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B.E./8.Tech.DEGREEEXAMINATION,MAY/ruNE 2007.
Sixth Semester
(Regulation2A04)
Production Engineering
ME 1006- QUALITY CONTROL AND RELIABILITY ENGINEERING
(Commonto B.E. (Part-Time) Fifth SemesterRegulation 2005)
Time : Three hours

Maximum : 100 marks

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Statistical and Sampling Inspection tables are permitted as prescribed

in the svllabus.

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Answer ALL questions.

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PARTA-(10 x2=20 marks)

Distinguish between quality control and quality assurance.

2.

Define processvariability and state causesbehind variability.

3.

State the conditions under which p-chart preferred over np-chart.

;.

Define attributes in the context of processcontrol and give two examples.

5.

Name the two standard sampling systemsand their authors.

6.

What are the different ways of constructing operating characteristic curves?

7.

Differentiate between mean time to failure and mean time between failures
based on their applicability.

8.

Define availability and give relation for its estimation.

9.

Contrast quality and reliability.

10.

List various costs involved in product life cycle.

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PARTB-(5x16=80marks)
11. (a)

(6)

(i)

Discusson philosophybehind statistical quality control.

(ii)

During the manufacture of superior quality chalks, the main

parameter controlling the quality is the density of the chalks.
Experience has shown that the chalk gives good perfonnance if the
density is between 4.5 and 5.0 glcmz. If the sample of 100 pieces
gives an average of 4.8 and a standard deviation of 0.2, is the
process aimed at proper density? Discuss with help of Coand Cor.

( 10)

values.
Or

Quality control is to be introduced for the chromium content present in

an alloy the nominal percentage of which is \Vo. It is desired that the
percentage will not vary by more than 0.25Vo,either way. Sampling
inspection is carried out taking samples of 5 pieces at a time at regular
intervals. TWenty samples gave the following results as shown in table
below. Comment on the suitability of the processof the present technique
(16)
of manufacture and calculate the proportion defective.

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(b)

Sample Number

11 L2 13 L4 15 16 L7 18 19 20

345678910

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5 . 1 5 . 0 5.1 4.8 4.9 5.0 5.0 4.7 4.9 5.0 4.9 5.0 5.0 5.1 4.9 4.5 5.0 5.2 5 . 0 5 . 2
5.0 4,8 4.9 5.2 4.9 5.0 5.1 4.9 4.8 5.2 5.0 5.1 4.9 4.8 4.9 4.8 5.1 5.1 5.1 5.1

5 . 0 4 . 9 5.1 5.0 5.0 5.1 4.4 5.2 5.2 5.0 5.3 5.0 4.8 4.8 4.9 5.0 5.1 5.0 5.0 4 . 6

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5 . t 5 . 2 4.9 4.9 5.0 5.0 5.0 5.0 5.r 4.7 5 . 2 4 . 9 4 . 8 4 . 8 4 . 9 4 . 8 5 . 0 5 . 1 4 . 9 5 . 0

L2.

(a)

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5 . 3 5 . 0 5.1 4.9 5.0 5.1 5.2 4.8 4.8 5.0 5.1 5.3 4.8 4,9 5.0 4.9 4.8 5.3 4 , 9 5 . 1
The Stosh Motor Company, manufactures bolts for its model X-350
high-perfonnance racing engine. If defective, the bolts typically have
damaged threads or improper diameters. A defect can be easily
discoveredby threading the bolt into a block of steel with a hole of correct
threading and diameter. If a defective bolt is passed to the assembly line
there is a chance that the threads in the engine block hole will be
damaged or that bolt may work itself loose during operation of the
engine.The historical proportion defective average has been 0.015. Setup
a suitable control chart for this process.Assume that management wants
99.? percent of the normal variation to fall lrithin the control limits. The
sample size is 16. The numbers of defects found in the last five samples
(16)
were 1, L,2,2, and 3 respectively.Is there a need for concern?
Or

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(b)

(i)

Assuming all the plotted points are inside the 3 o limits in a

control chart, state the additional rules to identifu the process
(8)
variations and showthe samegraphically?

(ii)

The Metropolitan Tlansit Company encourages the customers to

comment on the service they provide and it is considered normal to
receive 4 complaints per week. Over the past six weeks, the
following numbers of complaints were registered: 2,'l ,3, 5, I and 6.
The company uses two-sigma control limits on its c-chart. Is there
any reason for management to take action?

(a)

(i)

What are the considerationsinvolved in choosingbetween sampling

(6)
and complete inspections?Between variables and attributes?

(ii)

Consider a certain raw material for which a single-sampling plan

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13.

(8)

using attributes is needed.The AQL is 0.01 and the LTPD is 0.040.

TVo plans have been proposed. Plan I : n = 100, c = 3 and

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Plan 2 i n = 200, c = 6. Are these two plans equivalent?

(b)

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Or

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Substantiate your response by determining the producer's risk and

(10)
consumer's risk for each plan.

You presently have an acceptablesampling plan in which n = 50, c = 1,

but you are unsatisfied with its performance. The AQL is 0.01 and the

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LTPD is 0.05. What are the producer's and consumer's risks for this
plan? Specify a plan that will decrease the producer's risk and the

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consumer's risk. Specify the producer's and consumer's new risks.

Compare the AOQLs for your plan and the old plan. Assume the lot size
(16)
is 1000units.
L4. (a)

(i)

The reliability

of a turbine blade can be represented by the

following:R(t)=(1 -tlh)z

0<r<fo

wherefo isthemaximum

Iife of the blade. Compute the MTTF, Failure probability, Hazard

rates, probability density function (PDF) as a function of the

(ii)

maximum life.

(8)

State different life tests and their applications.

(8)

Or

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(a)

Define maintainability
measure.

(ii)

Find the system reliability of the following configuration. What will

be the increase in reliability if componentlevel redundancy is added
(12)
wherever not present?

(i)

Why optimization is important in establishing reliability of

products? What are the approaches to optimize the product
(8)
reliability?

(ii)

What is the relation between product design and product

(8)
reliability? What are the major steps in design for reliability?

and mention

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Or

paranneters to
(4)

(8)

Write aboutvarioustypesof redundancies.

(ii)

Discuss on Pareto analysis and its use in reliability improvements?

(8)

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(b)

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15.

(i)

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(b)

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