Control Chart

Problem-1 For the quality measurement under Inspection process, if the sub-group Sample size is 14, no. of sub-group is 20, sum of measurements of the sample is 357.50 and Sum of the sample-ranges is 9.90, (i) Indicate Center Line, UCL & LCL for X-chart & R- Chart, (ii) Comment on the Process Capability and Whether the process is under control, if specified dimension is 17.5 0.5. (iii) Suggest possible ways for improving the situation. [Given A2 = 0.18, d2 = 3.735, D3 = 0.41, D4 = 1.59] Solution : = Process Mean of measurements, X = X N = 357.50 / 20 = 17.875 _ Mean Range, R = R N = 9.90 / 20 = 0.495 (i) For X-chart, = = _ Central Line = X =17.875 , UCL = X + A2R = 17.875 + 0.18 x0.495 = 17.9641 LCL = 17.875 0.18 x0.495 = 17.7859 For R-chart _ Central Line = R =0.495 , _ UCL = D4 x R = 1.59 x 0.495 = 0.78705 _ LCL = D3 x R = 0.41 x 0.495 = 0.20295 _ = R / d2 = 0.495 / 3.735 = 0.13253

(ii) Standard Deviation of Universe,

Natural Spread (Band) = 6 = 6 x 0.13253 = 0.79518 and 3 = 0.39759

Solution -1(contd.)
=

Control Chart

Upper Natural Tolerance Limit, UNTL = X + 3 = 17.875 + 0.39759 = 18.2726 Lower Natural Tolerance Limit, LNTL = X - 3 = 17.875 - 0.39759 = 17.4774 Center Line of natural Spread , X = 17.875, Specified dimension = 17.5 0.5 Upper Specified Limit, USL = 17.5 + 0.5 = 18.00 Lower Specified Limit, LSL = 17.5 - 0.5 = 17.00 Specified Spread = 18 17 = 1.0 Center line of Specified Spread = (18 + 17)/2 = 17.5 Process Capability Ratio, Cp = Specified Spread = 1.0 . > 1 , but < 2 6 0.79518 so the process is marginally capable, and capable only if the Process Center Line is placed on or very close to the Center Line of Specified Spread. But there is slight off-set between the center line of specified spread (17.5)and Process Center Line (17.875). Now, UNTL > USL , UNTL is not within the specified limit, so considerable rejections are expected which indicates that the process is not under control. LNTL > LSL , LNTL is within the specified limit, so no rejections are expected which indicates that the process is under control. (iii) Suggestion : 1) Process is marginally capable, so process improvement is recommended 2) Designed Process Center-line must be set very close to Center Line of the specified spread 3) Specified Spread is to be relaxed to some extent, if possible.
=

Control Chart

Problem-2 For the quality measurement under Inspection process, if the sub-group Sample size is 4, no. of sub-group is 20, sum of measurement means of the sample is 412.83 and Sum of the sample-ranges is 3.39, (i) Indicate Center Line, UCL & LCL for X-chart & R- Chart, (ii) Comment on the Process Capability and Whether the process is under control, if specified dimension is 20 0.2. (iii) Suggest possible ways for improving the situation. [Given A2 = 0.73, d2 = 2.059, D3 = 0, D4 = 2.28.]

Solution-2 : = Process Mean of measurements, X = X N = 412.83 / 20 = 20.6415 _ Process Mean of Range, R = R N = 3.39 / 20 = 0.169 _ Standard Deviation of Universe, = R / d2 = 0.169 / 2.059 = 0.082 Natural Spread (Natural Tolerance range) = 6 = 6 x 0.082 = 0.492 Specified Spread = 0.2 (-0.2) = 0.4 Process Capability Ratio, Cp = Specified Spread = 0.4 . <1 , So the process 6 0.492 is not capable
For X-chart, = = _ Control Line = X =20.6415, UCL = X + A2R = 20.6415 + 0.73x0.169 = 20.7649

LCL = 20.6415 0.73x0.169

For R-chart _ _ Control Line = R =0.169 , UCL = D4 x R = 2.28 x 0.169 = 0.3853 _ LCL = D3 x R = 0 x 0.169 =0

= 20.5181

Control Chart

Problem-3 For the quality measurement under Inspection process, if the sub-group Sample size is 10, no. of sub-group is 18, sum of measurements of the sample is 595.8 and Sum of the std. Deviations is 8.24, Estimate (i) Control Line, UCL & LCL for X-chart & s - Chart. (ii) Process Capability and whether the process is under control if specified dimension is 32 2, (iii) Suggest possible ways for improving the situation. [Given A3 = 0.98, A2 = 0.31, C2 = 0.9727, d2 = 3.078, B3 = 0.28, B4 = 1.72 D3 = 0.22, D4 = 1.78] Solution : = Process Mean of measurements, X = X N = 595.8 / 18 = 33.10 _ Mean Std. Deviation, S = S N = 8.24 / 18 = 0.4577 _ Population Standard Deviation, = s / C2 = 0.4577 / 0.9727 = 0.496 Process Capability (Natural Tolerance range) = 6 = 6 x 0.496 = 2.976 For X-chart,

= Control Line = X =33.10,

For S -chart _ Control Line = s = 0.4577 ,

= _ UCL = X + A3 s = 33.1 + 0.98 x 0.4577 = 33.5485 LCL = 33.1 0.98 x 0.4577 = 32.6515
_ UCL = B4 x s = 1.72 x 0.4577= 0.7872 _ LCL = B3 x s = 0.28 x 0.4577 = 0.12815