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Quality Control

(a) To calculate the number of units that must be started: - First step scrap rate is 10% of units started - Second step scrap rate is 6% of units passing first step - Third step scrap rate is 6% of units passing second step Let x = number of units started 0.9x will pass first step (10% scrap) 0.94x will pass second step (6% of 0.9x scrap) 0.94 * 0.94x = 0.8836x will pass third step (6% of 0.94x scrap) We want 0.8836x to be at least 450 So x must be at least 450/

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EuniceChung
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499 views

Quality Control

(a) To calculate the number of units that must be started: - First step scrap rate is 10% of units started - Second step scrap rate is 6% of units passing first step - Third step scrap rate is 6% of units passing second step Let x = number of units started 0.9x will pass first step (10% scrap) 0.94x will pass second step (6% of 0.9x scrap) 0.94 * 0.94x = 0.8836x will pass third step (6% of 0.94x scrap) We want 0.8836x to be at least 450 So x must be at least 450/

Uploaded by

EuniceChung
Copyright
© © All Rights Reserved
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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Quality Control

Purpose of QC

To assure that the process is performing in an acceptable manner


Done through monitoring the process via inspection

Quality Assurance Relies on inspection

Inspection after production (acceptance sampling)


Inspection during production (statistical process control, or SPC)

Basic Issues in Inspection:


1) How much and how often to inspect
2) At what points in the process to inspect
3) Whether to inspect in a centralized or on-site location
4) Whether to inspect attributes (counting something) or variables (measure
something)
Where to inspect:

Raw materials and purchased parts


Finished products
Before a costly operation
Before an irreversible process
Before covering a process

Key Concepts:

Variation is the enemy of quality


Every process exhibits some form of variation
The degree of this variation is a measure of the capability of the process
Process variation can be classified as:
o common cause variation - inherent in system
o special cause variation - presence is detected using SPC

Control Charts

Key tool for monitoring and controlling processes. A control chart is a time-ordered plot
of sample statistics

Purpose: used for detecting presence of special cause variation.

Components of a Control Chart


(1) Upper Control Limit
(2) Middle Value
(3) Lower Control Limit

Possible Errors in SPC


Type I error
Type II error
Managerial Considerations Concerning Control Charts
1. At what points in the process to use control charts
2. What size samples to take
3. What type of control chart

Four Common Types of Charts


A.

Control charts for Variables


(1) Mean chart (a.k.a x-bar chart) - used to monitor the average of the process

UCL x z ( /

n)

LCL x z ( /

n)

UCL x A2 R
LCL x A2 R
where :

x grand mean
z confidence level
population standard deviation
n sample size
R average range
A2 value from table given a sample size

(2) Range chart (a.k.a. R-chart) - used to monitor the variability of the process
UCL D4 R
LCL D3 R

B. Control charts for Attributes


(1) p-chart (proportion chart) - used to monitor the proportion of defectives

UCL p z

p (1 p )
n

LCL p z

p (1 p )
n

where :
p average proportion
z confidence level

(2) c-chart (used when the goal is to control the number of defects per unit
UCL c z

LCL c z

where :
c average number of defects
z confidence level

Charts Illustrating a Process Not in Control

Table for A2, D3 and D4

Factor for R
Chart
Number of
Observation
s in
Subgroup
n

Factor
for xbar
Chart
A2

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

1.88
1.02
0.73
0.58
0.48
0.42
0.37
0.34
0.31
0.29
0.27
0.25
0.24
0.22
0.21
0.20
0.19
0.19
0.18

Lower Upper
Control Control
Limit
Limit
D3
D4
0.00
0.00
0.00
0.00
0.00
0.08
0.14
0.18
0.22
0.26
0.28
0.31
0.33
0.35
0.36
0.38
0.39
0.40
0.41

3.27
2.57
2.28
2.11
2.00
1.92
1.86
1.82
1.78
1.74
1.72
1.69
1.67
1.65
1.64
1.62
1.61
1.60
1.59

Problems
4 Control charts for Variables Mean and Range charts
6 Control chart for Attributes p-chart
7 Control chart for Attributes c-chart
8 How many to produce given a certain production survival rate

Problem 10.4 (p. 462)


Computer upgrades have a nominal time of 80 minutes. Samples of 5 observations each have been taken, and
the results are listed below. Determine the upper and lower control limits for mean and range charts, and decide if
the process is in control.

1
79.2
78.8
80.0
78.4
81.0

2
80.5
78.7
81.0
80.4
80.1

SAMPLE
3
4
79.8
78.9
79.4
79.4
80.4
79.7
80.3
79.4
80.8
80.6

5
80.5
79.6
80.4
80.8
78.8

6
79.7
80.6
80.5
80.0
81.1

Excel Solution

UCL x A2 R

UCL D4 R

LCL x A2 R

LCL D3 R

Problem 10.6 (463)


A medical facility does MRIs for sports injuries. Occasionally a test yields inconclusive results and must be
repeated. Using the following sample data and n=200, determine the upper and lower control limits for the
fraction of retests using two-sigma limits.
Is the process in control? If not eliminate any values that are outside the limits and compute the revised limits.

Number of
defectives

SAMPLE
6
7
8

10

11

12

13

Excel Solution

UCL p z

p (1 p )
n

LCL p z

p (1 p )
n

PROBLEM NO. 10 - 7
The postmaster of a small western city receives a certain number of complaints each day
about mail delivery. Assume that the distribution of daily complaints is Poisson. Construct
a control chart with three sigma limits using the following data. Is the process in control?

Number of
complaints

SAMPLE
6
7
8

10

14

12

10

11

12

13

14

13

10

Excel Solution

Problem 18
A production process consists of a three-step operation. The scrap rate is 10 percent for the first step and 6
percent for the other two steps.
(a)

If the desired daily output is 450 units, how many units must be started to allow for loss due to scrap?

(b)
If the scrap rate for each step would be cut in half, how many units would this save in terms of the scrap
allowance?

(c )
If the scrap represents a cost of $10 per unit, how much is it costing the company per day for the original
scrap rate?

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