Assignment 9

Control Charts, Process capability and QFD

Instructions:
1. Total No. of Questions: 25. Each question carries one point.
2. All questions are objective type. Only one answer is correct per numbered item.

1. How do you find the process capability?

𝑈𝑈𝑈𝑈𝑈𝑈−𝐿𝐿𝐿𝐿𝐿𝐿
a) By Process Capability Ratio = Cp = 6𝜎𝜎
b) By USL and LSL only
c) By normal distribution curve
d) By spread and mean shift of the process

2. In a certain process it is given that USL is 14, LSL is zero. The process has a mean of 10
and standard deviation 2. What will be the Process Capability Ratio?
a) 0.83
b) 1.17
c) 1.33
d) 1.5

3. In a process the inverse of process capability ratio is 0.65. Which statement is correct?
a) The process is capable.
b) The process is incapable.
c) The process is capable with tight control.
d) None of the above

4. A process having mean 8.80 and process standard deviation 0.12 has spread of
specification limit: 9.0±0.4. What will be the process capability index?
a) 0.55
b) 1.67
c) 1.33
d) 0.83

5. How 𝐶𝐶𝑝𝑝𝑝𝑝 is different than 𝐶𝐶𝑝𝑝 ?

a) 𝐶𝐶𝑝𝑝 Looks at the centrality of the process.
b) 𝐶𝐶𝑝𝑝𝑝𝑝 Looks at the overall variability of the process.
c) Both look at the overall variability of the process.
d) 𝐶𝐶𝑝𝑝𝑝𝑝 Looks at the centrality of the process.
6. A QC scheme is in operation for a process producing ball-bearings. A sample of 6
bearings is taken every hour and diameters is measured. The mean diameter which the
process delivers is 2 cm. A bearing meets specification within the range 1.998cm–
2.002cm. If the specification limits are considered at 1𝜎𝜎 level, what is the Process
Capability?
a) 0.11
b) 0.44
c) 0.22
d) 0.33

7. What is true about Process Capability Index (Cpk) and Process Performance Index (Ppk)?

I. Cpk tells you about what the process is CAPABLE of doing in future, assuming it
remains in a state of statistical control. Ppk tells you how the process has performed in
the past and verifies is the process capable to meet Customer CTQs (requirements).
II. Ppk only applies to a specific batch of material.
III. Ppk generally uses sample sigma in its calculation; Cpk uses the process sigma value
determined from either the Moving Range, Range or Sigma control charts
IV. Both the indexes are same

a) I, II, III are correct

b) I and II are correct
c) IV is correct
d) All are correct

8. A process is having net weight specifications 9.0± 0.5 with process mean 8.80 and
standard deviation 0.12.The sample standard deviation is 0.11. What will be the process
performance capability?
a) 0.83
b) 0.90
c) 1.94
d) 2.12

9. How Quality Function Deployment differs from conventional product development?

a) It listens to the customer.
b) It develops and manufacture towards measured goals.
c) It optimises products and processes.
d) All of the above
10. If a Company is late to market to deliver its product by 4 months in ship building industry
a) Gross profit potential is reduced by 18%.
b) Gross profit potential is reduced by 33%.
c) Gross profit potential is reduced by 25%.
d) Gross profit potential is reduced by 13%.

11. What does the roof of the House of Quality indicate?

a) The customer requirements
b) The correlationship matrix showing the conflicts between engineering
characteristics.
c) The relationship matrix between customer requirement and engineering
characteristics
d) The target value of the organisation for the product

12. What is the output from 2nd phase of QFD?

a) Design Requirements
b) Process Operations
c) Part/Item Characteristics
d) Operations Requirements

13. How Kano Model is different than QFD?

a) QFD gives information about delighted needs
b) QFD distinguishes the quality of requirements
c) Kano Model captures the Voice of the customer
d) Kano Model captures the Mind of the customer

14. Which of the following statement is true regarding Kano Model?

a) Threshold attributes are those for which more is generally better.
b) Performance attributes are the expected attribute that must be there in a
product.
c) Excitement attributes are unspoken and unexpected by customer.
d) None of the above

15. Which of the following statements is incorrect?

Quality Function Deployment (QFD)….
a) Reduces product development cycle time
b) Increases engineering changes
c) Reduces start-up cost
d) Helps to identify specific competitive advantages easily
16. Which step is out of DMAIC?
a) Measure
b) Improvement
c) Control
d) Design

17. Which of the following statements are true about the Value Stream Map?
I. Links the material and information flows
II. Ties together lean concepts and techniques
III. Less useful than quantitative tools
a) Only III
b) I and II
c) Only II
d) I and III

18. Checkout time at a supermarket is monitored using a range and mean chart. Six samples
which contain 20 observations per sample have been collected and the sample means and
sample ranges have been computed as shown below.
Sample Mean Range
1 3.06 0.42
2 3.15 0.50
3 3.11 0.41
4 3.13 0.46
5 3.06 0.46
6 3.09 0.45

Which chart should be used first to analyse the checkout time variability?
a) U chart
b) X bar chart
c) Mean chart
d) Range chart

19. Which chart is used when the control chart is having quality characteristics as attributes
and defective with constant sample size?
a) p chart or np chart
b) c chart or u chart
c) X bar chart and R chart
d) X bar chart and s chart
20. What are the formulae used to find the control limits in u chart?
𝑢𝑢 �
𝑢𝑢
a) 𝑈𝑈𝑈𝑈𝑈𝑈 = 𝑢𝑢� + 3�𝑛𝑛 𝐿𝐿𝐿𝐿𝐿𝐿 = 𝑢𝑢� − 3�𝑛𝑛
𝑖𝑖 𝑖𝑖

𝑢𝑢 𝑢𝑢
b) 𝑈𝑈𝑈𝑈𝑈𝑈 = 𝑢𝑢� + 3�𝑛𝑛 , 𝐿𝐿𝐿𝐿𝐿𝐿 = 𝑢𝑢� − 3�𝑛𝑛
𝑖𝑖 𝑖𝑖

�
𝑢𝑢 𝑢𝑢
c) 𝑈𝑈𝑈𝑈𝑈𝑈 = 𝑢𝑢� + 3�𝑛𝑛 , 𝐿𝐿𝐿𝐿𝐿𝐿 = 𝑢𝑢� − 3�𝑛𝑛
𝑖𝑖 𝑖𝑖

�
𝑢𝑢 �
𝑢𝑢
d) 𝑈𝑈𝑈𝑈𝑈𝑈 = 𝑢𝑢� + 3�𝑛𝑛 , 𝐿𝐿𝐿𝐿𝐿𝐿 = 𝑢𝑢� − 3�𝑛𝑛
𝑖𝑖 𝑖𝑖

21. Mean values and ranges of data from 20 samples (sample size=4) are shown in the table
below.
S.N Mean of Sample Range S.N Mean of Sample Range
1 10 4 11 12 5
2 15 4 12 13 4
3 12 5 13 12 4
4 11 4 14 12 3
5 9 5 15 11 3
6 11 6 16 15 4
7 11 4 17 12 4
8 9 4 18 15 3
9 10 4 19 11 3
10 11 6 20 10 4

What are the central line and control limits of R chart?

a) Central Line = 4.15, UCL = 9.47 and LCL = 0.00

b) Central Line = 3.57, UCL = 6.87 and LCL = 0.33
c) Central Line = 4.15, UCL = 7.44 and LCL = 0.48
d) Central Line = 4.15, UCL = 9.87 and LCL = 0.00

22. Mean values and ranges of data from 20 samples (sample size = 4) are shown in the table
below.
S.N Mean of Sample Range S.N Mean of Sample Range
1 10 4 11 12 5
2 15 4 12 13 4
3 12 5 13 12 4
4 11 4 14 12 3
5 9 5 15 11 3
6 11 6 16 15 4
7 11 4 17 12 4
8 9 4 18 15 3
9 10 4 19 11 3
10 11 6 20 10 4
 What are the central line and control limits of X bar chart?

a) Central Line = 13.6, UCL = 15.83 and LCL = 8.57

b) Central Line = 11.6, UCL = 14.63 and LCL = 8.57
c) Central Line = 11.6, UCL = 14.63 and LCL = 9.45
d) Central Line = 13.6, UCL = 15.63 and LCL = 9.47

23. A bank manager receives a certain number of complaints each day about the bank’s
service. Complaints for 14 days are given in the table shown. Find out the upper control
limit and lower control limit using three-sigma limits. (Hint: use c chart)
Days Number of Complaints
1 5
2 4
3 3
4 6
5 2
6 5
7 4
8 7
9 6
10 5
11 4
12 2
13 3
14 1

a) UCL is 8 and LCL is 0

b) UCL is 10 and LCL is -2
c) UCL is 8 and LCL is -2
d) UCL is 10 and LCL is 0

24. Match the following

1. X-bar and R charts a) Binomial Distribution
2. p charts b) Poisson Distribution
3. c charts c) Normal Distribution

a) 1-c,2-b,3-a
b) 1-b,2-a,3-c
c) 1-c,2-a,3-b
d) 1-b,2-c,3-a
25. A QC manager counted the number of defective nuts produced by an automatic machine
in 12 samples. Using the data given in table below, calculate the upper limit and lower
limit of the control chart that will describe 99.74% of the chance variation when the
process in control. Each sample contained 200 nuts.

Samples Number of Defects

1 12
2 14
3 13
4 10
5 12
6 11
7 14
8 12
9 14
10 9
11 13
12 10

a) UCL is 0.05136 & LCL is 0.02124

b) UCL is 0.11037 & LCL is 0.00963
c) UCL is 0.18634 & LCL is 0.00357
d) UCL is 0.27963 & LCL is 0.00014

Answer Key
1 2 3 4 5 6 7 8 9 10
a b a a d d a b d a

11 12 13 14 15 16 17 18 19 20
b c d c b d b d a d

21 22 23 24 25
a b d c b