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Problems Chapter 13

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20 views7 pages

Problems Chapter 13

Uploaded by

aurezantoine4
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Problem 1

a) Should this inspection be eliminated ?

To determine whether the inspection position should be eliminated, we need to compare the
cost of maintaining the inspection position with the cost of replacing defective items later.
Let's calculate the costs:

Current Cost of Inspection:Inspection rate:

- 50 units per hour


- Defective rate: 0.04 (4%)
- Hourly rate (including fringe benefits) for the inspection position: $9

The number of defective units per hour = 50 units/hour * 0.04 = 2 units/hour


The cost per hour for inspecting defective units = 2 units/hour * $9/unit = $18/hour

Cost of Replacing Defective Items Later:

​ Cost to replace each defective unit: $10

If the inspection position is eliminated, defective units will go into product assembly and will
be detected later. So, the cost of replacing defective units later = Number of defective units *
Cost to replace each defective unit.

Number of defective units per hour = 50 units/hour * 0.04 = 2 units/hour


Cost of replacing defective units later per hour = 2 units/hour * $10/unit = $20/hour

Now, let's compare the costs:

● Current cost of inspection: $18/hour


● Cost of replacing defective items later: $20/hour

In this case, eliminating the inspection position would result in a slightly higher cost of
$20/hour compared to the current cost of inspection at $18/hour. So no, it shouldn’t be
eliminated.

b) What is the cost to inspect each unit

Number of defective units per hour = 50 units/hour * 0.04 = 2 units/hour


Cost to inspect defective units per hour = 2 units/hour * $9/unit = $18/hour
Calculate the cost to inspect non-defective units:

Cost to inspect non-defective units per hour = 50 units/hour * $9/unit = $450/hour

Calculate the total cost to inspect each unit:

Total cost to inspect each unit = ($18/hour + $450/hour) / 50 units/hour = $468 / 50 = $9.36
per unit

So, the cost to inspect each unit is $9.36.


c) Is there a benefit (or loss) from the current inspection process ? How much ?

Total cost of inspection per hour = Cost to inspect each unit * Inspection rate
$9.36/unit * 50 units/hour = $468/hour

Now, let's compare the total cost of inspection with the cost of replacing defective items later:

Total cost of inspection per hour: $468/hour


Cost of replacing defective items later per hour: $20/hour

There is a clear cost benefit associated with the current inspection process. The total cost of
inspection per hour ($468) is significantly lower than the cost of replacing defective items
later ($20). Therefore, the current inspection process results in a cost savings.

Problem 3

a) What is the cost to inspect each item ?

Cost to inspect each Item = Inspection cost/hr / Inspection rate/hr = 8/20 = $0.4/unit
Cost not to inspect each item = defective rate*replacement cost = 0.02*$25 = $0.5/unit

b) What is the benefit (or loss) from the inspection process

Benefit from inspection process = Cost not to insp/unit - cost to insp./unit = 0.5 - 0.4 = 0.1
It’s better to inspect before

Alternatively : Cost to inspect/hour = $8


Cost not to inspect/hour = (def rate)*(Insp rate)*(replacement cost)
= 0.02*20*$25 = $10
benefit also to do it at an early stage

Problem 7

a) Develop a p-chart for 95% confidence (1.96 standard deviation)

p-bart = Total defective items/ total of sample*sample size


= 8/(15*10)
= 0.053

Sp = Sp Rt of [(p-bar)(1-p-bar)/n]
=[ (0.053/(0.94,7/15]
= Sq Rt of (0.00335) = 0.0578

UCLpbar = p bar + Z95% *Sp


= 0.053 + 1.96* 0.0578
= 0.166
LCLpbar = p bar - Z95%*SP
= 0.053 - 0.1133
= - 0.0603

b) What comments can you make


With a confidence of 95% we can say that 99.7% of time the number of defectives items will
not exceed 3 per sample.

Problem 9
a) Develop an Xbar chart and R-chart and plot the values

Sample 1 = (1010+991+985+986/4) = 993


Sample 2 = (995+996+1009+994/4) = 996.5
1004, 1010.5 1007.5 998.5 995.75 994.75 1001.75 996 997 1004.25 991 991
Sample 15 = (1013+1002+1005+992) = 1003

Then Average X bar = (993 + 996.5 + …. + 1003)/15


= 998.97

Similarly compute 15 R Values by subtracting the bigger one by the smallest one.

Sample 1 = 1010-985 = 25
Sample 2 = 1009 - 994 = 15
25 22 26 11 38 15 18 28 17 28 22 15
Sample 15 =1013-992 = 21

Then average R bar =( 25 + 15 + …. + 21)/15


= 21.7

Computing the controls limits

So we have average X bar = 998.97 and R bar = 21.7


Look in the table for the values n = 4

A2 = 0.729 D3 = 0 D4 = 2.282
Constructs X bar limits

= UCLx bar = Average xbar + A2*r bar


= 998.7+ (0.729*21.7)
= 1014.5193

LCLx bar = Averag xbar - A2*Rbar


= 998.7 - (0.729*21.7)
= 982.881

Construct R limits

UCLr = R bar* D4
= 21.7*2.282
= 49.52

LCLr = R bar*d3
= 21.7*0
=0
b) What comments can you make about the process ?

X-bar Chart:
● Center Line (CL) or Average (X-double bar): 998.97
● Upper Control Limit (UCLx-bar): 1014.5193
● Lower Control Limit (LCLx-bar): 982.881
The process average (X-bar) of 998.97 falls within the control limits. This suggests that, on
average, the process is stable and centered around the expected value.

R Chart
● Center Line (CL) or Average (R-bar): 21.7
● Upper Control Limit (UCLr): 49.52
● Lower Control Limit (LCLr): 0
● Observation: The range (R) of 21.7 falls within the control limits. This indicates that
the variability in the process is stable and within expected limits.

In summary, based on the control chart analysis, the process appears to be in control both in
terms of the average (X-bar) and variability (R). This suggests a stable and consistent
process. However, it's important to continue monitoring future data points to ensure ongoing
process stability.

Problem 15

a) Develop a Sampling Plan :

Given Specifications:
AQL (Acceptable Quality Level) for the LSI manufacturer: 1.5%
LPTD (Lot Percent Defective) acceptable by the assembly department: 4%

Sampling Plan:
​ Select a Sample Size (n):
● Assume a sample size of 100 items.
​ Determine Acceptance Number (c) and Reject Number (r):
● Assume an acceptance number (c) of 3 and a reject number (r) of 5 based on
statistical tables.
​ Establish the Sampling Plan Parameters:
● AQL: 1.5%
● LPTD: 4%
● Sample Size (n): 100
● Acceptance Number (c): 3
● Reject Number (r): 5

b) Explain the Sampling Plan (Real Example):

Meaning of AQL and LPTD:


AQL (Acceptable Quality Level):

- In this example, the LSI manufacturer is willing to accept, on average, up to 1.5%


defective items in the lots they produce.

LPTD (Lot Percent Defective):

- The assembly department is willing to tolerate a maximum of 4% defective items in a


lot. If the percentage exceeds 4%, the entire lot will be rejected.

Implementation of the Sampling Plan:


- Sampling Process:
● Randomly select 100 items from each lot for inspection.
- Inspection:
● Inspect each of the 100 items for defects.
- Decision:
● If 3 or fewer items are defective, accept the lot.
● If 5 or more items are defective, reject the lot.

Communicating the Test Procedure :


"Randomly select 100 items from each lot. Inspect each item for defects, and based on the
number of defective items found, determine whether to accept or reject the entire lot. If 3 or
fewer items are defective, the lot is accepted. If 5 or more items are defective, the lot is
rejected. This ensures that the manufacturer's acceptable quality level (AQL) and the
assembly department's maximum tolerable defect level (LPTD) are adhered to, helping
maintain quality standards during production."

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