Determine the upper &
lower control limits when n=8.

2 The following tabulation gives defects c observed in an aircraft sub assembly operation and shows the
number of units produced on each shift during a week. Prepare a control chart. Assume u’=4.2
shift Mon. Tue. Wed. Thu. Fri. Sat.
c n c n c n c n c n c N
S1 19 5 25 5 15 5 29 5 36 4 27 5
S2 20 4 20 4 14 4 9 4 22 3 24 4
S3 8 2 7 2 2 2 2 2 4 1 6 2

3 The following table gives the results of the inspection of a 100-yd pieces of wooden goods.
Piece No. No. Of Piece No. No. Of Piece No. No. Of
Defects Defects Defects
1 3 10 8 19 5
2 3 11 4 20 1
3 6 12 10 21 1
4 3 13 5 22 0
5 0 14 5 23 1
6 1 15 5 24 1
7 3 16 4 25 4
8 5 17 3
9 7 18 4
Find c , compute trial control limits and plot a chart for c. What value of c’ would you suggest for the
following period?

4 Find control limits for a c chart when c’ = 6.5. and when c’ = 13.0

5 A control chart for defects per units u uses probability limits corresponding to the probabilities of 0.975 &
0.025. The central line on the control chart is at u’= 2.0. The limits vary with value of n. Determine the
correct position of these upper & lower control limits when n=5.