Chapter 6 Exercise Solutions

Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

Chapter 6 Exercise Solutions

Notes:
1. The MINITAB convention for determining whether a point is out of control is: (1) if
a plot point is within the control limits, it is in control, or (2) if a plot point is on or
beyond the limits, it is out of control.
2. MINITAB uses pooled standard deviation to estimate standard deviation for control
chart limits and capability estimates. This can be changed in dialog boxes or under
Tools>Options>Control Charts and Quality Tools>Estimating Standard Deviation.
3. MINITAB defines some sensitizing rules for control charts differently than the
standard rules. In particular, a run of n consecutive points on one side of the center
line is defined as 9 points, not 8. This can be changed under Tools > Options >
Control Charts and Quality Tools > Define Tests.
6.2.
(a)
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-R

The process is in statistical control with no out-of-control signals, runs, trends, or cycles.

(b)
2
4, 10.33, 6.25, / 6.25/ 2.059 3.035
X
n x R R d o = = = = = = . Actual specs are 350 5 V.
With x
i
= (observed voltage on unit i 350) 10: USL
T
= +50, LSL
T
= 50
USL LSL 50 ( 50)

5.49
6 6(3.035)
P
C
o
+
= = = , so the process is capable.

MTB > Stat > Quality Tools > Capability Analysis > Normal
Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.


(c)
MTB > Stat > Basic Statistics > Normality Test


A normal probability plot of the transformed output voltage shows the distribution is
close to normal.


Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

6.7.
MTB > Stat > Control Charts > Variables Charts for Subgroups > Xbar-S (Ex6.2Vl)


The process is in statistical control with no out-of-control signals, runs, trends, or cycles.


6.12.
50 50
1 1
6 items/sample; 2000; 200; 50 samples
i i
i i
n x R m
= =
= = = =
(a)
50 50
1 1
2
2
4
3
2000 200
40; 4
50 50
UCL 40 0.483(4) 41.932
LCL 40 0.483(4) 38.068
UCL 2.004(4) 8.016
LCL 0(4) 0
i i
i i
x
x
R
R
x R
x R
m m
x A R
x A R
D R
D R
= =

= = = = = =
= + = + =
= = =
= = =
= = =


(b)
natural tolerance limits:
( )
2
3 3 / 40 3(4/ 2.534) [35.264, 44.736]
x
x x R d o = = =

(c)
USL - LSL 5.0 ( 5.0)

1.056
6 6(1.579)
P
x
C
o
+
= = = , so the process is not capable.

Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

(d)
scrap
36 40
Pr{ LSL} Pr{ 36} ( 2.533) 0.0057
1.579
p x x
| |
= < = < = u = u =
|
\ .
, or 0.57%.
rework
47 40
Pr{ USL} 1 Pr{ USL} 1 1 (4.433) 1 0.999995 0.000005
1.579
p x x
| |
= > = < = u = u = =
|
\ .
or 0.0005%.

(e)
First, center the process at 41, not 40, to reduce scrap and rework costs. Second, reduce
variability such that the natural process tolerance limits are closer to, say, 1.253
x
o ~ .


6.49.
(a)
2
/ 8.91/ 2.970 3.000
LCL UCL
Pr{ LCL} Pr{ UCL} 1
357 360 363 360
1 ( 3) 1 (3) 0.0013 1 0.9987 0.0026
3 9 3 9
x
x x
R d
x x
x x
o
o
o o
= = =
| | | |
= < + > = u + u
| |
\ . \ .
| | | |

= u + u = u + u = + =
| |
\ . \ .


(b)
USL LSL 6 ( 6)

0.667
6 6(3)
P
x
C
o
+
= = =
The process is not capable of producing all items within specification.

(c)

new
= 357
new new
UCL LCL
Pr{not detect on 1st sample} Pr{LCL UCL}

363 357 357 357
(6) (0) 1.0000 0.5000 0.5000
3 9 3 9
x x
x
n n

o o
| | | |

= s s = u u
| |
| |
\ . \ .
| | | |

= u u = u u = =
| |
\ . \ .


(d)
( ) ( )
( )
/ 2 0.01/ 2 0.005
0.01; 2.576
UCL 360 2.576 3 9 362.576
LCL 360 2.576 3 9 357.424
x x x
x
k Z Z Z
x k x k n
o
o
o o
= = = = =
= + = + = + =
= =

Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

6.53.
MTB > Stat > Control Charts > Variables Charts for Individuals > I-MR

There may be a sawtooth pattern developing on the Individuals chart.

16.1052; 0.021055; MR2 0.02375
x
x o = = =

MTB > Stat > Basic Statistics > Normality Test

Visual examination of the normal probability indicates that the assumption of normally
distributed coffee can weights is valid.
Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

%underfilled 100% Pr{ 16 oz}
16 16.1052
100% 100% ( 4.9964) 0.00003%
0.021055
x = <
| |
= u = u =
|
\ .


Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

6.67.
(a)
MTB > Stat > Control Charts > Variables Charts for Individuals > I-MR


2
/ 1.305/1.128 1.157
x
R d o = = =

(b)
MTB > Stat > Basic Statistics > Descriptive Statistics
Descriptive Statistics: Ex6.67Meas
Total
Variable Count Mean StDev Median
Ex6.67Meas 25 10.549 1.342 10.630
4
/ 1.342/ 0.7979 1.682
x
S c o = = =
Chapter 6 Exercise Solutions
Reference: Montgomery, D. Introduction to Statistical Quality Control, John Wiley & Sons Inc, New York,
2009.

6.67 continued
(c)
MTB > Stat > Control Charts > Variables Charts for Individuals > I-MR


2
/ 1.283/1.128 1.137
x
R d o = = =

(d)
Average MR3 Chart:
2
/ 2.049/1.693 1.210
x
R d o = = =
Average MR4 Chart:
2
/ 2.598/ 2.059 1.262
x
R d o = = =
Average MR19 Chart:
2
/ 5.186/ 3.689 1.406
x
R d o = = =
Average MR20 Chart:
2
/ 5.36/ 3.735 1.435
x
R d o = = =

(e)
As the span of the moving range is increased, there are fewer observations to estimate the
standard deviation, and the estimate becomes less reliable. For this example, o gets
larger as the span increases. This tends to be true for unstable processes.