EXERCISE – STATISTICAL QUALITY TOOLS

HISTOGRAM
Q1. The following table shows the contents in fluid ounces of 60 randomly selected cans of
soda:
12.05 12.02 12.04 11.97 11.97 12.03
11.99 11.94 11.95 11.93 12.01 11.93
12.06 11.98 12.00 12.10 11.96 12.02
11.97 11.97 11.93 12.06 11.96 12.05
12.04 12.00 11.97 11.95 12.02 12.05
11.95 12.08 12.01 12.02 12.01 11.99
12.01 12.02 12.04 11.97 11.98 12.01
11.97 12.00 11.94 11.97 12.01 11.95
12.03 11.98 12.03 12.00 11.97 12.00
11.98 11.98 12.02 12.01 11.99 11.94
In the work below, use a leftmost cell boundary at 11.90 fl.oz. and width of 0.05 fl.oz. If an
observation falls exactly on a boundary, place the cell that will appear in the histogram
immediately to the right c boundary (the cell with values higher than the boundary; this is what
- statistical packages actually do).
a. Develop a frequency distribution for the data.
b. The specifications for this variable are 12.00 +/- 0.15 fl.oz. How well does the process
output seem to satisfy those specifications?

Q2. The time to failure in hours of an electronic component subjected to an accelerated life test
is shown below. To accelerate the failure test, the units were tested at an elevated temperature.
127 124 121 118
125 123 136 131
131 120 140 125
124 119 137 133
129 128 125 141
121 133 124 125
142 137 128 140
151 124 129 132
160 142 130 129
125 123 122 126

a. Develop a frequency histogram and use it to prepare a brief summary of the main
features of the data.
b. The specifications for this variable are 130 +/- 10. How well does the process output
seem to satisfy those specifications?

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Dr. Nguyen Thuy Quynh Loan
 Q3. The data shown below are chemical process yield readings on successive days (read
across, then down). Construct a histogram for these data. Comment on the shape of the
histogram.
94.1 87.3 94.1 92.4 84.6 85.4
93.2 84.1 92.1 90.6 83.6 86.6
90.6 90.1 96.4 89.1 85.4 91.7
91.4 95.2 88.2 88.8 89.7 87.5
88.2 86.1 86.4 86.4 87.6 84.2
86.1 94.3 85.0 85.1 85.1 85.1
95.1 93.2 84.9 84.0 89.6 90.5
90.0 86.7 87.3 93.7 90.0 95.6
92.4 83.0 89.6 87.7 90.1 88.3
87.3 95.3 90.3 90.6 94.3 84.1
86.6 94.1 93.1 89.4 97.3 83.7
91.2 97.8 94.6 88.6 96.8 62.9
86.l 93.1 96.3 64.1 94.4 67.3
90.4 66.4 94.7 62.6 96.1 66.4
69.1 87.6 91.1 83.1 98.0 64.5

PARETO DIAGRAM

Q4. In a customer satisfaction survey at a local fast-food restaurant, the following complaints
were lodged. Create a Pareto chart with this information.

Complaint Number of Complaints

Cold Food 105
Flimsy Utensils 20
Food Tastes Bad 10
Salad Not Fresh 94
Poor Service 15
Food Greasy 9
Lack of Courtesy 5
Lack of Cleanliness 25

Q5. Develop a Pareto diagram for frequency and the average weekly costs of defect printed
circuit boards shown in the following table.

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Dr. Nguyen Thuy Quynh Loan
 No. of Average scrap and repair
Defect type
Defects cost per defect ($)
Defective components 105 12.60
Component out of alignment 210 4.75
Improper solder joint 32 8.75
Solder balls 76 3.25
Component missing 8 2.50

SCATTER PLOT

Q6. Identifying a correlation between two characteristics of a product. Data is shown in the
following table.

Sample Characteristic Characteristic Sample Characteristic Characteristic

No. 1 2 No. 1 2
1 5 0 16 10 2
2 2 -1 17 7 0
3 7 -1 18 3 -2
4 6 2 19 6 1
5 9 2 20 6 -1
6 3 0 21 5 0
7 9 1 22 8 1
8 5 0 23 2 -2
9 8 -3 24 5 0
10 4 -1 25 3 -1
11 4 3 26 4 -3
12 6 0 27 5 -1
13 1 -2 28 6 1
14 5 0 29 4 -1
15 2 -3 30 8 2

Q7. Product specifications were written for static back-out torque (Newton-meters) of a bolt.
The dynamic installation torque (pound-inches) was used to set up and monitor the bolt
installation station. A study of 60 random bolts was conducted by measuring first the dynamic
torque at installation and then the static back-out torque required for loosening.

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Dr. Nguyen Thuy Quynh Loan
 Bolt Static Dynamic Bolt Static Dynamic Bolt Static Dynamic
1 10 90.8 21 14 92.9 41 15 90.4
2 10 91.9 22 12 92.9 42 14 92.1
3 9 91.2 23 12 92.1 43 12 91.5
4 10 89.6 24 13 92.3 44 12 90.3
5 10 92.9 25 12 91.1 45 13 93.8
6 10 94.8 26 12 91.6 46 13 92.3
7 9 91.1 27 12 95.7 47 14 92.6
8 10 91.4 28 13 91.7 48 12 91.4
9 10 90.5 29 14 94.9 49 12 94.1
10 10 92.3 30 13 92.7 50 15 93.0
11 10 91.4 31 12 93.1 51 13 92.9
12 10 89.8 32 12 93.6 52 12 91.4
13 10 91.8 33 13 91.2 53 13 93.3
14 10 89.4 34 15 91.3 54 15 94.3
15 10 92.7 35 12 91.2 55 12 95.4
16 10 93.2 36 12 91.6 56 13 94.9
17 10 90.3 37 14 92.9 57 13 91.9
18 10 89.9 38 12 90.4 58 14 92.3
19 10 89.9 39 12 92.0 59 13 91.9
20 10 94.2 40 12 92.9 60 15 91.7
a. Prepare a scatter plot of dynamic (X) versus static torque (Y). Identify the correlation
coefficient r. Interpret the plot.
b. What are the process implications of these results?

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Dr. Nguyen Thuy Quynh Loan
CONTROL CHART

Variable control chart

Q10. Twenty-five samples of size 4 yielded the following coded data:

Sample X1 X2 X3 X4 Sample X1 X2 X3 X4
Number Number
1 54 62 40 76 14 44 35 38 31
2 68 62 93 99 15 61 52 37 71
3 69 21 68 105 16 36 54 43 61
4 90 81 76 63 17 48 71 38 41
5 60 42 53 37 18 56 39 75 68
6 70 75 41 54 19 78 66 57 93
7 80 81 63 95 20 31 38 34 45
8 37 77 56 62 21 94 75 36 51
9 80 65 82 45 22 60 43 36 54
10 61 60 55 35 23 68 99 99 92
11 70 42 95 90 24 73 38 36 68
12 75 97 82 99 25 62 36 79 55
13 52 61 72 88
Develop the x-bar and R control charts for this process.

Q11. The data below are and R values for 24 samples of size n = 5 taken from a process
producing bearings. The measurements are made on the inside diameter of the bearing, with
only the last three decimals recorded (i.e., 34.5 should be 0.50345).

Sample Number x-bar R Sample Number x-bar R

1 34.5 3 13 35.4 8
2 34.2 4 14 34.0 6
3 31.6 4 15 37.1 5
4 31.5 4 16 34.9 7
5 35.0 5 17 33.5 4
6 34.1 6 18 31.7 3
7 32.6 4 19 34.0 8
8 33.8 3 20 35.1 4
9 34.8 7 21 33.7 2
10 33.6 8 22 32.8 1
11 31.9 3 23 33.5 3
12 31.6 9 24 34.2 2
a. Set up x-bar and R charts on this process. Does the process seem to be in statistical
control? If necessary, revise the trial control limits.
b. If specifications on this diameter are 0.5030 ± 0.0010, find the percentage of non-
conformities produced by this process.

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Dr. Nguyen Thuy Quynh Loan
Attribute control chart

Q12. Small electrical assemblies are produced in lots of size 144. The table below shows the
number of defective assemblies in 24 lots that were sampled, each at the end of a 30-minute
period, to control the process.

Lot number Number defectives Lot number Number defectives

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

a. Develop a p chart for this process. Does the process appear to be in control?
b. Develop an np chart for the process and contrast it with the p chart you developed in
part (a).

Q13. Thirst-Quench Inc. has been in business for over 50 years. The engineer is to record data,
evaluate those data, and implement strategy to keep quality at a maximum. The plant operates
8 hours a day, 5 days a week, and produces 25,000 bottles of Thirst-Quench each day. Problems
that have risen in the past include partially filled bottles, crooked labels, upside-down labels,
and no labels. Samples of size 150 are taken each hour. Create appropriate charts.

Subgroup Number Inspected n Number Proportion Nonconforming

Number Nonconforming np p
1 150 6 0.040
2 150 3 0.020
3 150 9 0.060
4 150 7 0.047
5 150 9 0.060
6 150 2 0.013
7 150 3 0.020
8 150 5 0.033
9 150 6 0.040
10 150 8 0.053
11 150 9 0.060
12 150 7 0.047
13 150 7 0.047
14 150 2 0.013
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Dr. Nguyen Thuy Quynh Loan
 15 150 5 0.033
16 150 7 0.047
17 150 4 0.027
18 150 3 0.020
19 150 9 0.060
20 150 8 0.053
21 150 8 0.053
22 150 6 0.040
23 150 2 0.013
24 150 9 0.060
25 150 7 0.047
26 150 3 0.020
27 150 4 0.027
28 150 6 0.040
29 150 5 0.033
30 150 4 0.027
Total 4500 173

Q14. A manufacturer of lightbulbs is keeping track of the number of nonconforming bulbs

(the number that don’t light). Create the centerline and control limits for a number
nonconforming chart. Assume assignable causes and revise the chart.

n np n np
1 300 10 11 300 31
2 300 8 12 300 32
3 300 9 13 300 10
4 300 12 14 300 8
5 300 10 15 300 12
6 300 11 16 300 10
7 300 9 17 300 11
8 300 10 18 300 9
9 300 12 19 300 10
10 300 11 20 300 8

Q15. The Par Fore G&f Company is a producer of plastic divot fixers. They produce the fixers
In bags of 30. They sample these tools in a sample size of 1. The nonconformities range from
overall size to individual flaws in the production of the plastic tool. These tools are inspected
four times daily. Create a chart with the following data. Assume assignable causes and revise
the chart.

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Dr. Nguyen Thuy Quynh Loan
 Serial Number Count of Nonconfomiities Comment
1 JG100 7
2 JG101 3
3 JG102 5
4 JG103 4
5 JG104 6
6 J0105 6
7 JG106 17 Wrong mold used
8 JG107 7
9 JG108 2
10 JG109 0
11 JG110 3
12 JG111 4
13 JG112 2
14 JG113 0
15 JG114 21 Not enough time in mold
16 JG115 3
17 JG116 2
18 JG117 7
19 JG118 5
20 JG119 9
Total 113

Q16. The following table shows data on defects in electronic organizers manufactured by
COSCO.
Organizer Number of Organizer Number of
number defects number defects
1 4 15 2
2 1 16 5
3 6 17 0
4 0 18 4
5 3 19 5
6 7 20 1
7 0 21 0
8 4 22 6
9 3 23 2
10 1 24 7
11 4 25 11
12 7 26 2
13 5 27 1
14 4 28 4
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Dr. Nguyen Thuy Quynh Loan
Develop an appropriate control chart to determine whether this process seems to be stable over
time.

Process Capability

The ABC Company produces steel tubes. The steel tube process is a stable cut-to- length
operation that generates tubes that have a mean of 12.00 inches and standard deviation of 0.10
inches.

Q17. The XYZ Company wishes to buy tubes from the ABC Company. The XYZ Company
requires steel tubes between 11.77 inches and 12.23 inches in length.
a. Compute Cp.
b. Compute CPU.
c. Compute CPL.
d. Compute Cpk.
e. Compare and contrast the preceding capability indices with respect to their ability to
explain the capability of the ABC Company’s steel tube process.

Q18. The LMN Company wishes to buy tubes from the ABC Company. The LMN Company
requires steel tubes 11.95 inches long with a tolerance of 0.30 inches.
a. Compute Cp
b. Compute CPU.
c. Compute CPL.
d. Compute Cpk.
e. Compare and contrast the preceding capability indices with respect to their ability to
explain the capability of the ABC Company’s steel tube process.

Q19. A hospital is using x-bar and R charts to record the time it takes to process patient account
information. A sample of five applications is taken each day. The first four weeks’ (20 days’)
data give the following values:
X-two bar = 16 min R-bar = 7 min
If the upper and lower specifications are 21 minutes and 13 minutes respectively. calculate
6σ, Cp, and Cpk. Interpret the indices.
Q20. Suppose you have the following stable process (Process Spread = 6). Compute the Cp and
Cpk indices. What new mean would be required to make the process “capable” (Cpk = 1)?
What new standard deviation would be required to make the process capable without changing
the mean?

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Dr. Nguyen Thuy Quynh Loan