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Roll No:
(To be filled in by the candidate)

PSG COLLEGE OF TECHNOLOGY, COIMBATORE - 641 004

SEMESTER EXAMINATIONS, OCTOBER / NOVEMBER - 2015

BE / BE(SW) PRODUCTION ENGINEERING Semester: 5

12P502 STATISTICAL QUALITY CONTROL

Time: 3 Hours Maximum Marks: 100

INSTRUCTIONS:
1. Answer ALL questions from GROUP I.
2. Answer any 5 questions from GROUP II.
3. Answer any ONE question from GROUP III.
4. Ignore the box titled as Answers for Group III in the Main Answer Book.
5. Use of scientific calculators and approved statistical tables permitted.
6. Graph sheets to be provided.
GROUP - I Marks : 10 x 3 = 30

1. Cite three attributes of chance causes.

2. To save money, quality control engineer in a plant decides to use a sample size of 2 for
plotting control charts on a mass production line. What effect will this approach have on
the control charts and the information that they yield?
3. A Production Engineer wishes to estimate the intrinsic variation of a process. How can
this be carried out?
4. Considering the nature of the problems in statistical inference and quality control, are
they similar or dissimilar? Justify.
5. How can a control chart help to bring about a change in specification or a fundamental
change in the production procedure?
6. What is meant by the term resolution of an experiment? What factor determines the
resolution of an experiment?
7. State the advantage that would accrue if three or more levels are considered for a factor
in a designed experiment.
8. When is an array said to be orthogonal? State the benefit of using orthogonal array in a
designed experiment.
9. Give the physical significance of the coefficients of correlation, determination and
regression.
10. Justify the use of t values in the formulae for calculating the confidence and
prediction intervals in the context of regression.
GROUP - II Marks : 5 x 10 = 50

11. Bolts are supplied by a certain manufacturer in boxes containing 1000 bolts. The bolts
are not counted when packed. The system used at the suppliers end is to simply fill the
boxes and consequently the actual number of bolts varies from box to box. 100 boxes
were taken at random, from the stock and their contents counted, with the results given
in Table 1.

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Table 1
992 1007 1001 1010 1001 1008 1013 1010 995 1003
1009 990 1003 1008 999 1002 992 990 998 1013
1014 992 991 1006 998 1001 991 998 1011 985
986 996 1010 1008 1008 1024 995 1023 1001 998
998 1004 1010 1000 1002 997 1013 1005 1006 1015
994 1002 999 1008 1025 998 1005 1008 992 1016
1003 981 1005 982 997 1004 1013 1018 984 1004
1009 1001 1014 1018 991 997 1009 1003 998 1007
1028 1000 988 1012 1012 1001 979 992 1002 989
1010 1017 1011 996 1006 1009 994 1011 976 1003
a. Draw a histogram for the above data. (8)
b. Determine the mean and standard deviation of the data. (2)
12. The data shown in Table 2 pertains to the diameter of a small piston. The specification is
45.05+0.10mm. There are 15 subgroups each of size 5. Estimate systematically the
process capability indices Cp and Cpk.
Table 2
Sample No X1 X2 X3 X4 X5
1 45.02 45.02 45.02 45.01 45.03
2 45.03 45.03 45.02 45.03 45.02
3 45.01 45.02 45.03 45.01 45.02
4 45.02 45.03 45.02 45.02 45.01
5 45.01 45.03 45.02 45.02 45.02
6 45.03 45.04 45.03 45.03 45.02
7 45.02 45.04 45.02 45.02 45.03
8 45.05 45.02 45.02 45.04 45.02
9 45.03 45.02 45.02 45.03 45.03
10 45.04 45.03 45.03 45.02 45.02
11 45.01 45.02 45.03 45.02 45.03
12 45.03 45.04 45.03 45.03 45.04
13 45.04 45.03 45.02 45.02 45.03
14 45.02 45.02 45.03 45.02 45.03
15 45.02 45.03 45.02 45.03 45.02
13. An experiment was run to determine the effect of the type of tool, the bevel angle and the
type of cut on the power consumption for ceramic-tool cutting. The data were recorded in
the form of Table 3.
Table 3
Tool Type
A B
Type of cut
Bevel Angle Bevel Angle
15 30 15 30
32 31 30 32
27 31 31 38
Continuous
35 34 30 32
28 39 24 30
30 28 23 29
24 32 24 30
Interrupted
27 29 30 28
27 29 26 26
On the basis of above data, determine which of the factors and interactions are
significant in influencing the power consumption at a significance level of 0.05.
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14. It was decided to optimize the process parameters in friction stir welding of aluminum
alloy AA5083. The objective is to maximize the weld tensile strength. The process
parameters and their levels considered are summarized in Table 4.
Table 4
Factor/Parameter
Level Rotational Speed Transverse Speed Axial Load C
A (rpm) B (mm/min) (kN)
1 500 115 9
2 650 135 13
3 800 155 17
L9 Orthogonal Array was used and each trial was repeated thrice. The experimental
array and the results are shown in Table 5.
Table 5
Trial Replication
A B C D
No. 1 2 3
1 1 1 1 1 191 186 188
2 1 2 2 2 171 175 169
3 1 3 3 3 147 154 146
4 2 1 2 3 287 280 279
5 2 2 3 1 295 280 279
6 2 3 1 2 228 231 225
7 3 1 3 2 157 156 156
8 3 2 1 3 127 129 131
9 3 3 2 1 130 135 136
a. Determine the statistical significance of the three factors on the weld tensile strength at
a significance level of 0.05. (7)
b. Determine the optimum process parameter combination using mean response
approach. (3)
15. It has been determined that the relation between stress and the number of cycles to
failure (N) for a particular type of alloy is given by
S = A / Nm
where A and M are unknown constants. An experiment is run yielding these data as
shown in Table 6.
Table 6
Stress N
(thousand psi) (million cycles to
failure)
55.0 0.223
50.5 0.925
43.5 6.75
42.5 18.1
42.0 29.1
41.0 50.5
35.7 126
34.5 215
33.0 445
32.0 420
Determine the values of A and m and hence the relationship.
16. In a certain fluid amplifier design, there are several passages through which the fluid
flows. The variation in the dimensions of these passages affects the output flow of the
amplifier. It was found that the flow rate is very sensitive to changes in dimension of one
particular passage. It is desired to establish the relationship between the passage
dimension and the flow rate of the amplifier. Ten fluidic amplifiers having different
passage dimensions were tested and the flow rates were measured.
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Dimension
10 15 20 25 30 35 40 45 50 55
x 10-3 in (x)
Flow rate,
0.26 0.38 0.55 0.70 1.05 1.36 1.75 2.20 2.70 3.20
gal/hr, (y)
Establish a second order relationship between the dimension of the passage and its
effect on the flow rate.
GROUP - III Marks : 1 x 20 = 20
17. Table 7 gives the results of a study of the effect of carbon content in steel wires on
electrical resistance:
Table 7
Carbon content (%) Resistance ( ohms at 20C)
0.10 15
0.30 18
0.40 19
0.55 21
0.70 22.6
0.80 23.8
0.95 26
a. Find the relationship between the effect of carbon content and electrical resistance
by the method of least squares. (5)
b. Determine the point estimate of the resistance of the wire having 0.5% carbon
content. (1)
c. Determine the 95% confidence interval for b0 and b1. (4)
d. Determine the 95% confidence band around the regression line. (6)
e. Perform an ANOVA to determine whether regression is significant. (4)
18. Sixteen observations on the viscosity of a polymer (y) and two process variables-
reaction temperature(x1) and catalyst feed rate (x2) are shown in Table 8.
Table 8
Observation Temperature Catalyst feed rate Viscosity
(x1, C) (x2, lb/hr) (y)
1 80 8 2256
2 93 9 2340
3 100 10 2426
4 82 12 2293
5 90 11 2330
6 99 8 2368
7 81 8 2250
8 96 10 2409
9 94 12 2364
10 93 11 2379
11 97 13 2440
12 95 11 2364
13 100 8 2404
14 85 12 2317
15 86 9 2309
16 87 12 2328
a. Assuming a linear relationship between x 1, x2 and y, estimate the relationship
between the three variables by the method of least squares. (10)
b. Perform an ANOVA for the regression and determine whether the regression is
significant. (7)
c. Determine r2. Give its interpretation. (3)
FD/RL /END/
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