King Abdulaziz University

Faculty of Engineering
IE-431 Quality Control
Section: FA

IE-431

Quality Control
Variables Control Charts

Team members
No. Name ID
1 Mohammad Hani Kashif 1847625
2 Yazid Abdul-Moneim Al-Mahi 1847375
3 Nasser Ahmed Al-Sulami 1847811

Instructor’s name: Dr. Ammar Al-Qahtani

 Assignment No.6

Table of Contents
Management Report ............................................................................................ 2
Technical Report ................................................................................................. 3

Question No.6.2 ....................................................................................................

Question No.6.4 ....................................................................................................

Question No.6.8 ....................................................................................................

Question No.6.10 ..................................................................................................

Question No.6.12 ..................................................................................................

Question No.6.15 ..................................................................................................

Question No.6.19 ..................................................................................................

Question No.6.21 ..................................................................................................

Question No.6.22 ..................................................................................................

Question No.6.26 ..................................................................................................

Question No.6.32 ..................................................................................................

Question No.6.33 ..................................................................................................

Question No.6.44 ..................................................................................................

Question No.6.47 ..................................................................................................

Question No.6.48 ..................................................................................................

Question No.6.49 ..................................................................................................

Question No.6.54 ..................................................................................................

Question No.6.62 ..................................................................................................

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Assignment No.6

Management Report

Practicality of the assignment No.6

Assignment No.6 make us learn how can we determined if our process is in control or not and if not, how
can we an out-of-control action plan. In addition, what the different type of controls chart and the difference
between each of them.

Statement of the problem

The problems in Assignment No.6 are about how can plot the data on X-bar chart, R chart, s chart and MR
chart and check if the process is in control or not.

Using data to show contribution & importance

We found form the problems in Assignment No.6 that most of the process is in control.

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Assignment No.6

Technical Report
Introduction
In technical report, we try to show and explain what we did to solve problems, case studies. In the case of
Assignment No.6. there are 18 questions. Each one of them cover several sup-question. During solving this
assignment, we used nearly all the concepts in chapter 6. We draw X-Bar chart, R-Chart and MR-Chart with
calculating the central and upper, lower limits. In each chart we plotted the given data on order to check if it in
control or out-of-control. In control if all the samples within the range(upper limit and lower limit). Otherwise,
we need to check the out-of-control samples, if there is unexpected accident or mistake happened or not. If there
is mistake such as mistake while collecting the data we will delete the sample and calculate the limits again as
well as plotting the rest data. We solved each question either by Excel software or Fx-9860 CASIO calculator
software.

Question No.6.2
In question 6.2 there is a company manufacture oil seals. They want to draw X-Chart and R-Chart. They
collect 25 preliminary samples of size 5 on the internal diameter of the seal. The summery data as follow:
25 25

∑ 𝑋̅ = 1253.75 𝑎𝑛𝑑 ∑ 𝑅 = 14.08

𝑖=1 𝑖=1

Part-A)
Find the control limits that will be use in X-chart, R-chart.
Part-B)
Assume that the 25 preliminary samples plot in control on both charts. Estimate the process mean and SD.

Solution
Part-A:
1253.75
𝑋̿ = = 50.15
25
14.08
𝑅̅ = = 0.5632
25
Limits of X-Chart
𝑈𝐶𝐿 = 𝑋̿ + (𝐴2 )(𝑅̅) = 50.15 + (0.577)(0.5632) = 50.4749664

𝐿𝐶𝐿 = 𝑋̿ − (𝐴2 )(𝑅̅) = 50.15 − (0.577)(0.5632) = 49.8250336

𝐶𝐿 = 𝑋̿ = 50.15

Limits of R-Chart
𝑈𝐶𝐿 = (𝐷4 )(𝑅̅) = (2.114)(0.5632) = 1.1906048

𝐿𝐶𝐿 = (𝐷4 )(𝑅̅) = (0)(0.5632) = 0

𝐶𝐿 = 𝑅̅ = 0.5632

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Assignment No.6
Part-B:
𝑅̅ 0.5632
𝜎̂ = = = 0.2421324
𝑑2 2.326
𝜇 = 𝑥̿ = 50.15

Question No.6.4

Solution
Total Statical control considers both the mean and the variation. While the x bar control chart monitors the
average quality level in the process, and also showcases the possible differences between the samples. The R
chart highlights a missing point, which is the variation within the individual samples we take from. This helps
keep variability within the sample to a proposed chance, instead of an actual error in the process. It is advised to
construct and review the R chart prior to the X-bar chart, as the variation between the individual observations in
the sample is a better visualizer of the level of variation between the different units the process produces. For a
low variation in the x bar chart, but a medium to high variation in the R chart, can portray an output that’s
mildly inaccurate. Moreover, the causes between a variation within the sample are in most cases a bigger cause
and indication to explore the causes of an error or deviation in the process, rather than random error through for
instance a misplacement by a worker, through the X-Bar chart.

Question No.6.8
a) Draw 𝑋̅ chart and R chart for the data in Table 1.
b) Find the capability for the process if the specifications are at 350 V ± 5 V.
c) Check if the data normally distributed.
Sample Number x1 x2 x3 x4
1 6 9 10 15
2 10 4 6 11
3 7 8 10 5
4 8 9 6 13
5 9 10 7 13
6 12 11 10 10
7 16 10 8 9
8 7 5 10 4
9 9 7 8 12
10 15 16 10 13
11 8 12 14 16
12 6 13 9 11
13 16 9 13 15
14 7 13 10 12
15 11 7 10 16
16 15 10 11 14
17 9 8 12 10
18 15 7 10 11
19 8 6 9 12
20 13 14 11 15
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Assignment No.6

Solution
First, we will use excel for most of the solution .
1. To solve part we need to find the average for every sample, and we will call it 𝑋̅
2. Calculate the Range in every sample 𝑅 = 𝑥𝑚𝑎𝑥 − 𝑥𝑚𝑖𝑛
3. Calculate the average of the sample averages and call it 𝑋̿
4. Calculate the average of the R
Sample Number x1 x2 x3 x4 𝑋̅ R
1 6 9 10 15 10 9
2 10 4 6 11 7.75 7
3 7 8 10 5 7.5 5
4 8 9 6 13 9 7
5 9 10 7 13 9.75 6
6 12 11 10 10 10.75 2
7 16 10 8 9 10.75 8
8 7 5 10 4 6.5 6
9 9 7 8 12 9 5
10 15 16 10 13 13.5 6
11 8 12 14 16 12.5 8
12 6 13 9 11 9.75 7
13 16 9 13 15 13.25 7
14 7 13 10 12 10.5 6
15 11 7 10 16 11 9
16 15 10 11 14 12.5 5
17 9 8 12 10 9.75 4
18 15 7 10 11 10.75 8
19 8 6 9 12 8.75 6
20 13 14 11 15 13.25 4
10.325 6.25
𝑋̿ 𝑅̅

5. Calculate UCL, CL and LCL for 𝑋̅ chart . In every sample there is 4 observation 𝑛 = 4 and form that we
can get A2 ,D3 and D4 values from the table Factors for Constructing Variables Control Charts.
a. 𝑈𝐶𝐿 = 𝑋̿ + 𝐴2 𝑅̅ = 14.881
b. 𝐶𝐿 = 𝑋̿ = 10.325
c. 𝐿𝐶𝐿 = 𝑋̿ − 𝐴2 𝑅̅ = 5.7688

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Assignment No.6

6. Now plot the UCL, CL , LCL and sample averages 𝑋̅

X Bar-Chart
16

14

12

10

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

X-Bar UCL CL LCL

7. Calculate UCL, CL and LCL for R chart

a. 𝑈𝐶𝐿 = 𝐷4 𝑅̅ = 14.2625
b. 𝐶𝐿 = 𝑅̅ = 6.25
c. 𝐿𝐶𝐿 = 𝐷3 𝑅̅ = 0

8. Now plot the UCL, CL , LCL and R for Run-chart

R-Chart
16

14

12

10

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

R UCL CL LCL

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Assignment No.6

9. From figure 1 & 2 we can see that the process is in control

10. Now to solve Part b we need to find the stander devotion and d2.
a. As we said n=4 so form the table we can get d2 value 𝑑2 = 2.059
𝑅̅
b. 𝜎 = = 3.036
𝑑2
c. 𝑈𝐶𝐿 = 350 𝑉 + 5 𝑉 = 355 𝑉
d. 𝑈𝐶𝐿 = 350 𝑉 − 5 𝑉 = 345 𝑉
𝑈𝐶𝐿−𝐿𝐶𝐿
e. 𝐶𝑝 = = 0.549
6𝜎
f. We can see that 𝐶𝑝 = 0.549 < 1 so the process is not capable.

11. In part c we need to do a normality test

12. We need to rank the sample averages X-Bar using the Rank function in excel.

3
(𝑅𝑎𝑛𝑘− )
8
13. Then Calculate the Index 𝐼𝑛𝑑𝑒𝑥 = 1
(𝑛− )
4

14. Calculate z-score by using the NORM.INV function in excel the probability will be the Index and mean
will be 0 and stander deviation will be 1.

15. Plot the z-score and the X-Bar. Also, you can calculate the correlation between the z-score and X-Bar using
CPRREL function in excel we found that correlation is equal to 0.9825 which close to 1 form that and figure
3 we can say that the data is normally distrusted.

Normality Test
3

0
0 2 4 6 8 10 12 14 16 18

-1

-2

-3

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Assignment No.6

Question No.6.10
In question 6.10, there is a data of 25 sample size 3 of thickness of a printed circuit board. The data as
follow:
Data
N-1 0.0629 0.0636 0.064
N-2 0.063 0.0631 0.0622
N-3 0.0628 0.0631 0.0633
N-4 0.0634 0.063 0.0631
N-5 0.0619 0.0628 0.063
N-6 0.0613 0.0629 0.0634
N-7 0.063 0.0639 0.0625
N-8 0.0628 0.0627 0.0622
N-9 0.0623 0.0626 0.0633
N-10 0.031 0.0631 0.0633
N-11 0.0635 0.063 0.0638
N-12 0.0623 0.063 0.063
N-13 0.0635 0.0631 0.063
N-14 0.0645 0.064 0.0631
N-15 0.0619 0.0644 0.0632
N-16 0.0631 0.0627 0.063
N-17 0.0616 0.0623 0.0631
N-18 0.063 0.063 0.0626
N-19 0.0636 0.0631 0.0629
N-20 0.064 0.0635 0.0629
N-21 0.0628 0.0625 0.0616
N-22 0.0615 0.0625 0.0619
N-23 0.063 0.0632 0.063
N-24 0.0635 0.0629 0.0635
N-25 0.0623 0.0629 0.063

Part-A)
Set up and R control charts. Is the process in statistical control?

Part-B)
Estimate the process standard deviation.

Part-C)
What are the limits that you would expect to contain nearly all the process measurements?

Part-D)
If the specifications are at 0.0630 in. ± 0.0015 in what is the value of the PCR Cp?

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Assignment No.6
X-Chart Avg.
Solution N-1 0.0629 0.0636 0.064 0.064
Part-A: N-2 0.063 0.0631 0.0622 0.063
Based on X-bar chart. There is a point out of control. So, the N-3 0.0628 0.0631 0.0633 0.063
process out of control. But there must be investigation if there is N-4 0.0634 0.063 0.0631 0.063
mistake while collecting or something happened while N-5 0.0619 0.0628 0.063 0.063
collecting the out-of-control sample. N-6 0.0613 0.0629 0.0634 0.063
N-7 0.063 0.0639 0.0625 0.063
N-8 0.0628 0.0627 0.0622 0.063
N-9 0.0623 0.0626 0.0633 0.063
N-10 0.031 0.0631 0.0633 0.052
N-11 0.0635 0.063 0.0638 0.063
X-Chart N-12 0.0623 0.063 0.063 0.063
CL 0.062524 N-13 0.0635 0.0631 0.063 0.063
UCL 0.064779 N-14 0.0645 0.064 0.0631 0.064
LCL 0.060269 N-15 0.0619 0.0644 0.0632 0.063
N-16 0.0631 0.0627 0.063 0.063
N-17 0.0616 0.0623 0.0631 0.062
N-18 0.063 0.063 0.0626 0.063
N-19 0.0636 0.0631 0.0629 0.063
N-20 0.064 0.0635 0.0629 0.063
N-21 0.0628 0.0625 0.0616 0.062
N-22 0.0615 0.0625 0.0619 0.062
N-23 0.063 0.0632 0.063 0.063
N-24 0.0635 0.0629 0.0635 0.063
N-25 0.0623 0.0629 0.063 0.063

X Bar-Chart
0.070

0.068

0.066

0.064 0.064
0.064 0.063 0.063 0.0630.0630.063
0.0630.0630.0630.0630.0630.0630.0630.063 0.0630.063 0.0630.063
0.062
0.0630.063
0.062 0.0620.062

0.060

0.058

0.056

0.054

0.052 0.052

0.050
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
AVG CL UCL LCL

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Assignment No.6
Based on Run-Chart. There is a point out of control. So, Data Range
the process out of control. But there must be investigation if N-1 0.0629 0.0636 0.064 0.00110
there is mistake while collecting or something happened N-2 0.063 0.0631 0.0622 0.00090
while collecting the out-of-control sample.
N-3 0.0628 0.0631 0.0633 0.00050
N-4 0.0634 0.063 0.0631 0.00040
N-5 0.0619 0.0628 0.063 0.00110
N-6 0.0613 0.0629 0.0634 0.00210
N-7 0.063 0.0639 0.0625 0.00140
N-8 0.0628 0.0627 0.0622 0.00060
N-9 0.0623 0.0626 0.0633 0.00100
N-10 0.031 0.0631 0.0633 0.03230
Run-Chart N-11 0.0635 0.063 0.0638 0.00080
CL 0.002204 N-12 0.0623 0.063 0.063 0.00070
UCL 0.005673 N-13 0.0635 0.0631 0.063 0.00050
LCL 0 N-14 0.0645 0.064 0.0631 0.00140
N-15 0.0619 0.0644 0.0632 0.00250
N-16 0.0631 0.0627 0.063 0.00040
N-17 0.0616 0.0623 0.0631 0.00150
N-18 0.063 0.063 0.0626 0.00040
N-19 0.0636 0.0631 0.0629 0.00070
N-20 0.064 0.0635 0.0629 0.00110
N-21 0.0628 0.0625 0.0616 0.00120
N-22 0.0615 0.0625 0.0619 0.00100
N-23 0.063 0.0632 0.063 0.00020
N-24 0.0635 0.0629 0.0635 0.00060
N-25 0.0623 0.0629 0.063 0.00070

0.03230 R-Chart
0.03000
R

0.02500 CL

UCL
0.02000
LCL

0.01500

0.01000

0.00500

0.00210 0.00250
0.00110
0.00090 0.00110 0.00140 0.00100 0.00080 0.00140 0.00150 0.00120
0.00110 0.00100 0.00060
0.00000 0.00050
0.00040 0.00060 0.00070
0.00050 0.00070
0.00040 0.00040 0.00070
0.00020
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

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Assignment No.6
Part-B:
The standard deviation as follow:
𝑅̅ 0.002204
𝜎= = = 0.001302
𝑑2 1.693

Part-C:
I think the above limits are the best and there is a mistake while collecting the sample that out the range.

Part-D:
𝐿𝑆𝐿 = 0.0630 − 0.0015 = 0.0615

𝑈𝑆𝐿 = 0.0630 + 0.0015 = 0.0645

𝑈𝑆𝐿 − 𝜇 𝜇 − 𝐿𝑆𝐿 0.0645 − 0.062524 0.062524 − 0.0615

𝐶𝑝 = 𝑀𝑖𝑛 ( , )=( , ) = (0.506, 0.262) = 0.262
3𝜎 3𝜎 3(0.001302) 3(0.001302)

Question No.6.12

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Assignment No.6
Question No.6.15
a) Draw 𝑋̅ chart and R chart for the data in Table 3.
b) 𝑋̅ chart control limits for this problem is identical to 𝑋̅ chart control limits for example 6.3 in the book
,will this always happen?
c) Find the capability for the process if the specifications are at 74.000 ± 0.05 mm.

Sample Number Observations

1 74.03 74.002 74.019 73.992 74.008
2 73.995 73.992 74.001 74.011 74.004
3 73.988 74.024 74.021 74.005 74.002
4 74.002 73.996 73.993 74.015 74.009
5 73.992 74.007 74.015 73.989 74.014
6 74.009 73.994 73.997 73.985 73.993
7 73.995 74.006 73.994 74 74.005
8 73.985 74.003 73.993 74.015 73.988
9 74.008 73.995 74.009 74.005 74.004
10 73.998 74 73.99 74.007 73.995
11 73.994 73.998 73.994 73.995 73.99
12 74.004 74 74.007 74 73.996
13 73.983 74.002 73.998 73.997 74.012
14 74.006 73.967 73.994 74 73.984
15 74.012 74.014 73.998 73.999 74.007
16 74 73.984 74.005 73.998 73.996
17 73.994 74.012 73.986 74.005 74.007
18 74.006 74.01 74.018 74.003 74
19 73.984 74.002 74.003 74.005 73.997
20 74 74.01 74.013 74.02 74.003
21 73.982 74.001 74.015 74.005 73.996
22 74.004 73.999 73.99 74.006 74.009
23 74.01 73.989 73.99 74.009 74.014
24 74.015 74.008 73.993 74 74.01
25 73.982 73.984 73.995 74.017 74.013

Solution
First, we will use excel for most of the solution .
1. To solve part we need to find the average for every sample, and we will call it 𝑋̅.
2. Calculate the Range in every sample 𝑅 = 𝑥𝑚𝑎𝑥 − 𝑥𝑚𝑖𝑛 .
3. Calculate the average of the sample averages and call it 𝑋̿.
4. Calculate the average of the R .

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Assignment No.6

Sample
Observations 𝑋̅ s R
Number
1 74.03 74.002 74.019 73.992 74.008 74.010 0.0148 0.038
2 73.995 73.992 74.001 74.011 74.004 74.001 0.0075 0.019
3 73.988 74.024 74.021 74.005 74.002 74.008 0.0147 0.036
4 74.002 73.996 73.993 74.015 74.009 74.003 0.0091 0.022
5 73.992 74.007 74.015 73.989 74.014 74.003 0.0122 0.026
6 74.009 73.994 73.997 73.985 73.993 73.996 0.0087 0.024
7 73.995 74.006 73.994 74 74.005 74.000 0.0055 0.012
8 73.985 74.003 73.993 74.015 73.988 73.997 0.0123 0.03
9 74.008 73.995 74.009 74.005 74.004 74.004 0.0055 0.014
10 73.998 74 73.99 74.007 73.995 73.998 0.0063 0.017
11 73.994 73.998 73.994 73.995 73.99 73.994 0.0029 0.008
12 74.004 74 74.007 74 73.996 74.001 0.0042 0.011
13 73.983 74.002 73.998 73.997 74.012 73.998 0.0105 0.029
14 74.006 73.967 73.994 74 73.984 73.990 0.0153 0.039
15 74.012 74.014 73.998 73.999 74.007 74.006 0.0073 0.016
16 74 73.984 74.005 73.998 73.996 73.997 0.0078 0.021
17 73.994 74.012 73.986 74.005 74.007 74.001 0.0106 0.026
18 74.006 74.01 74.018 74.003 74 74.007 0.007 0.018
19 73.984 74.002 74.003 74.005 73.997 73.998 0.0085 0.021
20 74 74.01 74.013 74.02 74.003 74.009 0.008 0.02
21 73.982 74.001 74.015 74.005 73.996 74.000 0.0122 0.033
22 74.004 73.999 73.99 74.006 74.009 74.002 0.0074 0.019
23 74.01 73.989 73.99 74.009 74.014 74.002 0.0119 0.025
24 74.015 74.008 73.993 74 74.01 74.005 0.0087 0.022
25 73.982 73.984 73.995 74.017 74.013 73.998 0.0162 0.035
74.0012 0.009404 0.02324
𝑋̿ 𝑆̅ 𝑅̅

5. Calculate UCL, CL and LCL for 𝑋̅ chart . In every sample there is 4 observation n=5 and form that we
can get A2 ,D3 and D4 values from the table Factors for Constructing Variables Control Charts.
a. 𝑈𝐶𝐿 = 𝑋 𝐷𝑜𝑏𝑙𝑏𝑎𝑟 + 𝐴2 𝑅 𝐵𝑎𝑟 = 74.01459
b. 𝐶𝐿 = 𝑋 𝐷𝑜𝑏𝑙𝑏𝑎𝑟 = 74.00118
c. 𝐿𝐶𝐿 = 𝑋 𝐷𝑜𝑏𝑙𝑏𝑎𝑟 − 𝐴2 𝑅 𝐵𝑎𝑟 = 73.98777

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Assignment No.6

6. Now plot the UCL, CL , LCL and sample averages 𝑋̅

X Bar-Chart
74.020

74.015

74.010

74.005

74.000

73.995

73.990

73.985
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

x-Bar UCL CL LCL

7. Calculate UCL, CL and LCL for R chart

a. 𝑈𝐶𝐿 = 𝐷4 𝑅 𝐵𝑎𝑟 = 0.049129
b. 𝐶𝐿 = 𝑅 𝐵𝑎𝑟 = 0.02324
c. 𝐿𝐶𝐿 = 𝐷3 𝑅 𝐵𝑎𝑟 = 0

8. Now plot the UCL, CL , LCL and R for R chart

R-Chart
0.06

0.05

0.04

0.03

0.02

0.01

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

R UCL CL LCL

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Assignment No.6

9. From figure 4 & 5 we can see that the process is in control

10. For part b the answer is no not always this will happen.
11. Now to solve Part b we need to find the stander devotion and d2.
a. As we said n=5 so form the table we can get d2 value 𝑑2 = 2.326
𝑅 𝑏𝑎𝑟
b. 𝜎 = = 0.009991
𝑑2
c. 𝑈𝐶𝐿 = 0.05
d. 𝑈𝐶𝐿 = −0.05
𝑈𝐶𝐿−𝐿𝐶𝐿
e. 𝐶𝑝 = = 1.6681
6𝜎
f. We can see that 𝐶𝑝 = 1.6681 > 1 so the process is capable.

Question No.6.19
Samples of n = 4 items are taken from a process at regular intervals. and X, S values are calculated for each
sample. After 50 subgroups have been analyzed, we have

50 50

∑ 𝑋̅ = 1000 𝑎𝑛𝑑 ∑ 𝑆 = 72
𝑖=1 𝑖=1

Part-A)
Compute the control limit for the and s control charts.

Part-B)
Assume that all points on both charts plot within the control limits. What are the natural tolerance limits of the
process?

Part-C)
If the specification limits are 19 ± 4.0, what are your conclusions regarding the ability of the process to produce
items conforming to specific cations?

Part-D)
Assuming that if an item exceeds the upper specification limit it can be reworked, and if it is below the lower
specification limit it must be scrapped, what percentage scrap and rework is the process now producing?
Assuming that if an item exceeds the upper specification limit it can be reworked, and if it is below the lower
specification limit it must be scrapped, what percentage scrap and rework is the process now producing?

Part-E)
If the process were centered at m = 19.0, what would be the effect on percentage scrap and rework?

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Assignment No.6

Solution
Part-A:
1000
𝑋̿ = = 20
50
72
𝑆̅ = = 1.44
50
S-Chart limits
𝑈𝐶𝐿 = 𝐵4 𝑆̅ = 2.2666(1.44) = 3.26304
𝐿𝐶𝐿 = 𝐵3 𝑆̅ = 0(1.44) = 0
𝐶𝐿 = 𝑆̅ = 1.44

Limits of X-Chart
𝑈𝐶𝐿 = 𝑋̿ + (𝐴2 )(𝑅̅) = 20 + (1.628)(1.44) = 22.34432

𝐿𝐶𝐿 = 𝑋̿ − (𝐴2 )(𝑅̅) = 20 − (1.628)(1.44) = 17.65568

𝐶𝐿 = 𝑋̿ = 20

Part-B:
𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝑇𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 = 20 ± 3(1.563008792) = 15.31097362, 24.68902638

Part-C:
23−20
USL = 23 and LSL = 15, 𝐶𝑝 = = 0.63979 I think it can provide a products that meet the
3(1.563008702)
specification limits.

Part-D:
By using Fx-9860 calculator, the upper percentage that out the specification limits is 0.02746843 so the
percentage of rework is 2.746843%. the lower percentage that out the specification limits is 0.00068963 so the
percentage of scrap is 0.068963%.

Part-E:
If the center is 19. The percentage of rework will become 0.005246 or 0.52462%. The percentage of scrap is
0.005246 or 0.52462%.

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Assignment No.6

Question No.6.21
Question No.6.22

Question No.6.26
Samples of size n = 5 are taken from a manufacturing process every hour. A quality characteristic is
measured, and R are computed for each sample. After 25 samples have been analyzed.

25 25

∑ 𝑋̅ = 662.50 𝑎𝑛𝑑 ∑ 𝑅 = 9
𝑖=1 𝑖=1
Part-A)
Find the control limits for the X and R charts.

Part-B)
Assume that both charts exhibit control. If the specifications are 26.40 ± 0.50, estimate the fraction
nonconforming.

Part-C)
If the mean of the process were 26.40, what fraction nonconforming would result?

Solution
Part-A:
662.50
𝑋̿ = = 26.50
25
9
𝑅̅ = = 0.360
25
Limits of X-Chart
𝑈𝐶𝐿 = 𝑋̿ + (𝐴2 )(𝑅̅) = 26.5 + (0.577)(0.36) = 26.70772

𝐿𝐶𝐿 = 𝑋̿ − (𝐴2 )(𝑅̅) = 26.5 − (0.577)(0.36) = 26.29228

𝐶𝐿 = 𝑋̿ = 26.5
Limits of R-Chart
𝑈𝐶𝐿 = (𝐷4 )(𝑅̅) = (2.114)(0.36) = 0.76104

𝐿𝐶𝐿 = (𝐷4 )(𝑅̅) = (0)(0.36) = 0

𝐶𝐿 = 𝑅̅ = 0.36

Part-B:
𝐷 26.50
𝑝̂ = = = 5.3
𝑛 5
Part-C:
𝐷 26.40
𝑝̂ = = = 5.28
𝑛 5
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Assignment No.6

Question No.6.32

a) Find UCL, CL and LCL for 𝑋̅ chart

b) Find UCL, CL and LCL for R chart
c) Find UCL, CL and LCL for S chart.
Given that.
- 𝑋̅ = µ = 10
- 𝜎 = 2.5
- 𝑛=2
Solution

1- Calculate UCL, CL and LCL for 𝑋̅ chart . In every sample there is 2 observation n=2 and form that we
can get D1,D2,d2,c4,B5 and B6 values from the table Factors for Constructing Variables Control Charts.
𝜎
a. 𝑈𝐶𝐿 = µ + 3 = 15.3014
√𝑛
b. 𝐶𝐿 = µ = 10
𝜎
c. 𝐿𝐶𝐿 = µ − 3 = 15.3014
√𝑛

2- Calculate UCL, CL and LCL for R chart

a. 𝑈𝐶𝐿 = 𝐷2 𝜎 = 9.215
b. 𝐶𝐿 = 𝑑2 𝜎 = 2.82
c. 𝐿𝐶𝐿 = 𝐷1 𝜎 = 0

3- Calculate UCL, CL and LCL for s chart.

a. 𝑈𝐶𝐿 = 𝐵6 𝜎 = 6.515
b. 𝐶𝐿 = 𝐶4 𝜎 = 1.9947
c. 𝐿𝐶𝐿 = 𝐵5 𝜎 = 0

Question No.6.33

a) Find the control limit for X-Bar and R .

b) Find the stander deviation.
c) Find the process capability.
d) Find the probability of no detecting this shift on the first subsequent sample. Process mean shifts to 24.
Given that.
- 𝑋̿ = 20
- 𝑅̅ = 4.56
- 𝑚 = 25
- 𝑛=5
- 𝑠ℎ𝑖𝑓𝑡𝑒𝑑 µ = 24

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Assignment No.6
Solution
1. Calculate the control limit for X-Bar and R
a. X-Bar chart
i. 𝑈𝐶𝐿 = 𝑋̿ + 𝐴2 ∗ 𝑅̅ = 22.6311
ii. 𝐶𝐿 = 𝑋̿ = 20
iii. 𝐿𝐶𝐿 = 𝑋̿ − 𝐴2 ∗ 𝑅̅ = 17.3689
b. R chart
i. 𝑈𝐶𝐿 = 𝐷4 ∗ 𝑅̅ = 22.6311
ii. 𝐶𝐿 = 𝑅̅ = 4.56
iii. 𝐿𝐶𝐿 = 𝐷3 ∗ 𝑅̅ = 17.3689

2. For part b we need to calculate stander deviation

𝑅̅
a. 𝜎 = = 1.9604
𝑑2

3. Part c calculate the Cp

a. 𝑈𝐶𝐿 = 19 + 5 = 24
b. 𝑈𝐶𝐿 = 19 − 5 = 14
𝑈𝐶𝐿−𝐿𝐶𝐿
c. 𝐶𝑝 = = 0.85016
6𝜎
d. We can see that 𝐶𝑝 = 0.85016 < 1 so the process is not capable.

4. Part d calculate the probability of not detecting this shift on the first subsequent sample.
𝑈𝐶𝐿−𝑆ℎ𝑖𝑓𝑡𝑒𝑑 𝜇 𝐿𝐶𝐿−𝑆ℎ𝑖𝑓𝑡𝑒𝑑 𝜇
a. 𝛽 = Φ [ 𝜎 ]−Φ[ 𝜎 ] = 0.05921
√𝑛 √𝑛

Question No.6.44
In case of question 6.44, there are two parts assembled as in the below figure. Assume that X,Y are normally
distributed. Mean of X and Y are 𝜇𝑥 𝑎𝑛𝑑 𝜇𝑦 . The standard deviations are 𝜎𝑥 𝑎𝑛𝑑 𝜎𝑦 . Each part produced on
different machines. The range of each sample is 5. Both ranges in control.

Part-A)
Given that for 20 samples on the range chart controlling x and 10 samples on the range chart controlling y. We
get the following:
20 10

∑ 𝑅𝑋𝑖 = 18.608 𝑎𝑛𝑑 ∑ 𝑅𝑦𝑗 = 6.978

𝑖=1 𝑖=1
Estimate 𝜎𝑋 𝑎𝑛𝑑 𝜎𝑌 .

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Assignment No.6

Part-B)
If it is desired that the probability of a smaller clearance (i.e., x − y) than 0.09 should be 0.006, what distance
between the average dimensions (i.e., mx – my) should be specified?

Solution

Part-A:
𝑅̅ 0.9304
𝜎𝑥 = = = 0.4
𝑑2 2.326

𝑅̅ 0.6978
𝜎𝑦 = = = 0.3
𝑑2 2.326
Part-B:
Between 0.04 and 0.09

Question No.6.47

UCL
M + A2 Q
10 0.729 8 15.832
LCL
M - A2 Q
10 0.729 8 4.168

Question No.6.48

a) Find the probability that the control chart would exhibit lack of control by at least the third point plotted.
Given that. 𝑋̅ parameter
- µ = 98
- 𝜎=8
- 𝑛=5
- 𝑈𝐶𝐿 = 104
- 𝐶𝐿 = 100
- 𝐿𝐶𝐿 = 96

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Assignment No.6

Solution

1- calculate the probability of not detecting this shift on the first subsequent sample.
𝑈𝐶𝐿− 𝜇 𝐿𝐶𝐿− 𝜇
a. 𝛽 = Φ [ 𝜎 ]−Φ[ 𝜎 ] = 0.6651
√𝑛 √𝑛
b. Let P be the control chart exhibit lack of control by the third plotted point.
i. 𝑃 = 1 − 𝛽 3 = 0.7058

Question No.6.49
Consider the chart defined in Exercise 6.48. Find the ARL1 for the chart

Solution

1 1
𝐴𝑅𝐿1 = ( )=( ) = 2.992
1−𝛽 1 − 0.6651

Question No.6.54

Question No.6.62

a) Draw X-Bar chart and MR chart for the data in Table.

b) Check if the data normally distributed.
Heat Hardness
1 52
2 51
3 54
4 55
5 50
6 52
7 50
8 51
9 58
10 51
11 54
12 59
13 53
14 54
15 55

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Assignment No.6
Solution
1- To solve part we need to find the average for the samples, and we will call it 𝑋̅.
2- Calculate the MR in every sample 𝑅 = | 𝑥𝑖 − 𝑥𝑖−1 |.
3- Calculate the average of the ̅̅̅̅̅
𝑀𝑅.
Heat Hardness MR
1 52
2 51 1
3 54 3
4 55 1
5 50 5
6 52 2
7 50 2
8 51 1
9 58 7
10 51 7
11 54 3
12 59 5
13 53 6
14 54 1
15 55 1
53.26667 3.214286
𝑋̅ ̅̅̅̅̅
𝑀𝑅

4- Calculate UCL, CL and LCL for X-Bar chart . In every sample there is 2 observation n=2 and form that
we can get d2 and D4 values from the table Factors for Constructing Variables Control Charts.
̅̅̅̅̅
𝑀𝑅
a. 𝑈𝐶𝐿 = 𝑋̅ + 3 𝑑2 = 61.8153
b. 𝐶𝐿 = 𝑋̅ = 53.26667
̅̅̅̅̅
𝑀𝑅
c. 𝐿𝐶𝐿 = ̅̅̅̅̅
𝑀𝑅 − 3 = 44.71803
𝑑2

X Bar-Chart
65

60

55

50

45

40
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Hardness UCL CL LCL

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Assignment No.6

5- Calculate UCL, CL and LCL for MR chart .

a. 𝑈𝐶𝐿 = ̅̅̅̅̅
𝑀𝑅 ∗ 𝐷4 = 10.50107
̅̅̅̅̅
b. 𝐶𝐿 = 𝑀𝑅 = 3.214286
c. 𝐿𝐶𝐿 = 0 𝑖𝑡 𝑎𝑙𝑤𝑎𝑦𝑠 0

MR-Chart
12

10

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14

MR UCL CL LCL

6- From figure 6 & 7 we can see that the process is in control.

7- In part b we need to do a normality test.

8- We need to rank the sample X using the Rank function in excel.

3
(𝑅𝑎𝑛𝑘− )
8
9- Then Calculate the Index 𝐼𝑛𝑑𝑒𝑥 = 1 .
(𝑛− )
4

10- Calculate z-score by using the NORM.INV function in excel the probability will be the Index and mean
will be 0 and stander deviation will be 1.

11- Plot the z-score and the 𝑋̅. Also, you can calculate the correlation between the z-score and 𝑋̅ using
CPRREL function in excel we found that correlation is equal to 0.9825 which close to 1 form that and
figure 8 we can say that the data is normally distrusted.

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Assignment No.6

Normality Test
3

0
0 2 4 6 8 10 12 14 16 18

-1

-2

-3

Conclusion
By the end of Assignment No.6. we practices to controls charts such as X-Bar chart, Run-Chart and MR-
Chart and S-Chart in addition to S2- Chart. We used all concepts that have been covered in the last three
lectures. In addition, we used old concepts such as plotting the normality from design of experiment course.
During this assignment we used Excel software in order to plot the data on charts and drawing the normality
chart, and we used Fx-9860 CASIO calculator software to calculate the Upper, Lower limits. In addition to
finding the probability of outer area from the upper/lower sides.

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