Engineering and Quality Management

Exercises Statistical Process Control 2020-2021

1.

Ref. Production and Operations Analysis, Steven Nahmias (Ex. 11.12)

a) R-chart with:
• Rbar = 3,825
• Total samples = 200
• Sample size = 6
R-chart UCL and LCL formulas:
• 𝑈𝐶𝐿 = 𝑑4 ∗ 𝑅𝑏𝑎𝑟 = 2,004 3,825 = 7,65
• 𝐿𝐶𝐿 = 𝑑3 ∗ 𝑅𝑏𝑎𝑟 = 0 3,825 = 0
Look in Table A-6 for the d values for sample size 6
b) X - chart
3∗ σℎ𝑎𝑡 3∗ σℎ𝑎𝑡 6 σℎ𝑎𝑡
• U𝐶𝐿 − 𝐿𝐶𝐿 = (μ + ) - μ − =
𝑛 𝑛 𝑛
What is σℎ𝑎𝑡 ?
• We have R and we have a sample size
𝑅𝑏𝑎𝑟 3,825
• σhat = = = 1,5094
𝑑2 2,534
6 σℎ𝑎𝑡
As such UCL − LCL = = 3,6975
𝑛
 Engineering and Quality Management
Exercises Statistical Process Control 2020-2021

2.

Ref. Production and Operations Analysis, Steven Nahmias (Ex. 11.13)

Given UCL = 13,8 and LCL = 8,2 and σhat = 6,6
Asked : μ and n

3 ∗ σℎ𝑎𝑡 3 ∗ σℎ𝑎𝑡
(μ + ) + (μ − )
𝑈𝐶𝐿 + 𝐿𝐶𝐿 𝑛 𝑛 13,8 + 8,2
a) μ = = = = 11
2 2 2

3 ∗ σℎ𝑎𝑡
𝑏) 𝑈𝐶𝐿 = (μ + ) → n = 50
𝑛
 Engineering and Quality Management
Exercises Statistical Process Control 2020-2021

3.
See Dataset (exercise 3-4-5-6)

Ref. Production and Operations Analysis, Steven Nahmias (Ex. 11.15)

Is the process under control?
• Pass/fail control system  p-chart
• Variance in production  go for Z values

1) Calculate the p and pbar values with

𝑇𝑜𝑡𝑎𝑙 # 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠
• p𝑏𝑎𝑟 = 𝑎𝑛𝑑
𝑇𝑜𝑡𝑎𝑙 # 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑
#𝑓𝑎𝑖𝑙𝑠 𝑖𝑛 𝑠𝑎𝑚𝑝𝑙𝑒
• p=
𝑠𝑎𝑚𝑝𝑙𝑒 𝑠𝑖𝑧𝑒

2) Calculate Z values for every sampling using

𝑝 −𝑝𝑏𝑎𝑟
• 𝑍=
𝑝𝑏𝑎𝑟 ∗(1−𝑝𝑏𝑎𝑟)
𝑛

3) −3 < 𝑍 < 3 → 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑖𝑛 𝑐𝑜𝑛𝑡𝑟𝑜𝑙?

See Excel (exercise 3-4-5-6)

Yes is in control
 Engineering and Quality Management
Exercises Statistical Process Control 2020-2021

4.
See Dataset (exercise 3-4-5-6)

Ref. Production and Operations Analysis, Steven Nahmias (Ex. 11.18)

Number of defects  C-chart!

Steps :
a) Calculate the c value (average number of defects)
~ 93/20 = 4.65 per roll on average

b) Determine UCL and LCL

UCL = 4,65 + 3√4,65 = 11,12
LCL = 4,65 - 3√4,65 = -1,82 ~ 0

c) Is the system in control?

Yes! (Solution: See Excel (exercise 3-4-5-6))
 Engineering and Quality Management
Exercises Statistical Process Control 2020-2021

5.
See Dataset (exercise 3-4-5-6)

Ref. Production and Operations Analysis, Steven Nahmias (Ex. 11.69)

We want to develop Xbar and R charts / we need upper and lower limits for both

•R R  calculate the range of each sample  average of the ranges

• 𝑈𝐶𝐿 = 𝑑4 ∗ 𝑅𝑏𝑎𝑟 d3  table for sample size 4
• 𝐿𝐶𝐿 = 𝑑3 ∗ 𝑅𝑏𝑎𝑟 d4  table for sample size 4
σhat  Formula using R and d2 for sample size 4
μ  calculate average of each sample  average of the averages
• Xbar
3∗ σℎ𝑎𝑡
• 𝑈𝐶𝐿 = μ + Step 1. Calculate all the means and averages
𝑛
3∗ σℎ𝑎𝑡 Step 2. Determine the UCL and LCL for both charts
• L𝐶𝐿 = μ −
𝑛 Step 3. Plot the data points and imply the limits
Step 4. Plot the histogram
(See Excel (exercise 3-4-5-6))
 Engineering and Quality Management
Exercises Statistical Process Control 2020-2021

6.
See Dataset (exercise 3-4-5-6)

Ref. Production and Operations Analysis, Steven Nahmias (Ex. 11.70)

• Pass/fail  p-chart Day
1
# Produced
400
# Rejected
23
St Z
0.3677
2 480 18 -1.5467
• Variable production  Z value! 3
4
475
525
24
34
-0.2755
1.1615

• See Excel (exercise 3-4-5-6) 5

6
455
385
17
17
-1.5189
-0.8042
7 372 12 -1.8114
8 358 19 -0.0248
9 395 24 0.6536
10 405 29 1.6329
11 385 16 -1.0309
12 376 19 -0.2446
13 395 23 0.4297
14 405 14 -1.6833
15 415 25 0.6230
16 440 34 2.2309
17 380 26 1.3056
18 318 19 0.5062

• Based on these standardized Z values and assuming 3- limits, the

process appears to be in control.
Note that 2- limits would give one out of control point.